Bonneville-Transmission ACSubstations DAS

B O N N E V I L L E P O W E R A D M I N I S T R A T I O N
Alternating Current (AC) Substations

Sustain Program
Asset Management Strategy
Jerry Almos, Program Manager

March, 2012
Agenda
Executive Summary
What equipment is covered?
Strategic environment & drivers
Strategies
Process improvements
Equipment Strategies
• Power transformers and reactors
• Switchgear
• Shunt capacitors
• Instrument transformers and surge arresters
• Station auxiliary
• Substation bus & structures
What will it cost?
Program Accomplishments FY10 & FY11
2
Executive Summary
BPA’s Alternating Current (AC) Substation Assets
 There are approximately 250 alternating current (AC) Substations

on the BPA system
• Over 50 of the 250 substations operate at 500 kV
 AC Subs represent 39% of BPA’s transmission asset base
 Per a benchmarking study conducted by 1st Quartile in May 2011

• BPA’s substations are older than most other surveyed utility’s
substations
• Overall capital spending at BPA (activity-based) is lower than
average, and our replacement rate is low in comparison to those
other utilities
3
Executive Summary, cont.

AC Substation Equipment Types
BPA operates approximately 27,000 major (serial numbered)

pieces of high voltage electrical outdoor substation equipment
and another 5,000 with limited attribute data. The AC
Substations sustain program assets include the following:
Transformers and Reactors

Circuit Breakers and Switchgear
Shunt Capacitors
Instrument Transformers and Arresters
Station Auxiliary
Substation Bus and Structures
4

Strategic Drivers
• Manufacturing practices and vendor support are changing, however, and the
new practices are forcing electric utility and transmission providers to
replace equipment earlier than in the past.
• Newer equipment has shorter life span
• Long term vendor support is becoming increasingly limited
− Affects spare parts availability and cost
• System capacity is increasing while equipment operating margins are
decreasing due to age and/or effective life cycle
• Technology obsolescence
• Workforce obsolescence
• Transmission will continue to promote standardization in the purchase of

new equipment that meets system operating requirements which will
balance warehousing costs of spare parts while continuing to support
maintenance activities. This effort also helps mitigate spare parts
unavailability and lack of vendor support of obsolete equipment.
5
Criteria For Asset Replacement
Assets are targeted for replacement based on the following key drivers:
 Asset Condition Assessment
 System Upgrade (Capability/Capacity)
 Asset Risk (Failure and Consequence)
6

Replacement Strategy
 Historically, BPA has replaced AC substation equipment based

primarily on failures and failure rates.
 Approximately 85% of breakers are replaced today due to the
inability to obtain spare parts, unacceptable lead times for obsolete
spare parts and/or excessive cost of re-manufacturing obsolete
spare parts.
 A more strategic approach where assets are proactively maintained
and replaced for optimized risk management based on the strategic
drivers is being developed.
7
Replacement Strategy
 The strategy is focused on four key areas
for all major equipment groups:
• Performance monitoring and data analysis
• Maintenance and Operations approaches
• Equipment standardization
• Maintaining a proper level of equipment
spares
8

Transformers and Reactors
Over a 10 year planning horizon
 Replace 6 – 500kV, 7 – 230kV and 4 – 115kV

transformers
 Replace 3 – 500kV shunt reactors
• Based on statistical calculations and mean time
between failures.
 Maintain the proper level of spare transformers

and reactors based on BPA’s sparing strategies
in the event of a transformer/reactor failure.
9

Circuit Breakers and Switchgear
 Replace 37 - 500kV air blast and gas blast circuit breakers, as well as 67 –
230kV, 78 – 115kV and 41 – 69kV and below circuit breakers
• Based on age, obsolescence and effective life-cycle
 Replace 7 – 500kV Mark IV circuit switchers on reactor positions, as well as
31 – 230kV, 22 - 115kV circuit switchers of various technologies
• Due to end of mechanical life and technological obsolescence
 Replace 163 – 230kV, and 106 – 115kV disconnect switches
• Based on age, lack of spare parts, effective life cycle and identified
safety issues.
 Emergency spares are maintained at a proper level to have at least one

spare that can be applied to each voltage class in the event of failure.
10

Shunt Capacitors
 Replace 1 – 115kV shunt capacitor group

• Based on age, condition and effective life cycle.
 Replace all capacitors in 1 – 115kV and 1 – 500kV shunt
capacitor group
• Due to manufacturer defect.
 Add current limiting reactors at 3 sites
• To eliminate existing operating restrictions.
 Spare capacitor cans and fuses are stocked to an

appropriate level.
11

Instrument Transformers and Arresters
 Replace the remaining 1,100 instrument transformers containing

PCBs > 50PPM
• Regulated by the Toxic Substance Control Act
 Replace 440 SiC arresters
• Based on age, condition and effective life cycle
 Replace rod gaps with arresters on 17 – 500kV line terminals, and
48 – 230kV and 115kV line terminals and transformers
• Reduce momentary outages thus increasing reliability
• Improved insulation coordination
 Emergency spares are maintained at a proper level to have at least

one spare that can be applied to each voltage class and rating in the
event of failure.
12

Low Voltage Auxiliary
 Replace 112 DC control batteries and chargers

• Based on age, condition and effective life cycle.
 Upgrade station service at 44 substations
• Based on the age, condition and effective life cycle of the
equipment and cabling
 Emergency spares are maintained for station service

equipment at a proper level to have at least one spare
that can be applied to each voltage class in the event of
failure.
13

Substation Bus and Structures
 Replace the bus at 4 substations

 Replace multiple foundations at 13 substations
 Replace 35 engine generators
 Perform seismic upgrades on 42 – 500kV line
terminals
14

Capital Forecast Based on Asset Strategy
Impacts of Constraints on Budget, Resources, Outages, etc.

Potential impacts from not fully funding the proposed asset strategy due to budget constraints include the following
 Asset Performance Objectives and Targets

• Corrective maintenance costs will rise or remain high on equipment in poor health or reaching it’s effective life-cycle
 Asset Failure
• Vendor support for some equipment is becoming scarce or non reliable
• May be more emergency replacements of circuit breakers and circuit switchers
• Will risk a run to failure approach on some assets thus replacing under emergency
 Other Risks
• Retaining an inventory of obsolete parts for equipment that is scheduled to be replaced
• Vendor support for spare parts is becoming scarce or non reliable
 Replacement Backlogs
• Would continue to keep obsolete and aging equipment in service thus affecting reliability
Other possible constraints
 Labor constraints can be remedied by using contract design and construction at a greater cost
 Outage constraints can be remedied through the efficient use of work planners and schedulers.
Note: This implementation plan is a replacement program with the optimal funding, staffing resources, and outage
availability to best mitigate risks identified in the strategy. These numbers are not aligned with the currently constrained
IPR budget. Each sustain program is under review to determine a revised implementation plan that will align with
capital budget availability, priorities, and resource constraints. This review will be complete by March 2012.
15
Executive Summary
Strategies
• Switchgear
What will it cost?
16
BPA’s Alternating Current (AC) Substation Assets
 There are approximately 250 alternating current (AC) Substations on the

BPA system.
• Over 50 of the 250 substations operate at 500 kV
 Substation assets facilitate the efficient transfer of power from source to
load and protect the circuits delivering power including transmission lines.
 Substation equipment operates at voltages ranging from 120 V to 500 kV.
• Substations that interconnect multiple utilities, generators, or serve to
transfer power are considered “Network Facilities” – typical network
operating voltages are 115 kV – 500 kV
• Substations that serve radial utility loads are “Delivery Facilities” –
delivery voltages range from 4160V up to 230 kV, the vast majority
deliver power from 12.5 kV to 115 kV
• Per a benchmarking study conducted by 1st Quartile in May 2011

• BPA’s substations are older than most other surveyed utility’s
substations
• Overall capital spending at BPA (activity-based) is lower than average,
and our replacement rate is low in comparison to those other utilities
17
AC Substation Asset Overview
18
Criteria for Asset Replacement

• Asset Condition: The physical condition of a piece of equipment, structure, material, or
sub-component and its ability to perform its designed task or function regardless of its criticality or
position on the power system. The condition rating for an AC substation component (electrical
equipment, structure, or material) includes “obsolescence” which considers the ability to maintain
the equipment due to workforce obsolescence, lack of spare parts, compatibility of operating
systems (i.e., software, control hardware), and manufacturer design flaws.
• Upgrade: While most AC substation assets will be replaced as they reach the end of their life due to
poor physical condition and/or obsolescence, some equipment will need to be replaced prior to end
of life. AC asset upgrades are driven by transmission system changes that render the equipment
inadequate or obsolete in terms of the new system operating requirements. Most common are
switchgear, either replaced or modified, to meet increased system fault current (fault duty)
requirements. The “upgrade” shall provide equipment with a new, higher rating that will meet the
changed system operating requirements.
• Transmissions Priority Ranking Criteria: A methodology developed by BPA to assess and rank the
overall criticality of a substation or transmission line in support of: Asset Management; Workload
Planning; System Restoration Plans; Line & Equipment Maintenance; and Seismic/Hazard Mitigation
Measures.
• Asset Risk: The assessment of equipment or facility likelihood and consequence of failure,
obsolescence, inadequacy, health/safety risk, etc.
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BPA operates approximately 27,000 major (serial numbered) pieces of high voltage
electrical outdoor substation equipment and another 5,000 with limited attribute data. The
AC Substations sustain program assets include the following quantities in service:
1. Power Transformers (679), Reactors (750), and Fuses(1,620). Power Transformers facilitate
utility and generation points of interconnection and power transfer; Reactors control voltage
and current to prevent damage to other equipment and for safety.
2. Switchgear – Power circuit breakers(1,869), Circuit switchers(222) & Disconnects (6,715).

