Real Time Monitoring for Critical Assets Mike Kilpatrick, S&C Electric Ken Elkinson, Doble Engineering EEI Transmission, Distribution & Metering Conference October 6 - 9, 2013 Charleston, SC USA

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S&C Electric Company • Headquartered in Chicago, IL • Over 100 Year Old Company • Employee Owned • Specialize in Electric Power Switching and Protection • Decades of product and service expertise

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Asset Management Goals

1. Maintain equipment per industry standards 2. Monitor equipment to proactively spot failures 3. Reduce the operations and maintenance costs 4. Maximize total cost of ownership 5. Avoid lead times ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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Asset Management – Data Center

Deployment of Sensors Routine Maintenance of Circuit Breakers Real-Time Monitoring of Main Power Transformer Spare Parts and Parts Inventory Programs Real-Time Monitoring of Transformer Infra-red and visual inspection of equipment

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Balance is Key

Condition Based Monitoring

Routine Maintenance Asset Management

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Balance is Key

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What can be done? Routine Maintenance Activities • NETA Testing • Visual Inspections • Maintenance and Cleaning – CO2 Cleaning Services • Infra-red Testing • Ultra-sound Testing • Preventative Inspections • Preventative Maintenance • Emergency Response (Reactive Maintenance) ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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What can be done? Condition Based Monitoring • Monitor Breaker Positions • Real-Time Dissolved Gas Analysis (DGA) • Temperature Alarms • Inverter Alarms • Gas Pressure and Temperature • System Availability • Run Cycles

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The Solutions for End Users

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Condition Monitoring: Motivations & Benefits Motivations: - Real time information - Improve understanding of ‘true’ asset condition - Support asset related decisions – short and long term Expected benefits - Reliability improvement - can reduce the risk of an un-scheduled outage.

- Failure avoidance costs: - Equipment replacement costs - Safety & Environmental penalties and fines - O & M Costs

- Capital investment deferment - O&M cost reduction ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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What are the most common transformer failure modes?

From “Analysis of Transformer Failures” William Bartley, HSB, presented at Doble Client Conference, Boston, 2012 ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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What are the most common transformer failure modes? Large IOU Failure History, 1988 – 2008 (96 failures) 4% 4%^ 5%

26 %

8% 13%

20 % 15% ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

Through-Fault Winding Bushing Gassing Leads Lightning Tap Changer Unknown Vandalism Leaking Valve Design Problem 12 Overheating

The Key is in Visualization • Informative, role-based views for decision support • One person’s critical assets are not another’s • Concentrate on the things that are important to you

– “At-a-glance” understanding of asset condition • Drill down to events • No need to search for information • Views provided within a geospatial, substation or asset context • SCADA-like in nature-e.g. live alarms, trends, status, values

• Provides real time, substation asset health • System architecture allows rapid integration of new data sources, and then prototype & deployment of new views ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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Visualization of Information is Important

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Visualization of Information is Important

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Visualization of Information is Important

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Options Should you put online monitoring on every transformer, or only the most critical units?

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Why Monitor Bushings? • Success in applying monitoring – Control the measurement – Understand Context and impacting parameters – Actionable Conclusions

• We have identified two broad modes of bushing failure: – Cases and saves from Doble conferences – “graceful deterioration” where indication of failure develops over several days to weeks – “sudden and rapid” onset failures where deterioration occurs rapidly and may lead to failure in a matter of hours ©2013 Doble Engineering Company. All Rights Reserved 80th International Conference of Doble Clients

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Why Monitor Bushings?... Graceful Deterioration • This case shows a graceful deterioration in on-line dissipation factor (power factor) occurred over several months • Analysis of the parameter on daily, weekly and monthly parameters showed the insulation was degrading “gracefully”

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Why Monitor Bushings?... Rapid Onset • In this case a sudden variation in leakage current, detected by an intelligent diagnostic device (IDD), raised an alarm • The bushing was one of a type which had several failures around the world recently • Operations took the bushing off line and replaced it – a tear down indicated they had just hours before catastrophic failure

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Risk Signatures

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© Buckland

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Risk response strategies

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© Buckland

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Power Transformer Replacement List Represents those already on the list for replacement FY10 Represents replacement candidates for FY11-FY14 in order of priority. Represent replacement candidates for FY15-FY25 in order of priority. LAST DGA HYDROGEN METHANE CARBON ETHANE ETHYLENE ACETYLENE COMBUST MONOXIDE GAS STA LOC Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer Transformer

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

EQNUM 20757 21601 23586 23898 20363 21112 21111 20113 20152 20151 22955 22956 22957 20135 20136 20149 20150 21899 21545 20653 20250 21756 20657 20065 20238 21046 20387 20248 20249 21047

MVA 7 6.25 12.5 9.38 3.75 10 10 7.25 9.38 9.38 1.5 1.5 1.5 7.5 7.5 10 10 7 6.25 9.38 9.38 6.25 9.38 3.65 12.5 9.38 9.38 9.38 9.38 9.38

VOLT 23 23-13.2 34.5-22.9 34.5-22.9 13.8-4.33 k 24.6-4.16 24.6-4.16 23-2.4 23-4.16 23-4.16 13.2-2.3 kV 13.2-2.3 kV 13.2-2.3 kV 13.8-2.4 13.8-2.4 23.46-4 23.46-4 13.8-13.2Z 22.9-13.8 k 13.8-2.4 kV 22.9-4.16 k 13.2-2.4 kV 13.2-2.4 kV 13.8-4.36 k 23.5-13.8 k 22.9-2.4 kV 13.8-2.4 23-2.4 23-2.4 22.9-2.4 kV

AGE 41 37 23 21 59 62 62 62 47 47 79 79 79 85 85 69 59 36 37 59 59 59 58 58 57 57 61 ? ? 57

36 855 154 16 542 32 18 0 0

64 53 62 9 43 8 6 17 25 2 33

5 0 14 27 29 49 8 0 17 6 14 5 185 0 0 1 12

300 344 727 1140 509 158 90 73 3 259

105 3 24 2 1 8 8 83 17 28

28 701 2 46 58 6 4 16 3 85

0 2 0 0 0 0 0 0 0 0

533 1958 969 1213 1153 212 126 214 25 405

1130 1100 567 1980 184 3 42 23 1100 10 151 7 38 11 103

144 2 90 1 0 8 110 398 1 1 45 5 34 153 10 9 13 3 26

2 3 36 39 126 273 39 0 200 1 34 9 3 1 25 0 14

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

156 95 1207 1204

3 1 27 30 145 469 5 1 58 5 85 21 9 4 10 4 18

©2013 Doble Engineering Company. All Rights Reserved For each transformer a plan is generated to mitigate failure th 80 International Conference of Doble Clients

237 5 362 40 1267 198 358 21 86 19 173

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Assigning Condition Codes & Scores

Condition Code 3

Condition Code 4

Condition Code 1:

Condition Code 2

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Justification

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Conclusions – Why Bother? • Online monitoring presents challenges, but great value can be found: – Bushing saves – DGA analyses – PD

• Monitoring may create vast amount of data for analysis • Need a coordinated analytics system – At the asset, at the station, across families

• Great opportunity to realize a truly intelligent grid

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Conclusions

Questions? [email protected] [email protected]

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