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MAYBE
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IN MICROFICHE
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Steven L. Purucker and Richard T. Goeltz

Energy Division
Oak Ridge National Laboratory
Oak Ridge, Tennessee

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Ken Hemmelman

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Bonneville Power Administration

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Van Couver, Washington

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August 1992

and Rod Price

For Presentation
Plant Monitoring

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at the EPRI Computer-Assisted

Technologies
Workshop, Philadelphia, Pennsylvania

for NDE &

Prepared by the
OAK RIDGE NATIONAL LABORATORY
Oak Ridge, Tennessee 37831-6285
managed by
MARTIN MARIETI'A
ENERGY SYSTEMS, INC.
for the
U.S. DEPARTMENT
OF ENERGY
Under Contract No. DE-AC05-840R21400

"The _itted
_t
hns been
authored by a co_ttr_etor of the U.S.
Government under co_trnct No. DEACOS-84OR21400. Accordingly, the U.S.
Governm_t
ret_ a
no_x_,
royalty-f_ee_
to publish o_ rel_oauce
tpe publ_ted form of this contribute, o_
allow others to do so, fo U.S, Goverr_tent

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Reliability Centered Maintenance

of Power Transformers and Circuit Breakers

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by
Ken Hemmelman, Rod Price

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Steve Putucke,Rick Goeltz

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Oak Ridge National Laboratory

At the Bonneville Power Administration (BPA), we have i_;storicBllymaintained high voltage

equipment, Including transformers andpower circuit breakers, on a time clriven basis. While this
has served our needs in the past, newer methoOsare needed to effectively maintain the I_ower
system in future years. Today aging equipment, maintenance backlogs, and budget constraints ira
a reality. BPA has Initiated a researnh and develol_mentI_rojectto examineraliab;liW centered
maintenance (RCM] as an alternative to time t:_seclmaintenance on high voltage equipment.
Under RCM, the performance of each piece of equipment is to be monitored by observing many
_erating paremeter#. I=orexample, with circuit breakers we will observe (measure) the aridtime,
accumulated corttect,wear _:slng lit, timing of the rnechanicm, plus leveral o',hir perimeters.
EQuil3mentI)er'formin_ bcJlOwa oredetermined lea,el, or equipment h_,viagaccumulated a large
amount of "usage* will recetve maintenance. The miintsninel
will restore full performance and
preserve an acceptable service lifo for tl_at piece of equipment.
To develop and evaluate RCM concepts, BPA is installing a I_rototyge system at our Alvey
Substation on 4 traniformers and 25 breakers. The Alvey prototVlOewttl be used to elal_orateon
the basic princil_laaof RCM as apptled to high voltage equipment, and to provide the 10asiifor a
design that could be used across the BPApower system. Our present schedulecells for completion
of the monitoring sylltem by fall of 1992, and development of the RCM algorltl_msfor the
equipment by the foil of 1993. The system will be evaluated for a periodof time beginning in the
fall of 199:3 to finalize the algorithms, and develop a system-wide Implementation strategy =f
warranted,

1. _NTRODUCTION
Historically at BPA, the scheduling of maintenance on power syitem equipment, including
transformers and pewter circuit breakers, has bean driven primarily by the time Ilncl lbl lilt
maintenance. Aging power system equipment, growing maintenance backlogs, and budget
constraints constitute pressures that are compelling us to change our historical metlnoda. Hence,
we are evaluating newer an(:lootentially batter ,Iternatlves to schedulin0maintenance, methods that
are sensitive to Individual equipment performance, manufacturer and model, age, etc. We believe
that RCM will provide a tool that can provide for reliable operation and good service life from our
equipment, yet be =eniltlve to changing corporate culture.
Reliability centered maintenance (RCM] has been used successfully in the power generation Industry
for many yelr= (see EPRI reference). With RCM, the performance of each piece of eluil_menttl
monlt;or=}don in on_oing basis. If the performince of that piece of equil=mentfalls below a
predetermined level, then maintenance ii done to restore full service ii well as maintain In