Power Circuit Breakers (PCB) and Circuit Switchers (CS) protect high voltage substation
equipment from damage during system disturbances and provide rapid clearing of system
faults to maintain service. Disconnect switches provide isolation for maintenance and system
operating purposes.
3. Shunt Capacitors and Current Limiting Reactors for capacitors (232 groups). Shunt Capacitors
– Provide reactive compensation to increases power transfer and boost system voltage.
20

Continued
4. Instrument Transformers (6,994) & Surge Arresters (3,511). Instrument Transformers (IT’s)
measure the voltage or current in the electric power system. These large quantities are
transformed and scaled down to a standardized value. Instrument transformers isolate
measurement, protection and control circuitry (relays, control, metering, AGC, SCADA, SER, RAS,
etc.) from the high voltages and currents being measured. Surge Arresters provide protection for
the insulation of high voltage equipment and to some extent transmission lines against
potentially harmful system over-voltages. Surge arresters reduce momentary outages (ground
faults) due to lightning strikes and switching surges.
5. Station Auxiliary – DC Control batteries (276), Battery Chargers (533), Station Service (SS)
Transformers (1,056) & SS Cabling, Engine Generator’s (55), Substation grounding. Station
auxiliary – Provides operating power for both Indoor and Outdoor substation equipment –
includes DC Control Batteries, SS TX’s, EG’s, SS Cabling, Grounding
6. Substation Bus & Structures – Bus supports, Dead-end towers, Lightning masts, and associated
Foundations; Insulators, Bus, and Engine Generator Fuel systems & housing. Substation Bus &
Structures – Substation Bus & Insulators - Interconnect HV substation equipment; Dead-end
Towers, and high voltage equipment structural Supports – Provide termination points into
substations and provide physical separation between equipment and ground and between
equipment.
Notes: 1. Non Electric Plant (NEP) excluded from this strategy; 2. Replacement forecasts for All DC Celilo facilities, Static VAR
Compensator (SVC) facilities within Keeler, Marion, and Rogue substations & Series capacitor facilities within other stations are covered
in the DC Asset Strategy. 3. This strategy does include statistical data for equipment in the DC facilities such as transformers,
capacitors, instrument transformers, etc. for comparison of asset demographics and for maintenances practices.
21
Transmission Net Plant

Transmission Sustain Programs
Historical Investment After Depreciation
as of Sept. 30, 2011
(in millions)
Total Book Value is $ 3,585 million
System Protection Control,

$310 , 9%
Power System Control,
$295 , 8%
Transmission Lines - Steel,
$963 , 27% Rights of Way,
$271 , 8%
3 Transmission Lines - Wood,

$262 , 7%
Celilo, $178 , 5%
Tools and Equipment Acquisition

Program, $29 , 1%
Control Center, $17 , 0%
AC Substations, Information Technology, $11 , 0%
$1,249 , 35%
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Executive Summary
Strategies
• Switchgear
What will it cost?
23
Products and Services
Customers and Stakeholders Served

• Network Transmission Customers – Utilities (Public & Investor owned) & Generators
(Independent Power Producers – IPP’s & Federal Hydro)
• Delivery Customers – Small utilities (public), small IPP’s (co-generation), Tribal PUD
• BPA Internal – System Protection Control (SPC), Power System Communications
(PSC), Substation Operations, Substation Maintenance, Billing, Non Electric Plant
(NEP) Facilities, Energy Efficiency; Environment, Fish & Wildlife
Products and Services

• Network Services: AC sustain enables interconnection/transfer Service (IOU’s, PUD’s)
• Generation Integration: (Hydro, Wind, Thermal, Coal, Co-Generation)
• Delivery Service: Radial service - Public utilities, small investor owned utilities
(IOU’s) (load service)
• Reactive Compensation: VAR Support, ATC, OTC

• Measurement & Indication (voltage & current) for System Protection & Control,
Revenue Metering, Control Area & Interchange Scheduling, AGC
• Spare power transformer support for regional customers, and nationally - member of
EEI (Edison Electric Institute) STEP Program since 2006
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Strategic environment and drivers
Standards that Apply

Reporting requirements are increasing for substation equipment maintenance, equipment failure
tracking/trending, and equipment ratings (thermal/continuous). AC substation assets must be managed to
meet a variety of standards and requirements:
• The Western Electric Coordinating Council (WECC) and North American Electric Reliability Corporation (NERC)
require BPA to report the actual cause for any reportable line wherein BPA is the designated “Transmission
Owner (TO).”(WECC Paths West of Hatwai, COI , North of John Day cutplane, COI/PDCI – North of John Day
cutplane)
• WECC - PRC-STD-005-1 – Transmission Maintenance (Power Transformers, Circuit Breakers, Regulators, Shunt
Capacitors, Shunt Reactors, and Tertiary Reactors)
• WECC - TOP-STD-007-0 – Operating Transfer Capability (West of Cascades – North, West of Cascades – South
• NERC – FAC (Facility Rating) and PRC-005, 011, 017 (Battery Maintenance) PRC-STD-005-1 (Transmission
Maintenance)
• NEPA – Toxic Substances Control Act (TSCA) – PCB containing equipment (SF6 Gas Reporting & Oil leak
mitigation – reporting) requirements
• ANSI/IEEE/IEC/ASTM – HV Equipment ratings and application standards, Structures & supports - Civil &
Structural standards including seismic
• NESC/OSHA – Safety
• OB-19 Significant Equipment, and other Operating Bulletins affecting the operation of HV equipment
• BPA system performance metrics and targets

25
Strategic Drivers
• Manufacturing practices and vendor support are changing and the new practices are forcing electric utility and transmission
providers to replace equipment earlier than in the past.
• Newer equipment has shorter life span
• Long term vendor support is becoming increasingly limited which affects spare parts availability and cost
• System capacity is increasing while equipment operating margins are decreasing due to age and/or effective life-cycle
• Technology obsolescence
• Workforce obsolescence
• Historically, BPA has replaced AC substation equipment based primarily on failures or failure rates.
• HV manufacturing practices for transformers and breakers show a trend toward decreased equipment operating margins,
decreased lifespan, and decreased vendor support (parts & service) for older equipment.
• Approximately 85% of breakers are replaced today due to the inability to obtain spare parts combined with excessive cost
or unacceptable lead times for spare parts
• Transmission will continue to promote standardization in the purchase of new substation equipment that meets system-
operating requirements, which will balance warehousing costs of spare parts while continuing to support maintenance
activities. This effort also helps mitigate spare parts unavailability and lack of vendor support of obsolete equipment.
• Power circuit breakers and disconnect switch ratings have been standardized at various continuous current ratings
that allow the greatest flexibility in using the equipment at almost any location on the system. This helps reduce the
number of spare parts.
• Instrument transformers and surge arrester ratings have also been standardized, to the extent possible, to reduce the
number of spare units needed for both system expansions and emergencies.
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Equipment Life-cycles
Power transformers and reactors shown by Age during 1. Life Expectancy: Average expected
failure and Number of failures per decade for the past life of a transformer is 45-50 years.
60 years. Total Installed (639), total failed (200). Nearly half of BPA’s power
transformers are 40 years and older.
Long and short-term strategies will
identify resources needed for
Average 13 yrs
Median 10 yrs
replacements and spares needed for
service continuity.
2. Failure Trends: The average and

median ages for recorded transformer
and reactor failures for all voltages,
since 1950, are 13 years and 10 years
respectively. Failures due to design
flaws, shipping damage, failed factory
tests account for most of the
premature failures. The majority of
these premature failures were
repairable.
Number of failures
by decade
Age of units
27
Increasing Demands on AC Substation Assets
• A key Transmission asset management goal is to make fuller, more optimal use of
existing system capacity. Among other impacts, this goal may lead to:
• Tighter margins on reliability and availability and ultimately equipment performance
• Reduced tolerance for equipment failure
• Reduced outage availability for maintenance
• Loads are projected to continue growing, putting increased demands on existing

equipment in terms of loading (thermal ratings) and decreased outage availability
for maintenance or system disturbances (contingencies).
• Integration of generation, such as wind generation, are also growing. Existing
substation equipment can accommodate, to some extent, integration of key wind
and other generation resources. However, using up existing system capacity tends
to:
• Put increased demand on equipment (thermal and short circuit ratings)
• Reduce operating margins that allow for system contingencies, and
• Reduce maintenance and operational flexibility
• Generators are frequently connected radially making terminal equipment and line
outages for maintenance harder to obtain – availability constraints.
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Factors
• The Substation Bus & Structures is a new AC sustain asset group that requires
development of an inspection, maintenance, and replacement program. RCM and the
Substation Maintenance and High Voltage Engineering group will develop criteria and
help implement inspection and maintenance procedures as well as implementing data
templates in TAS/Cascade for tracking asset condition, maintenance and resource
requirements.
• The loss of skilled/experienced workers (maintenance, technical support, parts

specialists) through retirement and attrition is a major factor in maintaining older
equipment. The effect is compounded by reduced vendor support (parts, service,
training).
• There is an increasing demand to monitor, test, and report on equipment condition,

both for regulatory and program strategy purposes. Cascade is the data repository
which is the source for regulatory reporting. Data contained in Cascade is also in the
program strategy development and evaluation.
29
Executive Summary
Strategies
• Switchgear
What will it cost?
30
Transmission Asset Management (TAM) Goals

