Replacement of damaged electrical insulators on live cross-over busbars inside a tunnel: a methodology based on risk assessment and numerical simulation

Abstract

With amperage creep, the croscr was severely damaged by excessive temperatures. Its replacement and upgrade was therefore necessary to ensure safe and continued operation of the potline. Electrical hazards, constrained space, heat stress, strong magnetic fields and poor lighting were amongst the challenges. This paper details the methodology developed by the project team to solve the issue. The first success key is that risk analysis was performed at each phase in partnership with the smelter, the original technology supplier and the contractors. The knowledge and experience of the original technology supplier was invaluable in the development of the solution. The second key is that Finite Element Analysis and in situ measurements were used extensively to define an optimized project scope including mitigation measures. The work was then executed with no incident, no damage and no cut-out while on schedule and below budget.