acceptable service life. The uti(ity industry investecl significant resc,urces toward DreO_cting
catastrolohic failures of ecluil_ment, but to our knowledoe retativelv little has been clone _ predict
t_e need for preventive maintenance (PM).
A significant amount of research needs to be done before an operational RCM system c_n ge
implemented for substation equipment, To evaluate RCM onceOtSo BPA hal made a decision to
leveloP end Install tsprototype system at our Al,oy Substation. The Alvey protoIype will monitor 4
on-line transformers and 25 on.line _ower circuit breaker=. The prototyl_e will bi used to =evetol_
t_e b&si principles of RCM as al_Diied to high voltage substation eauioment, and to I_rowde the
basis for e design that could by used across the BPA i_ower system, Our plan is to begin
maintaining the AIvey equipment per RCM Ioractices within the next :2 years.
Because of the magnitude of this I_roJect, we have contracted for supoort from the Oak Ridge
National Laboratory (ORNL). The ORNL personnel are doing the research and developing the
algorithms to predict equipment pedormance, and any subsequent need for maintenance. They are
working with other utilities, industries (e.g.J.W.
Harley, Doble, etc.), and research institutions
(EPRI, etc.) to develop analysis strategies,
Finally, they will develop or acquire the hardware and
software that will be used in the monitoring for the Alvey I_rototype, Eventually the RCM system
may be extended to BPA's entire system.
2.

J_CM SYSTEMDEVELOPMENT

T}_e basic RCM system will monitor various i_arameter$ of operating equipment. TheSe i_arameters
which we have termed observable variables _re fed ln..P,= malnten_n,_e decision matrix. OUtl:)Ut
from this matrix are recommendations Identifyin0 what maintenance needs to be do._e. Sae Figure
1. The kev to this process i$ tt_e decision logic. While this logic may be expret=ed as "and" and
"or" gates, it can also be comparisons to nominal values, references to datl bases, comDarlaor_$ tO
graphical data, trends, atc, This will become clearer as the logic for breakers nn_l transformere is
discussed,

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To research and evaluate RCM on high voltage equipment, we are <:leveleD[ng a RCM protot'vpe
r3roject for installation at our Alvey Substation. Four oloeration_i _ransformers and 25 operational
power circuit breakers (115-kV, 230-_,V, and 500-kV) will be instrumented with transformer end
breaker monitors, an(:l by sampling SCADA and relay data, in adaitlon, we will aSk users
(substation maintenance personnel) to make observations concerning the condition of the
equipment. The information from these sources will be collectea anti analyzed to aisess the
0erformance of each piece of eclulDment, its operatin0 condition, and predict the neea for
maintenance,
To better understand the BPA RCM i_hilosophy, let's look at the Alvey system, t:Igure 2 I_relentl 8
brief overview of the Alvey 13rototvDe system. The RCM sys_ilm data acquisition syltem (DA$)
consists of sensors and monitors attached to the equipment, SCADA analog and indication point
data, other substation data such as relay fault data, and a comlouter system to collect and analyze
the data. The RCM workstation collects that data in a datal_a_e, analyzes the data (o.g., statical
methods and expert system concepts}, and integrates RCM al_tications with the users PC.
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TO facilitate research and development with the prototype, we have installed a dedicated *RCM"
SCADA RTU at Alvey. (With the dedicated RTU for RCM, we can modify and work with the RCM
system without disturbing the oDerationat system. In the final implementation, we will use
operational SCADA data.) There nra several Other features designed into the AZvey prototype
system. One le the use of fiber optics to Interconnect the vartous sub-Systems. Another feature is
the use of en "off-the-shelf" network to tie major components of the system together.
Because we are not sure of the level of equipment monitoring that will be needed to adequately
predict the need for maintenance, we are installing more monitors a_ Alvey than mev ultimately be
needed, One goal of this 10reject is to determine what data will be needed for RCM, and from that
knowledge, what level of data acquisition wall be needed in the final system,
There are two major area_ where eauipment monitoring ia being develol_ed and/or evaluated,
Transformer monitor and power circuit breaker monitors w_il be deployed with the Alvey prototype,

3.

BI_EAKERMONITORING

For circuit breaker=, we are looking at three I;rimary sources of monitoring, The first is a loreaker
monitor that is being developed under contract with ORNL. lt will monitor the current Drofile in trip
coil(s) and close coil(s), contact interrupting current and time, and has the Cal:)abilitvto monitor
event= if the need erilel. Thll system ii shown in Figure 3.
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The second monitoringsystem is SCADA. Wlth SCADA we will get time tagged indication of
events that occur, Thls includes number of breaker ol_eratlons, alarms from auxiliary systems such
as SF, gas, compressorrun times for air systems, and substation operatingconditions such as
ambient temperature and bus voltages,
The third monitoringsystem is the Schweitzer EngineeringLaboratories (SEL) line and breaker failure
relays. These relays will provide fault magnitude end duratton data. This data will be used to
calculate the I=t which is en indicationof contact wear. Note that there is i redundancy in the
collection of fault dite with the breaker monitor. This provides correlation of variables from the
different systeme, and allows us to make an informed decision regardingthe most effective method
for collectin9 breaker dite In the final system,
The list of parametersto measurefor breakers ii shown in Figure 4. Fromthe observable variables,
a maintenance decision matrix (e sample ii shown in Figure 5) is used to determine the need to
correct an tncltent I_roblem, and project the need for preventive maintenance,