Applicable to AC Substation assets
Goals for sustaining transmission

Goals Strategic initiatives
G9 Information on asset attributes (condition , performance, I-12. Establish processes, procedures, controls, roles &
costs) is complete, accurate and readily accessible. responsibilities to ensure nameplate, condition assessment,
outage history, maintenance costs and other asset
information is accurate, complete, and readily accessible via
the Transmission Asset Register (implementation to be
addressed through the IPPI projects) (G9)
G10 Assets are proactively maintained and replaced I-14. Prioritize and manage maintenance and replacement backlogs
• Maintenance, replacements and sparing planning is to sustainable levels (target dates set in life-cycle strategies for
integrated each sustain program) (G10, G11)
• Priority is given to critical assets at greatest risk of
failure or noncompliance
• Reliability, availability, and other standards are met
at least life-cycle cost
G11 Maintenance is reliability centered (condition-based) I-15. Develop and implement a process that ensures replacement
and maintenance actions result in no more than X% of
critical assets at high risk of failure (target percents and target
dates sit in life-cycle strategies for each sustain program) (G10,
G11)
I-16. Develop and implement sparing strategies to assure a supply

of critical parts is geographically situated to enable timely
restoration of service (G10)
I-17. Establish condition-based maintenance standards and
implement reliability-centered maintenance as each asset
class is added to TAS (G11)
31
Strategies/ Process improvements
Process Improvement
Transmission Asset Management Goal G9
Information on asset attributes (condition , performance, costs) is complete, accurate and readily accessible.
Strategic Initiative I-12: Establish processes, procedures, controls, roles & responsibilities to ensure nameplate,
condition assessment, outage history, maintenance costs and other asset information is accurate, complete,
and readily accessible via the Transmission Asset Register (implementation to be addressed through the
IPPI projects) (G9)
TAS data repository
• Asset demographics – equipment category, type, manufacturer and model, location, ownership, licensing and age
• Condition – maintenance and inspection history, inspection and test results, trouble reports
• Performance - failure history and benchmarks, maintenance and material costs to be factored into life-cycle cost
• Is the official source(s) of asset information
• Provides ready access to the information with an intuitive interface
• Ensures data collection, validation and entry processes are efficient and timely
• Data is collected and entered close to their origin which reduces the chance of error
Asset information is assessed on a recurring basis so that only essential data is collected and unnecessary data is not.
Data requirements are determined by subject matter experts to help assess the following:
• Identify the agency decisions that require asset information
• Identify the information that is needed to supply the decisions
• Specify the data requirements
• Determine data sources
• Standardize the data definitions
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Actions to meet TAM Goal G9: Creating the Repository (TAS)
A complete and integrated life cycle asset strategy must include three core elements: (1) equipment
condition (health), (2) operating cost (labor & materials associated with operation and maintenance),
and (3) criticality (system impact) as it relates to reliability and availability.
The core of condition assessment data will be based on the continual, timely, and accurate recording of
data using the following methods:
• Operator Patrol Inspection – Performed by Substation Operators periodically or in response to trouble. Perform
visual inspection of equipment and record counters, gauges, oil leaks, damage, position, etc. that may be used
to trigger a condition based maintenance action.
• Monitoring - Monitoring provides raw data on the duty and stresses seen by equipment and their subsystems
(insulation, mechanisms, relays). Continual online monitoring is performed on a limited basis on high value
equipment where risk of loss is high and benefits warrant the added cost. Periodic monitoring is performed on
an “as needed” basis when condition indicators warrant closer and more frequent monitoring. Monitoring can be
improved with the use of newer technology like “smart relays” that can replace older relay technology and
facilitate the gathering of raw data (operating signatures and duty severity) particularly for critical breakers and
transformers.
• Maintenance – Record “Corrective” maintenance or ”Preventative” maintenance as prescribed and performed in
the “Preventative Maintenance Guides” (PMGs) which lists maintenance triggers based on equipment operating
performance, maintenance history, and failure trends, i.e. RCM principles.
• Analyze – Inspection, maintenance, monitored data must be collected in a repository which allows ready access.
CASCADE will be the key repository for condition data collection. The data will be analyzed to identify both
maintenance requirements and in part for the replacement or life-cycle strategies.
• Adjust – Adjust the triggers and values recorded based on the analysis of the data collected.
33
Actions to meet TAM Goal G9: CASCADE implementation

Objective: Asset attributes – Performance data: Includes outage history and duty severity data from other sources that
is integrated or linked with CASCADE and aligns with equipment maintenance and cost history.
Measures: Target:
Relevant system operating data from SCADA, PI, OARS, SER, DIR, Doble-DTA, TOA, etc. are integrated or linked with
CASCADE. This include (fault magnitudes, overvoltages) for critical transformers and breakers.
345 – 500kV transformer load (MW) and temperature 4th QTR 2013, Complete load and temperature data
data (peak load and temp, annual trends) are integration for 50% of all 345- 500 kV transformers.
integrated or linked with CASCADE.
Circuit breaker fault current (I2t and cumulative I2t) is 4th QTR 2013, Complete fault magnitude data integration
collected from smart relays where they currently exist for 10% - of most critical 500 kV circuit breakers.
and integrated into CASCDE.
34
Actions to meet TAM Goal G10: Life-cycle strategies

Assets are proactively maintained and replaced for optimum risk
management (resources and reliability)
• CASCADE provides full

integration and collection of
pertinent risk and condition
data.
• RCM principles are continually

applied and refined as the asset
repository (TAS) is populated
with equipment history.
• Life-cycle analysis - algorithms

are developed and implemented
in CASCADE and refined as
needed to integrate new
equipment technology and
changes in risk and condition
factors.
35
Actions to meet TAM Goal G10: Continually refine tools and data
Assets are proactively maintained and replaced for optimum risk
management (resources and reliability)
 Continually refine and update analysis tools and source data. Where value is added,
incorporate new data sources as monitoring technology advances and comes more
affordable
 Eliminate or discontinue collecting data that consumes resources but adds little or no
value since it doesn’t contribute to condition based maintenance.
 A capital replacement forecast spreadsheet has been developed which prioritizes the
next 10 years of replacements for all six of the AC Substation programs. This helps to
identify resource requirements and spare equipment/parts requirements until
equipment is forecasted to be replaced.
36
Actions to meet TAM Goal G10:

Prioritizing and managing maintenance and replacement backlogs
Objective: Using CASCADE - analyze maintenance activities resulting from both preventative
(currently time based) and corrective (driven by failures), inspections and reparability (parts & service) to
establish maintenance schedules and manage backlogs.
Measures: Target:
Scheduled preventative maintenance is deferred for equipment 4th QTR 2012, Forecasted 2 year maintenance
planned to be replaced as permitted under WECC criteria. schedules are modified to show reduced
maintenance for 50% of planned breaker
replacements.
Develop analytical criteria/algorithms to begin implementing “life- 4th QTR 2012, Preliminary maintenance
cycle” maintenance and replacement strategies for high risk algorithms are entered into CASCADE and
equipment. Develop objective, consistent, and repeatable methods maintenance priorities are tested using
that utilize the major data sources – condition, risk, material cost, and available CASCADE data.
labor costs.
37
Actions to meet TAM Goal G10: Equipment criticality

 Critical AC substation equipment is at low risk of failure.
• A Low risk of failure constitutes a Condition rating of “good, fine or fair” and a high risk of failure
constitutes an “impaired or poor” condition rating.
• Critical AC substation equipment generally consist of all power transformers and reactors,
capacitors; a majority of power circuit breakers and a small portion of circuit switchers; a large
portion of disconnect switches, primary station service power sources, and all DC control
batteries.
 Critical equipment is determined by Transmissions priority ranking criteria and other

system risk factors. Transmissions priority ranking criteria for substations and lines
assigns a ranking based on the overall criticality of the entire substation or line.
• There are minor limitations to this approach since it does not take into consideration
contingencies and variations in criticality within the substation or line.
 System operating and performance (reliability and circuit availability) criteria is developed
or identified for critical AC equipment. These include such factors as SAIFI and SAIDI,
ATC, OTC, and radial service requirements that define target service levels.
38
System Performance Measures and Targets
Applicable to AC Substation assets TAM Goal G10
Measures: Target:
Category A - Transmission Line Reliability & Availability: See System Performance Measures
AC substation terminal equipment failures or maintenance outages affecting & Targets on next slide
transmission line automatic or planned (maintenance) line outages. (Category A)
− Provide success indicators for minimizing unplanned line outages due to
substation equipment (terminal equipment) failures. ( SAIFI & SAIDI for lines)
− Provide success indicators for managing substation equipment maintenance
outages to minimize planned line outages.
Category B – Circuit Availability (Transmission Curtailment): TBD – ATC/OTC Targets

AC substation equipment failures or maintenance outages affecting transmission (Category B)
path ATC, OTC ratings.
− Provide success indicators for minimizing unplanned substation equipment
outages (failures) resulting in a reduction of available or operating transmission
capacity.
outages to minimize possible reductions in transmission availability
Category C – Circuit Availability (Load Shedding): TBD – Load Service Targets

AC substation equipment failures or maintenance outages affecting load service. (Category C)
− Provide success indicators for minimizing unplanned substation equipment
outages (failures) resulting in load loss, service disruption.
outages to minimize load loss, service disruption.
39
System Performance Measures and Targets TAM Goal G10

Category A - Transmission Line Reliability & Availability Applicable to AC Substation Assets
40
Actions to meet TAM Goal G10: Sparing strategies

Strategic Initiative I-16: Develop and implement sparing strategies to assure a
supply of critical parts is geographically situated to enable timely restoration of
service.
Objective: Develop new and revise existing maintenance standards such as

the Preventative Maintenance Guides (PMG’s) and Substation Maintenance
Standards and Guides to shift from time based to reliability centered
maintenance (RCM) as applicable. (Relates to G11)
Measures: Target:
Sparing strategies for 500 kV transformers are completed and 4th QTR 2012
approved by the CAB.
Sparing strategies for 69 kV – 345 kV transformers are 2nd QTR 2013
completed and approved by the CAB.
Sparing strategies 230 kV & 500 kV reactors are completed and 4th QTR 2013
approved by the CAB.
Emergency spare inventory is evaluated on all other equipment ANNUALLY
groups.
41
Transmission Asset Management Goal G11

Strategic Initiative I-17: Establish condition-based maintenance standards and implement reliability-
centered maintenance as each asset class is added to TAS (G11)
Strategy considerations:
• In order to modify existing time-based maintenance practices to RCM, a minimum amount of

historical data must be captured and analyzed.
• Equipment health algorithms can be implemented and tested in Cascade based on collected
maintenance and inspection data.
• BPA must continue to meet existing and new WECC/NERC maintenance requirements while
transitioning from traditional time based maintenance to a condition based maintenance approach
based on RCM principles.
42
Actions to meet Goal G11: “Maintain vs. Replace” Strategies
Operate to Failure Considerations – Criticality and risk objectives need to take into consideration
equipment functionality in making “maintain vs. replace” decisions. This includes providing criteria, in
terms of reliability, to permit functional failure to varying degrees for each equipment type. Having a
strategy which attempts to completely avoid all in service failures, i.e. striving for all assets to be “good”
condition - is not a realistic or financially attainable goal.
• Failure Definition – Failure can have many definitions and is defined here for the context of
this strategy. Failure means the equipment or component is no longer performing it’s function as
designed and does not necessarily imply destructive or irreparable failure. The goals set forth in
this strategy are focused on managing risk and resources by allowing “functional” failure in
some instances, but still planning for the replacement/retirement prior to destructive failure and
to levelize resource requirements.
• The “operate to failure” premise is intended to address the differences in equipment

maintenance, and associated repair/replace strategies. Some equipment lends itself to
repair/refurbishment after functional failure and others do not.
• Substation equipment that is repairable tends to have moving parts, is made up of subsystems
(i.e. interrupters, operating mechanisms, load tap changers, resealable insulation systems etc.)
and tend to be high cost. Equipment that is not repairable tends to have few if any moving parts
or subsystems and have insulation systems that are permanently sealed and tend to be lower
cost.
43
Actions to meet Goal G11: “Maintain vs. Replace” Strategies
Operate to failure guideline – Building on the “operate to failure” considerations from the
previous slide the following outline provides the predictors for the types of equipment that may be
permitted to fail while in service. This criteria should guide the level of effort for condition assessments in
terms of resources to expend and types of data to be collected for risk and condition factors.
Operate to Failure/Near Failure Do NOT Operate to Failure

Equipment Characteristics Equipment Characteristics
• Mainly equipment with many moving parts –

• Equipment with few moving parts and little inherently maintenance intensive
to no maintenance can be performed • Built in bypass capability in most stations for
• Condition monitoring relies mainly on maintenance
inspections and infrequent interval testing • Failure predictors rely on recordable maintenance
trend data/monitoring, duty severity, component
• Online monitoring is cost prohibitive in failure rates
most cases (monitor may cost more than
the equipment and measurement may not • Replacement predictors rely on:
be feasible) • Availability of spare parts
• Replacement predictions rely on long term • Ability to rebuild/refurbish
failure trend data & age for the entire unit • Equipment life cycle costs, component &
and associated degradation factors subsystem performance
(insulation life expectancy)
44
Actions to meet Goal G11: Implementing RCM
The following transition periods are based on existing maintenance intervals and the estimated time
needed to populate the CASCADE data repository with sufficient data to make well-guided transitions.
Objective: Develop new and revise existing maintenance standards such as Substation Maintenance
Standards and Guides to shift from time based to Reliability Centered Maintenance (RCM) as applicable
and outlined in the Preventative Maintenance Guides (PMG’s). (Relates to G11)
Measures: Target:
Timeline by which PMG’s for RCM methods are Target:4th QTR 2012: Preliminary RCM PMG’s are
approved for power transformers, grounding in place for all these equipment types.
transformers, oil filled reactors, instrument
transformers, disconnect switches (excluding Target 2017: Final Approved RCM PMG’s are in
operators), station service transformers. place for all these equipment types
3-5 year transitions: Power circuit breakers & Interim Target:4th QTR 2012, Implement/test
circuit switchers (operators and mechanisms), preliminary RCM maintenance for “light service
shunt capacitors, disconnect switch motor
operators, station service transformers, surge duty” SF6 Gas breakers.
arresters. Target 2015: Full RCM practices
2-4 year transitions: DC control batteries, battery 1st QTR 2013: Begin implementing full RCM
chargers, control circuits for power circuit breaker practices
and circuit switcher, engine generators.
45
Actions to meet Goal G11: Implementing RCM
• Subject matter experts (SME’s) in RCM, technical services groups, and IT will
facilitate integration of pertinent risk and duty severity data into CASCADE, i.e.
SCADA, PI, OARS, SER, DIR, Doble-DTA, TOA, etc. type data.
− This may require additional software tools to integrate or link data from these separate
data systems with CASCADE or an expansion/customization of CASCADE.
• SME’s will analyze, develop, and select appropriate replacement ranking methods
(algorithms) to prioritize replacements and use RCM principles to develop
maintenance triggers.
− Incorporate study results from EPRI, CEATI, KEMA, and other sources as applicable to BPA
assets to build algorithms in Cascade.
− Through BPA’s involvement in these outside organizations criteria has been developed to
assess asset health and develop algorithms to trigger maintenance, refurbishment or
replacement of equipment.
• Maintenance triggers will be adjusted based on the analysis of recorded data and
value of work being performed.
46
Executive Summary
Strategies
• Switchgear
What will it cost?
47
Transformers & Reactors: Asset Criticality

• Power transformers convert power (voltage and current) to maximize the efficiency
in moving and delivering power between generation sources and load centers.
Transformers facilitate the transfer of power between substations, utilities, and
generators that operate at different voltages.
• Reactors serve two primary roles: 1- Controlling potentially harmful system

overvoltages on long transmission lines, particularly during light load conditions; 2
- Reducing system fault currents.
• Criticality is determined by the combination of 1- Substation and Transmission Line

priority ranking criteria, 2-radial only service, and 3-various contingencies affecting
ATC/OTC and RAS schemes.
• All 500 kV, 345 kV, and many 230 kV power transformers are considered critical
equipment. This includes all 500 kV reactors used for voltage control and fault
reduction.
• Criticality is used in risk assessments and in prioritizing replacement and

maintenance work.
• Per a study conducted by 1st Quartile in May 2011 BPA’s transformers are generally
older than other utilities.
48
Equipment strategies/ Power transformers and reactors
Transformer & Reactor: Performance Objectives

Power Transformer Performance Objectives
• Performance Objective: Ensure that equipment and procedures are in place that allow service
restoration to be completed within targeted time limits.
− Measure(s):
 Service restoration performance
− End-Stage Target(s):
 Spare transformer strategies for 500 kV have been approved by the CAB Q4, FY 2012, and
for 69-345kV by Q2, FY 2013. Transformers are procured and deployed consistent with the
strategy. The number and location of spares is included in this strategy.
In the event of a transformer failure
 Emergency mobile transformers (trailer mounted) are energized 24 to 100 hours after
notification
 Non-mobile spares are energized within 24 hours for sites with a jack-bus to a maximum of
750 hours for sites with no jack-bus or no spare on site.
Reactor Performance Objectives
• Performance Objective: Ensure that equipment and procedures are in place that allow service
restoration to be completed within targeted time limits.
− Measure(s):
 Service restoration performance
 By 4th QTR 2013 loss of reactor contingency plans, including spares strategy, are completed.
This will include the number and location of spares for shunt (oil filled) reactors and
contingency options for loss of both shunt and series (air core) reactors .
49
Transformer & Reactor: Age Demographics

Power Transformers, Grounding Transformers and Reactors
by Age and Voltage Classification
BPA has enjoyed
exceptional
160
The average transformer life
spans. Approximately
expected life is 7 250 of BPA’s power
140 45-50 years transformers are 50
16 years or older and
about 90 of those are
120 over 60 years.
11
4
Number of Units
100 7 18
64 7
4
80 3
7 40 21
17 45
60
23
2 5
3 5
6 27
40 5 8 30 43
20
42 39
20 33
25 23
14 15
0
0-10 Yrs 11-20 Yrs 21-30 Yrs 31-40 Yrs 41-50 Yrs 51-60 Yrs 61-71 Yrs
345-500 kV 230 kV 115-161 kV 15-69 kV Missing kV
50
Transformer & Reactor: Failure Factors
Transformer failure history shows that BPA’s mean time between failures (MTBF) for 500 kV auto
transformers is 1 failure every 18 months. This is a statistical calculation that spans almost 5 decades
and 2917 transformer operating years. In 2009 when the study was completed 27 auto transformers had
failed with 18 being replaced and 9 being repaired. Since that time the numbers have increased to 29
failures with 20 being replaced and still only 9 being repaired.
 Transformers with bushing and load tap changer failures typically do not require complete
transformer replacement. However, both of these repairs are limited by the availability of vendor
support, the ability to stock adequate quantities of replacement bushings in inventory, and the
special facilities, tools, and skills required of BPA staff to carry out these repairs.
 Transformers with winding or insulation failures are frequently deemed not repairable. In many
cases the repair and shipping cost are comparable to buying a new transformer.
 Large Power Transformers and reactors tend to be unique in design and trouble indicators can vary
widely between units, vendors, and construction. Improvements in monitoring and use of
system/equipment event data can assist in evaluating transformer reliability. Power Transformers
and Reactors often fail without prior warning.
 Monitoring of system conditions affecting transformer load, duty (stress), and transformer
condition data is either severely limited or very decentralized. Improving monitoring practices will
become a key component in evaluating transformer reliability to better prepare for eventual
failures, minimize system interruptions, and help avoid potential oil spills in sensitive areas.
51
Transformer & Reactor: Demographics and Performance History

In its roughly 60
year history, BPA
has experienced
at least 14 power
transformer and
reactor failures
every ten years.
Industry asset
reports indicate
15 failed units
11 failed units
10 failed units
that there will be
< 10 yrs old
< 10 yrs old
< 10 yrs old

marked increases
in failure rates
when the existing
assets enter their
5th decade of
service.
Detailed data on
failures resulting
in replacement
vs. repair is
limited. Some
data for 1991-
2010 indicates a
high percentage
of 500 kV
transformer
failures that were
not repairable.
52
Maintenance Costs– Power Transformers and all Reactors
Maintenance cost fluctuations

due in part to:
• Natural peaks in maintenance

cycles due to 7 year
preventative maintenance
intervals
• Catching-up with existing
backlogs to meet new WECC
maintenance requirements
53
Transformer & Reactor: Assessing Risks
54
Transformers & Reactors: Strategy