4. T_ANSFORMfR MONITORING
There are two I_rimary systems for monitoring transformers One ii grovlded by J. W. Harley, Inc,,
the Transformer PerformanceAnalysis System (TPAS). The TPAS system monitors oil tsml:)eri*_ure,
gas.In-oil, internal vibration and tank vibration (for I_artialdischarge), and moisture-in-oil, TPAS
forms the bells for monitoring the transformer tn detail.
The second monltorlng system la via $CAOA,

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for transformer monitoring is shown in Figure 6. ".he maintenance

is being clevetoged.

FUTURE RCM SYRTLCM

The Alvey prototype is a relatively complex and expensive system. As note_l above Dart of its
purpose 18to evaluate monitors and sensors, and refine the algorithms and data system such that
we can i_lan for an effective system wide installation. We have consciously overbuilt the prototVl3e
to provide for development and analysis of substation RCM,
If we look Into the future, beyond the Alvey prototype to a system wide implementation, we can
predict several needed changes. We will add points to the ol_erational SCADA anti sequence of
events systems for data acquisition. This date wall provide the RCM system with event (data
Including alarms lind operating conditions (such as comloressor runnlng), and other Wplc81 $CADA
data such as ambient temperature, bus volta0es, atc, Figure 7 showl how the .,_timstesystem may
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The vreeentcost Ofthe HarleymonitorsIwhich are, In ell fairness,stillin the develocmentstages)ii

in the neighborhood of $100 k per transformer, while thA projected production cost of the bruker
monitor Ii lasl thin $5 k Der breaker. Cost for monitors must be minimized in order to maximize
their penetration for maintenance monitoring, If monitors could be installed In new equipment ai
oars of the Initial construction, the cost could be significantly reduced.
The RCM workstation, currently at Alvey is a Iocalizel system. Eventually it will become part of t
centralized system (tentatively titled a Maintenance Applications Processor MAP), MAP will be
installed at our Oittmer Control Cen_er. lt will run the algorithms for =il transformert end breakers

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notjustraw data,to theuser'sworkstation,By the
time that we are ready for a system wide implementation, there_will be a system wide Onerational
Data Network to handle the lntra-system transfer.
6, CONCLUSION
The pur0ose of the Alvev RCM pro_oty0eis to evaluate and refine the RCM concepts as al_131ied
to
high voltage substation equipment on BPA's power system. We have made initial assumptionsfor
(he specific parameters which must be monitored to predict the need for routine maintenance, The
algorithms for PM, failure prevention, and life extension are being developed. The prototype will be
used to refine these to provide a basis for an operetlonal system that will be installed throughout
the BPA I:)owersystem. We believe that some form of RCM will be a viable alternative to the
l_resenttime base0 method of scheduling maintenance,
After the completion of the Alvey prototype, BPA plans to use the RCM system for periodof time
as a basis for maintenance of breakers and transformers. Based on our experience with Alvey,
decisionswill be made regarding | system wide iml01ementation.Potential savings from RCM c|n
be significant. If =11transformers and breakers are added to the eQuiomentunder RCM, the gross
savings could increase tO $8M. These savtngscome mostly from Increase= in eQuivmentservice life
and reduced catastrophic failures. A smaller percentage of saving comes from reductions in
corrective maintenance and PM,

7. B_JEBEtCF,_
S. L. Purucker, B. E, Tonn, R. T. Goeltz, R. O. James, S. Kercel, O. T. R;cv, M, L. $1m_son,V. W.
Van Dyke, "Fusibility Study: Application of RCM Techniques for Substation Maintenance at the
BonnevillePower Administration', report prepared by Oak Ridge National Laboratory, managed by
Martin Marietta Energy Systems, Inc. for Oe0artment of Energy under Contract No. DE-AC0584OR21400,
EPRINP-6152, "Demonstration of Reliabil_y*Centered Maintenance, Volume 1' Project Descrll_tlon,=
Janu|rv 1989.
The author= would like to give credit to Sah_g Chilingerian and Abel Pereire, seniortechnical
engineers in the Division of System Maintenance, BonnevillePower Administration. Their exl_ertlee
was invaluable In setting uP the Alvey prototype and establishing the base line analysis system,

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