The Power Transformer and Reactor strategy is focused on four key areas:
• Maintenance and Operations approaches
• Maintaining the proper level of spare equipment and parts
Performance - Monitor/Record/Analyze Data

• Parameters to be monitored and recorded:
− Gas in Oil (GIO), currently very limited online monitoring with “Hydran” or similar monitors
− Temperature
− Loading (SCADA, PI)
− Inspections - recorded via CASCADE Patrol Inspection templates
− System conditions - Faults (Relay data from Digital Fault Recorders, Future “smart relays”)
− Corrective maintenance - triggered by equipment failure reports recorded via CASCADE
corrective maintenance templates)
− Preventative maintenance - Both periodic – Annual GIO, and triggered maintenance:
preventative maintenance guides (PMG’s) recorded via CASCADE Maintenance templates
• Maintenance data to be recorded (include frequency, maintenance hours, cost)
− GIO (Annual Test)
− Load Tap Changer service
− Bushings - Power Factor testing
− Oil leak inspection and mitigation
− Windings – Insulation Power Factor, Turns Ratio
55
Maintenance and Operations

Oil filled power reactors are very similar to power transformers in terms of life span,
maintenance, and failure predictions albeit they are somewhat simpler in design and
construction.
• Maintenance – Maintain the integrity of the transformer insulation system. Due to

relatively long lead times for replacing and repairing failed transformers the key to
this strategy is maintenance (preventative & corrective), data gathering (inspect,
test, monitor) and maintaining spares.
• Operations – Manage load levels below thermal limits to lengthen transformer life.
Protect against faults (relaying) and surges (MOV’s) to minimize internal mechanical
and electrical damage.
56

Equipment standardization
• For large Power Transformers (230 kV – 500kV) “Strategic Sourcing” is securing Master Agreements
and Compliance Contracts to optimize cost and delivery time. Power Transformer sizes have been
standardized at 433MVA (1-Phase) for 500 kV and 300MVA (3-phase) for 230 kV. This
standardization has allowed BPA to enter into a long term requirements contract reducing delivery
time from average 24-30 months down to 8-20 months. When making replacements, transformers
will be low loss, low noise, high internal fault capability transformers. They should be similar in
design for efficiency of support and redundancy across the system.
• Large Power Transformers and reactors tend to be unique in design and trouble indicators can vary
widely between units, vendors, and construction. Improvements in monitoring and use of
system/equipment event data can improve predictions in transformer reliability. Power Transformers
and Reactors often fail without prior warning.
Spare Equipment and Parts

• Spare transformer strategies need to be updated and revised to address the current risk criteria.
These spare transformers are necessary to maintain existing transformers, ensure transportation of
spare transformers does not affect BPA’s ability to continue reliable service for transformer failures,
and mitigates the risk associated with managing an aging transformer population.
• Installing fourth phase spare transformers would be in-line with practices at other major utilities
including TVA. It will ensure that as the transmission system becomes more and more congested
and outages become difficult to take, that maintenance can still be performed by placing the fourth
phase spare transformer in-service.
57

Purchasing and Spare Equipment Policies
• The current number of spare transformers for operating voltages 230 kV and below is
one spare for every 20 banks (3-phase) in service. The 1:20 ratio of spares is based
on historical failure rates, service restoration targets, and industry practices for
spares in this voltage range. This ratio allows BPA to cover the failure of two
transformers 95% of the time.
• The number of spare 345 kV & 500 kV transformers is risk based and the policy
guidelines vary depending on the type of service. Spare units of this size are not
determined by a fixed ratio but on system operating risk (ATC/OTC), transportation
constraints, generation curtailment, and maintenance requirements.
• In October 2008, a business case was approved to procure 5 additional 500 kV spare
transformers. These 5 new transformers are being used to improve transformer bank
availability in the event of a failure and also to serve as system spares for banks
which do not have an on-site spare transformer.
• The approach for spare transformers has been a subject of much discussion in recent
years due to increasing limitations in maintenance outages, limitations in
transportation (road & rail), and risk of damage during transportation of large 345
kV & 500 kV spares.
• Spare power transformer support for regional customers, and nationally - member of
EEI (Edison Electric Institute) STEP Program since 2006
58
Transformers & Reactors: Implementation Milestones

Sparing Strategy
• By 4th Qtr 2012 the transformer spare strategy for 500 kV transformers shall be updated and the new strategy
approved by the CAB. Approval by ACPRT will be completed by 3rd Qtr 2012.
• By 2nd Qtr 2013 the transformer spare strategy for 69 kV - 345 kV transformers shall be updated and the new
strategy approved by the CAB. Approval by ACPRT will be completed by 1st Qtr 2013.
• By 4th Qtr 2013 the 500 kV - 230 kV reactor spare strategy shall be updated and the new strategy approved by
the CAB. Approval by ACPRT will be completed by 3rd Qtr 2013.
• By 1st Qtr 2014 replace 230 kV Redmond bank T01626 (3-phase), and put the spare transformer T01670 back on
standby.
• By 1st Qtr 2014 replace 500 kV Pearl T01784 (single phase).
• By 1st Qtr 2015 replace Yaak 115 kV transformer T00502
Capital (Substantial Betterments- SB) & Expense
• By 2nd QTR 2013 SB - Complete bushing upgrades on 2 additional transformers to eliminate capacity limits
(bottleneck)
• By 4th QTR 2014 SB - Complete all Type “U” bushing replacements.

− The bushings are capital as they provide substantial betterment. Labor is expense for bushing upgrades and Type U bushing
replacements.
• Expense - Complete 10-15 load tap changer services (contracted work) annually. (Number based off historic
trends)
59
Executive Summary
Strategies
• Switchgear
What will it cost?
60
Switchgear: Asset Criticality
 Power Circuit Breakers (PCB) provide a means to clear system faults, and protect
substation equipment such as Power Transformers from damaging system
disturbances (faults, lightning).
 Circuit Switchers (CS) are primarily used to switch reactive equipment (Capacitors
and Reactors) in and out of service. Circuit Switchers are also used on a limited basis
to clear faults.
 Disconnect Switches (DS) allow isolation of equipment from energized parts of the
system and facilitate the maintenance of high voltage equipment in substations and
on transmission lines.
 Both Substation and Transmission Line priority ranking criteria will establish the
criticality of all switchgear and will be used to determine the magnitude and
consequence of an outage for purposes of assessing risk.
61
Equipment strategies/ Switchgear
Switchgear: Performance Objectives

Performance Objective - Maintenance, All Switchgear: Manage workload and resources to avoid regularly
scheduled preventative maintenance to exceed 25% past target due date.
− Measure(s):
 Number of switchgear that are more than 25% past their scheduled service dates unless there are
acceptable mitigating factors (i.e. planned replacement within 2 years or less).
 100% of all WECC and OB-19 Significant Equipment switchgear maintenance shall be completed within
the prescribed timeline – not to exceed 125% of the total maintenance interval.
• The only exception is if there is a deferral of the maintenance service approved by a subject matter expert in
Substation Maintenance and High Voltage Engineering.
Performance Objective - Replacements: Prioritize the replacement of switchgear based on system criticality and
performance. Those that ranked at high system risk (“high system impact” and “poor” condition”) and cannot be
maintained and refurbished to a reliable operating condition will be scheduled for replacement.
− Measure(s):
 Number or percent of replacement project designs and/or installations completed to meet the start of
year (SOY) projection for the asset group. Allow for adjustments based on resource ($, labor, materials)
availability.
 Complete all “emergency” replacements within the timeframe prescribed by Substation Maintenance and
High Voltage Engineering (TESM) and System Operations (TOP).
 In any fiscal year 85% of designs will be completed for all new start switchgear replacements.
 In any fiscal year 80% of the prior years’ planned switchgear replacements will have been installed and
energized.
62
Switchgear: Performance Objectives (2)
Performance Objective - Fault Duty Upgrades: - Avoid generation curtailment, bus sectionalizing (possible N-2
contingency), and increased safety risk due to inadequate nameplate ratings for fault duty on in service switchgear.
Applicable standards:
1. National Electrical Safety Code Section 17 , NERC TOP-004-2, NERC FAC-010. Comply with NESC Section 17
paragraph 171: . . . "Devices that are intended to interrupt fault current shall be capable of safely interrupting the
maximum short-circuit current they are intended to interrupt, and for the circumstances under which they are
designed to operate. The interrupting capacity should be reviewed prior to each significant system change."
2. NERC TOP-004-2, B. Requirements, R1. "Each Transmission Operator shall operate within the Interconnection
Reliability Operating Limits (IROLs) and System Operating Limits (SOLs)."
− Measure(s):
 Complete system fault current studies, breaker analysis, and Project Requirements Diagrams (PRD) to
identify required fault duty switchgear upgrades and replacements.
 Complete design and construction of fault duty switchgear replacements.
 By the end of 1st QTR, each year, complete initial system wide fault study’s and switchgear analysis
(TESM) for the subsequent 2 year capital planning cycle.
 By March 15th (beginning 3rd QTR) – Switchgear Replacement PRD’s are issued (TOP) for the
subsequent 2 year capital planning cycle.
 By the end of 2nd QTR business cases and resource schedules are completed for the subsequent 2
year capital planning cycle.
 Complete 100% of replacements/upgrades of underrated switchgear within 2 years prior to system
fault current exceeding switchgear ratings.
63
Switchgear: Current State of the Assets

Circuit Breakers, Circuit Switchers, and Disconnect Switches
Key issues with the current state - General Problem Areas:
• The availability and cost of spare parts is the most significant factor in keeping all
switchgear operating reliably. The decline in vendor support, for both parts and
refurbishment service, will drive an increase in replacements whether planned or
unplanned.
• The majority of replacements are based on the availability of spare parts and cost of
those parts compared to the remaining life, frequency and cost of repairs, and the
frequency of failures.
• Many existing breakers and switchers are maintenance intensive due to their
complexity – mechanical (hydraulic, spring, combination), insulation systems (oil, air,
SF6, vacuum)
• Life extensions may be performed but do not always deliver the expected additional
life. Parts used in life extensions, rebuilds/refurbishments are often aged, salvaged,
or inferior quality to the original part and may last only a fraction of the original
parts’ lifespan.
64
Switchgear: Current State of the Assets –

(Breaker Age Demographics)
15-69 kV Total = 1,794 115-161 kV 230 kV 500 kV
700
The average
601 expected life of a
600 power circuit
141 breaker is 25 -30
452
500 years
98
Quantity
400 307
209
300 177 64
162 152
104
200
181 23
24 47 92
144 80 19
100 62 60 28
21
70 59 53 52 5
33 45 23
0
0-10 11-20 21-30 31-40 41-50 51-60 60+
Age (years)
65
Maintenance Costs – All Circuit Breakers
Maintenance cost increases due in part to:
• Increased costs for spare parts & service;

• Increased corrective maintenance due to in-service
failures & aging
66
Maintenance Costs – All Circuit Switchers
Number of Units & Percent of Total

CS Maintenance cost for 6 Years:
500 kV CS = 8 (17.5%) !!!
230 kV CS = 82 (49.6%)
115 kV CS = 84 (29.9%)
Maintenance Cost $(k)
69 kV CS = 12 (3.1%)
Year
67
Switchgear: Failure modes

Power Circuit Breakers and Circuit Switchers:
• Mechanical Failures - Operating mechanism (Most Common failure mode) -

Moderate to high repair cost, may damage the breaker or switcher beyond
repair.
• Insulation Failures – Failure of the insulating medium, SF6 Gas, Oil, Air, or
vacuum leads to internal faults (least common failure mode) – Moderate to
high repair cost, may have significant system impact due to longer repair
time, can damage the breaker or switcher beyond repair. Has NEPA
Implications - SF6 Green house gas emission regulations or oil
contamination of soil or water.
• Control failures – (Most common after Mechanical Failures) - Tend to be

least cost to repair but can have significant system impacts during failure.
Disconnect Switches:
• Mechanical Failures – The moving parts of the switch itself or the operators
(manual or motor operated) wear out over time inhibiting the safe opening
and closing of the switches.
68
Switchgear : Failure Modes (2)
Disconnect Switches:
• Insulator failures - Fatigue on Low voltage fused disconnects - Safety Hazard: Insulator Failures
occur during open/close manual operation. Where replacement insulators cannot be fitted to the
old switch or other excessive wear is present the switch is replaced.
• Hydraulic operating mechanisms - Failures on certain models of 500 kV and 230 kV motor
operated disconnects are increasing due to component end of life and inability to obtain spare
parts to repair the hydraulic mechanisms.
• Mechanical Failures – The moving parts of a disconnect switch itself or the operators (manual or
motor operated) wear out over time inhibiting the safe opening and closing of the switches.
Poorly functioning switches increase arcing during opening that may put operators at risk,
introduce “noise” into the system, and prematurely wear out the contacts.
− Disconnects: Increased failure rates of insulators on low voltage 15 kV class fused
disconnect switches and inability to retrofit the older switches with new insulators.
• Mechanical Design Flaws – Safety Hazard: The RV 500, MK-40, and TA-4 Model switches were
recently found to have a design defect that does not provide positive mechanical restraint of the
switch blade in the open position and can result in inadvertent closing of the blade.
− Disconnects: The recent identification of approximately 110 switches with models in the
115, 230 & 500 kV voltage classes with safety restraint problems. Modifications are not
possible on these models without switch redesigns and the vendors are no longer in
business.
69
Switchgear: Assessing Risk for Circuit Breakers (PCB) & Circuit Switchers (CS)
Poor
High Maintenance
cost, Limited Vendor
Support & Parts
Fair
Good
70
Disconnect Switches: Assessing Risk
Switch blade design

problem
w/3 Model
types in all voltage
groups
Poor
Fair
Good
71
Maintenance Costs – All Disconnect Switches
Maintenance cost fluctuations due in part to:
• Natural peaks in maintenance cycles due to 8 year (500kV) & 10 year (<500kV)
preventative maintenance intervals
• Catching-up with existing backlogs to meet new WECC maintenance requirements
72
Switchgear Strategy
1. Maintenance (preventative & corrective) including stocking or securing quick access to stocked spare parts and vendor
supplied parts.
2. Spares - Maintaining emergency spares (EMS) – strategy is to have breakers, circuit switchers and disconnects that can
cover all voltage classes. For switchgear, “Strategic Sourcing” will be used to secure Master Agreements and
Compliance Contracts to optimize cost and delivery time.
− Emergency Stock (EMS) - goal is to have at least one spare that can be applied to each of the following voltage
classes, 15, 34.5, 69, 115, 138, 161, 230, 287, 345 and 500kV for all switchgear types. In addition - for breakers,
there will be at least two spares at 115, 230, & 500 kV. In some cases a higher voltage rating may be used to
cover for a lower one (i.e.: a 345-kV switch for 287 kV). Keeping the stocking numbers down and using higher
voltage ratings in a lower voltage position help maximize the benefit/cost ratio.
− Switchgear EMS levels are based on much shorter lead time compared to transformers. The ability to obtain a
replacement varies from two weeks to six months
− Emergency O&M agreements allow for purchase of equipment from partner utilities but will not be relied upon as
a primary source of spare equipment.
3. Data gathering (inspect, test, monitor) as applicable to develop failure prediction and replacement algorithms.
− Monitor/Record/Analyze Data - Parameters to be monitored and recorded:

 System risk data (external to CASCADE) SCADA, PI, OARS, SER, DIR, TOA, DTA, WPSS
 I2t and cumulative fault current
 Relay coil signatures and contact wear
 Gas density/purity
 Duty type, number of operations, etc.
 Insulation system condition (SF6 moisture/purity, SF6/Oil leaks)
 Bushing power factor, bushing condition
 Mechanical operating system condition (hydraulics, springs, compressors, etc.)
 Electronic control systems
− Relay signatures and current [amps] data could be collected with the replacement/upgrade of older relays with
digital “smart relays” where criticality and equipment value make it cost effective. Smart relays can provide
similar data to SCADA, PI, SER but integrated with specific breaker and relay operating characteristics.
73
Switchgear: Strategy – Condition driven replacements

Modern circuit breakers and circuit switchers, mostly SF6, mixed gas, air or vacuum devices, have an
average expected life span of 25 - 30 years.
Due to the large number of individual parts circuit breakers and circuit switchers are highly repairable.
Destructive failure is largely avoidable on these devices since most units are replaced when they can no
longer be repaired. Circuit breakers and circuit switchers are typically replaced when spare parts are no
longer available or the optimum life cycle cost has been exceeded.
− Strategy Focus:
 Breakers: Certain models of oil circuit breakers are obsolete due to a lack of spare parts.
Some life extensions/partial rebuilds are not providing the expected 15 years of extended,
reliable service. Certain models are no longer repairable - reliability is falling in spite of
service/maintenance.
 Circuit Switcher: Manufacturer support and spare parts for 230 kV and 500 kV S&C Mark
IV & Mark V is diminishing - combined with a steady increase in the replacement rate of
interrupters and operating mechanisms, and a decline in the life/performance of the
replacement interrupters. Replacement parts and maintenance costs have exceeded the
material replacement cost, over a 6 - 8 year period for most 500 kV units.
74
Switchgear: Strategy – Condition driven replacements (2)
Disconnect switches have an average lifespan of 35-45 years which is very dependent on the type of usage
and the ability to repair and replace components.
Similar to circuit breakers and circuit switchers disconnects have a large number of individual parts, and
are highly repairable. Violent failure is very rare due to the lack of a pressurized insulation medium. Units
are replaced when they can no longer be repaired or repair cost and frequency exceed optimum life-cycle.
Poorly functioning switches increase arcing during opening that may put operators at risk, introduce
“noise” into the system, and prematurely wear out the contacts.
− Strategy Focus:
 Mechanical Failures - The recent identification of approximately 110 switches with models in the 115, 230 &
500 kV voltage classes with safety restraint problems and no spare parts - modifications are not possible on
these models without switch redesigns and the vendors are no longer in business.
• Insulator Failures - Fatigue on Low voltage fused disconnects - Safety Hazard: Insulator Failures occur
during open/close during manual operation. Where replacement insulators cannot be fitted to the old switch
or other excessive wear is present the switch is replaced.
• Hydraulic Operating Mechanisms - Failures on certain models of 500 kV and 230 kV motor operated
disconnects are increasing due to component end of life and inability to obtain spare parts to repair the
hydraulic mechanisms – 50 total.
When making replacements, switchgear will be of proven technology from industry leaders in reliability.
Application of equipment will be made to meet current system operating demands and projected load
and generation growth.
Postponement of planned switchgear replacements shall be coordinated and approved by both the
Substation AC Sustain Program Manager and the Substation Maintenance engineer responsible for
prioritizing condition based switchgear replacements.
75
Switchgear: Strategy - Fault Duty driven replacements
• Fault current system studies are conducted bi-annually for

the entire transmission system.
• Individual, localized, studies are conducted for every new
proposed generation project or generation expansion.
• Fault studies are also conducted for any new line additions,
line reconfigurations, transformer additions/removals that
were not included in the bi-annual studies.
• Fault current studies and subsequent switchgear fault duty

analysis shall be geared toward a two year design and
construction upgrade window. This will provide adequate
time for design, material procurement, and labor resource
scheduling.
76
Implementation Milestones
Fault duty switchgear - Avoid standards violations.
− Measure(s):
 Any existing safety restrictions (limiting work around underrated equipment) and operating
restrictions/temporary operating bulletins are eliminated.
 4th QTR 2012 100% of prior years’ (2010 & 11) fault duty circuit breakers and circuit switcher
upgrades/replacements have been completed.
Emergency Spares - Ensure that equipment and procedures are in place to facilitate service restoration for
emergency replacements/failures.
− Measure(s):
 EMS PCB’s, CS’s, and DS’s are issued on an “as-needed” basis after review by SME’s for proper rating
application. Stock is cycled and usage triggers a re-order to pre-defined stocking levels. EMS PCB’s, CS’s,
and DS’s are checked for condition and readiness on a monthly basis to minimize restoration time.
Reporting on existing and re-ordered EMS equipment is available from TESM and Substation Design.
 In 2011 95% of all emergency replacements are achieved with “on hand” EMS stock for complete units
(2ea emergency replacement in FY2011: Troy L-953, Marion 4355 – both replaced using “on-hand” EMS
equipment). This is done to ensure cycling of the EMS stock equipment.
 By 2nd QTR 2012 80% of all preventative maintenance repairs are achieved with spare parts on hand.
Parts consisting of major components not readily available (interrupters, contactors, control relays, arcing
contacts, motor operators, “O” rings, etc.)
77
Executive Summary
Strategies
• Switchgear
What will it cost?
78
Shunt Capacitors: Asset Criticality
• Capacitors provide additional transmission capacity by boosting voltage and

decreasing reactive line losses thereby increasing power transfer between lines and
stations on both BPA’s system and interconnected utilities and generators.
• Small air core current limiting reactors are part of this asset group as they are used
in conjunction with multiple capacitor groups on the same bus to limit high
currents that can damage capacitors while switching. When more than one
capacitor group is connected to a bus and either one can be switched while the
other is in service it is called “back-to-back” switching.
• The criticality of shunt capacitors is determined by Transmissions priority ranking

criteria combined with system contingencies, and RAS – these include extreme
weather conditions that increase system loading.
• As a result of aggressive environmental mitigation all of BPA’s shunt capacitors are

PCB free. Compared to other AC asset groups the average age of BPA’s shunt
capacitors is 16 years which is relatively moderate in age due to the PCB
replacement program completed in 2004.
79
Equipment strategies/ Shunt capacitors
Shunt Capacitors: Performance Objectives

For Fused & Fuseless Capacitors and associated current limiting reactors (CLR’s)
• Performance Objective: Avoid reductions in ATC/OTC for loss of shunt capacitor groups or sections. Critical during
heavy load conditions. Critical links: Availability of capacitors is contingent on both the relays and switchgear
(breakers & circuit switchers) used to protect and control the capacitors.
− Measure(s):
 Reductions in ATC/OTC
 Load shedding to avoid system collapse or system instability
 Reliability of breakers or circuit switchers used to switch capacitors in and out of service
 Reliability of control & protection relays for shunt capacitor (Performance Targets in SPC Asset Strategy)
 Spare capacitors, fuses and associated hardware are stocked for all capacitor ratings installed on the
system
 By 3rd QTR 2012 Criteria is developed to correlate shunt capacitor availability to ATC/OTC
 Performance targets are developed for switchgear and relays in their respective Asset strategies
• Performance Objective: Avoid operating restrictions of shunt capacitor groups for loss of a current limiting reactor.
Current limiting reactors reduce the exchange of high current between capacitor groups that can damage capacitors
during switching.
− Measure(s):
 All stations with multiple capacitor groups on the same bus shall be capable of back-to-back switching.
 By 4th QTR 2015 install CLR’s at three remaining sites so that existing operating restrictions for back-to-
back capacitor switching can be eliminated.
80
Shunt Capacitors: Age Demographics
311
320 15
Average age
= 16 years
280
60
240 169
200 9 107
9
160
45
69
120
21
6 9
80 117 12 12 15
15
79 18
40 6 3 6 3 6
27
6 3 6
0
0 - 10 11 - 20 21 - 30 31 - 40 41 - 50 51 - 60
115 kV 138 kV 15 kV 230 kV 500 kV 69 kV
81
Shunt Capacitors: Failures Modes
Capacitors are made up of many individual units often referred to as “cans” that are connected together
to form “groups” and “sections” for operating purposes. There are three main types of capacitors that
are defined by the way individual cans are protected: externally fused, internally fused, and fuseless.
Capacitors are connected in various combinations of series and parallel strings made up of lower voltage
(ex. 22 kV) units to make a complete group that operates at the various system voltages (69kV - 500kV)
In general entire capacitor groups or sections are replaced infrequently for condition driven factors since
individual cans are replaced as needed. Some exceptions are an excessive quantity of capacitor can
failures that may be attributable to a poor design or poor manufacturing quality.
• Capacitors fail when their internal wrappings are damaged due to high electrical stresses (voltage
or current) or when moisture invades the sealed units also leading to electrical stress failures.
Capacitor failures are primarily a failure of the internal insulation of the individual cans. The
internal insulation frequently includes some type of insulating material such as paper and/or Mylar
which are impregnated with an oil such as mineral oil.
• Capacitor condition is based on individual capacitor “can” (single capacitor unit) failure rates,
which is largely based on electrical stresses, age and, and moisture ingression that leads to the
deterioration of the capacitors’ internal insulation.
• Fuse failures for fused shunt capacitors, premature degradation due to weather/moisture.
• Switching frequency (in and out) and exposure to transients that degrade insulation.
• For very old capacitor designs the existing racks and foundations may no longer meet the basic
structural and/or seismic design requirements particularly if the newer replacement cans are
physically larger, heavier, or the dimensions of the new cans won’t fit the old rack.
82
Shunt Capacitors: Assessing risks
Poor
Fair
Good
83
Shunt Capacitors: Strategy

The shunt capacitor strategy for both fused and fuseless types is focused on four key areas:
• Maintenance and operations approaches
Monitor/Record/Analyze Data
− Voltage measurement/monitoring for capacitor groups & sections
− Bushing & can condition (contamination, bulging, discoloration, moisture ingression)
− Condition of associated PT’s and control relays
• Maintenance data to be recorded (include frequency, maintenance hours, cost)
− String capacitance (fuseless banks)
− Capacitor can oil leaks
• Analyze
− Capacitor can & fuse failure rates
Optimal Replacement Window

• Capacitors have an average expected life span of 25-30 years.
• Capacitor “Groups” are highly repairable since individual cans and fuses can be replaced up to a certain point. If
can or fuse failures become excessive then a complete replacement may be needed.
• Up to this point obtaining replacement cans and fuses has not been an issue since most standard sizes and ratings
are still available from either the OEM or substitutions can frequently be made.
• If the existing capacitor rack and foundations design cannot accommodate changes in capacitor can or fuse design
and still meet seismic requirement then a complete replacement will be required.
• When making replacements, capacitors will be proven technology from industry leaders in reliability. Application of
equipment will be made to meet system operating demands. Installation will include testing and verification of
operation.
84
Maintenance Costs – All Shunt Capacitors
85
Shunt Capacitor: Purchasing and Spare Equipment Policies

 For emergencies BPA maintains two relatively small portable capacitor groups. One
group is rated for 69 or 115 kV operation and the other is rated for 230 kV operation.
Both portable units have dedicated circuit switchers, protection and control relaying,
and portable battery sets to operate the relays and circuit switcher.
 Portable Capacitors - The current strategy is based on practical limits associated with
size and historic need. Existing portable groups are sized for 69kV and 115kV
application with relatively small ratings. However, the current strategy should be
evaluated and either reaffirmed or updated as needed.
 Due to the relatively small number of new capacitors installed on the system today
and the current practice of replacing individual cans rather than entire capacitor
groups we currently do not have a master contract and there does not appear to be
significant benefit in pursuing strategic sourcing due to the low volume.
 Maintain adequate levels of inventory (capacitor cans, fuses and associated

hardware) for all sizes in service today. Inventory is to be located in the field and
centrally for rapid response.
 Maintain adequate levels of supporting equipment such as switchgear, instrument

transformers, and relays that provide control and protection. The asset strategy's for
the supporting equipment reflects the performance requirements for the shunt
capacitor assets.
86
Shunt Capacitor: Implementation Milestones
Sparing Strategy
• Spare inventory for all capacitor sizes and ratings currently in service is evaluated annually
by Substation Maintenance and High Voltage Engineering subject matter expert.
• Annually: Confirm 24 hour readiness of the two mobile/spare capacitor groups.
Capital
• By 4th Qtr 2013 replace the 115 kV Tillamook capacitor bank Fuses
Entire bank including concrete footings, racks, cans, CLRs, etc.
• By 4th QTR 2014 replace the 115 kV Bell capacitors

(cans only)
• By 4th QTR 2014 replace the 500 kV Echo Lake capacitors

(cans only)
Individual
capacitors
“cans”
87
Executive Summary
Strategies
• Switchgear
What will it cost?
88
Instrument Transformers: Asset Criticality
Instrument Transformers (IT) - System Indication and Data Measurement

• Instrument transformers provide the raw current and voltage data from the power
system for protection and control relaying, revenue meter data, AGC, generation and
stability control, and condition monitoring.
Instrument Transformers - Criticality:

• The combination of Substation and Transmission Line priority ranking criteria
establishes the criticality of all instrument transformers.
• The availability of spare or stock units, transformer condition and loading, critical
contingencies, and revenue data sensitivity will be used to determine the magnitude
and consequence of an outage for purposes of assessing risk.
• Key data:
− Instrument transformer condition is based on age, insulation performance
(bushings, windings, coupling capacitors), and voltage or current accuracy.
− Function – Provide the raw system data/measurements for protective relaying &
control, metering, AGC, RAS, SCADA, synchronization, WAM, hot line indication,
etc.
− Potential for PCB contaminated insulation oil
89
Equipment strategies/ Instrument transformers and surge arresters
Instrument Transformer Performance Objectives

Instrument Transformers (IT): PT/VT/CVT/ - potential & voltage transformers, CT - current
transformers
• IT Performance Objective: Instrument transformers are themselves monitoring equipment that

provide the raw data used by relays, meters, AGC, etc. to control and protect the system and for
revenue meter data. Maximize availability and plan for replacements to avoid data accuracy problems
associated with failing insulation or drifting of capacitor characteristics. IT’s have very few if any
maintainable/replaceable parts with the exception of oil gaskets.
− Measure(s):
 PT/VT/CVT - Secondary voltage monitoring & CT – secondary current accuracy
 Winding tests & Capacitance tests (drifting – only for CVT’s)
 Power factor tests (insulation failure) – Oil Filled > 69 kV
 Oil leak for non dry type transformers (>46 kV), PCB contamination is an issue with older
(1979 and older) vintages
 Failure trending – all IT types
− Strategy:
 Due to limited main bus outages – target all three (same age and model) phases for
replacement
 By 4th QTR 2012 criteria will be developed based on failure trending to predict optimum
replacement time
 Replace remaining 1,100 IT’s containing PCBs > 50 ppm by 2025. These IT’s are regulated
by the Toxic Substance Control Act - shared goal with Environment Fish & Wildlife (EF&W) –
link to asset strategy for EF&W.
90
Instrument Transformer: Age Demographics
737 770
800 Average Age
= 24 yrs
700 164
326 535
600
81 441
500 120 394
21
Quantity
213 117 41 75
6
400 49
Add
141 Chart72- Karlee
82
300 139
76
147 125 104
200 139
118 6 9
181 22
100 132 94
148 1
70 10 79 5 13
3
0
0 - 10 11 - 20 21 - 30 31 - 40 41 - 50 51 - 60 61 - 70
Age (years)
0 - 25 kV 115 - 161 kV 230 - 345 kV 34.5 - 69 kV 500 kV
91
Maintenance Costs – All Instrument Transformers

Spike may be due
increase in PT/CT
PM following Big
Eddy PT Failure –
PT had 100% PCB
Oil content,
previously
unknown.
Maintenance cost fluctuations due in part to:

• Natural peaks in maintenance due to 7 – 10 year preventative maintenance. intervals;
• Catching-up with old backlogs to meet new WECC maintenance req’s.;
• Some reduction in maintenance due to FY 2009/2010/2011 increases in capital replacements due to environmental
drivers and in service failures including replacement of sister units;
92
Instrument Transformer: Failure Modes
Instrument transformer (IT’s) consist of two major groupings listed below. Both types are
used and needed for control and protection, revenue metering, and other forms of data
acquisition for RAS, SCADA indication, PMU, Communications, etc..
1. Voltage Transformers – includes wirewound potential transformers, and CVT /

CCVT – capacitively coupled voltage transformers
2. Current Transformers – include wire wound transformers, and less common are
Hall effect devices.
− IT’s fail primarily due to insulation or bushing failures -similar to both power
transformer/reactor and capacitor failures.
− IT’s tend to have permanently sealed housings and are generally not repairable
with the exception of some high voltage units that are partially oil filled and can
have gaskets replaced.
− Most lower voltage IT’s typically below 46 kV are dry type and have no
appreciable oil inside them.
93
Instrument Transformer: Voltage and Potential transformers -

Assessing Risks
Note –
“High System
Impact” is Poor
indicative of
the overall
station
ranking based
on Add chart - Christine
Transmissions
priority Fair
ranking
criteria - Not
necessarily
the individual
equipment
criticality
Good
94
Instrument Transformer: Current transformers - Assessing Risks
Poor
Add chart - Christine
Fair
Good
95
Instrument Transformer: Strategy

The instrument transformer strategy for both voltage and current transformers is focused
on four key areas:
− Voltage and current measurement/monitoring on the secondary windings
− Bushing and insulation condition (oil leaks, external arching, moisture ingression)
• Maintenance data to be recorded
− Secondary winding voltage or current measurement
− Capacitance for CVT/CCVT
− Density monitor calibration for SF6 gas filled IT’s
• Analyze
− Failure and leak rates by model, voltage, and design type
• Instrument transformers have an average expected life span of 25-35 years.
• Failed units are typically replaced due to limited ability to repair.
• Standard ratings are available from most manufacturers
• When making replacements, IT’s will be proven technology from industry leaders in reliability.
Application of equipment will be made to meet system operating demands. Installation will
include testing and verification of operation.
96
Instrument Transformers: Implementation Milestones

Sparing Strategy
• Spare inventory for instrument transformers is completed annually to assure
emergency stock will provide direct replacement ratings for 90% of all ratings
and voltage levels in service today.
Capital
• By 4th QTR 2012 complete failure trend analysis for 2009, 10 & 11 emergency
replacements to develop replacement strategies for non-PCB (polychlorinated
biphenyl) IT’s. Criteria will be developed based on this failure trending to predict
optimum replacement time
Note: The ongoing Environmental PCB replacement program replaces
approximately $2-3M of IT’s annually which currently makes up the majority of
planned IT replacements. The environmental replacement program currently
also meets several goals for condition based replacements.
97
Surge Arresters: Asset Criticality
Surge Arresters (SA) - Surge Protection:

• Surge arresters are passive protective devices that control over-voltages during system
disturbances (lightning, faults, switchgear failures); and for normal operation where voltage
transients (switching surges) can harm power system equipment like transformers.
− Metal Oxide Surge Arresters (MOSA’s) are the industry standard for both system reliability and more
effective control of transient overvoltages. This includes insulation coordination which is a determining factor
in BPA’s minimum approach distances (MAD’s).
− Silicon Carbide (SiC) gapped arresters are no longer manufactured and obsolete in the industry. These
devices are aging on the power system and are prone to moisture ingression that will cause the unit to
dielectrically fail.
− Rod gaps are a crude form of surge protection against lightning. Upon each operation a line fault is created
that must be cleared by a breaker thus de-energizing the line. This momentary outage can contribute to
SAIFI and SAIDI.
Surge Arrester Criticality:

• Surge Arrester criticality is determined by Transmissions priority ranking criteria of the equipment
or line terminal they protect.
• Key Data:
− Condition of SiC and MOSA arresters is based on age , Watts loss tests, and insulation
(housing) performance (power factor tests and failure rates)
− Rod gaps are replaced with MOV’s to improve equipment protection and reliability. Rod gaps
have a disadvantage compared to MOSA’s when they operate by creating a line to ground
fault to protect equipment. These faults at the very least increase momentary (< 1minute)
line outages and require a breaker to clear the fault.
98
Surge Arrester: Performance Objectives

• Performance Objective - Maintenance, All Surge Arresters and Rod gaps
− Measure(s):
 Develop a new preventative maintenance guide (PMG) that covers testing, at least every 10 years of all
surge arresters and rod gaps. Current PMG only covers surge arresters installed on transformers and not
those installed on line terminals, reactors, capacitors and other others. Rod gaps currently have no
inspection requirements but should be checked for proper air gap distance, arching damage to the tips, and
corrosions of any parts including mounting brackets.
 Rod gaps do not have a system equipment record (SER) but do need to be identified and tracked for
replacement purposes. Develop an equipment type profile in CASCADE to allow tracking of rod gaps
including the open gap distance they are set to in the field.
 4th QTR 2012 Substation Maintenance and High Voltage Engineering SMEs will work with RCM to establish
new maintenance inspections for surge arresters and rod gap testing and tracking.
• Performance Objective – Replacements, All Surge Arresters and Rod Gaps

− Measure(s):
 Develop a 10 year replacement plan for Silicon Carbide (SiC) gapped surge arrester targeting all those
installed on 230 kV transformers and associated transformer low side arresters. Focusing first on arresters
predating 1974, followed by those predating 1978. To reduce forced outages caused by arrester failures.
 Develop a 10 year replacement plan for rod gap replacements to target and coordinate with critical 500 kV
transmission lines, and planned line outages - particularly those where “bare-hand, live-line” maintenance
techniques may be used. To reduce momentary outages thus increasing reliability and improved insulation
coordination.
 By 1st QTR 2013 develop a 10 year replacement plan for SiC gapped arresters
 By 1st QTR 2013 develop a 10 year replacement plan for rod gaps
 By 3rd QTR 2014 50% of all remaining SiC gapped arresters installed on 230kV transformers have been
replaced.
 By 4th QTR 2015 20% of all remaining 500 kV line terminals with rod gaps will have been upgraded with
MOSA’s.
99
Surge Arresters: Age Demographics
722 796 Average Age =

800 25 Yrs.
700
170 329 592
600 475
133 446
6
500 23
Quantity
216
104
142 141 81
400
300
365 109
200 336 325 318 342
6
22
100 103 3
19
0
0-10 11-20 21-30 31-40 41-50 51-60 61-70
Age (years)
< 115kV 138-230kV 287-345kV

100
Surge Arresters: Failures

Surge arrester failure modes for Silicon Carbide (SiC) gapped arresters, Metal Oxide surge
arresters (MOSA’s)
• Housing seal failures - Silicon Carbide (SiC) gapped and metal oxide surge
arresters (MOSA’s).
• Transient overvoltage protection on lines – Replacing Rod Gaps with metal oxide
surge arresters (MOSA’s)
• Momentary outages (< 1 minute) – Replacing Rod Gaps with surge arresters
(MOSA’s) effectively eliminates momentary outages for the operation of a surge
protective device. MOSA’s do not create a line-to-ground fault like rod gaps when
the operate.
• Surge arrester failures pose some risk to transformers or reactors during failure
for two reasons:
1. Porcelain housed arresters mounted directly on transformers may damage
transformers bushings from debris. This risk is very low at BPA since all of the
older SiC arresters have vents to relieve pressure during failure.
2. Arresters typically fail in a short circuit mode thereby causing a line to ground
fault at the transformer terminal. There is a low risk of damage and mainly a
concern where transformer protection may be poorly coordinated (slow
clearing of fuses or relays).
101
Surge Arresters: Assessing Risk
Poor
230kV = 15
(hidden)
Silicon Carbide
Fair arresters:
Approximately
440 of the 1,000
still in service –
are in poor
Good condition
102
Surge Arrester: Strategy
The surge arrester and rod gap strategy is focused on four key areas:
− Watts loss, power factor
− Watts loss, power factor
− Inspection of housing (porcelain, polymer) condition - external arching, evidence of ruptured pressure
disc.
− Rod gaps - check for corrosion of parts and arcing damage of tips and proper gap distance
• Analyze
− Failure rates by model, voltage, and design type

• Surge arresters have an average expected life span of 35 years.
• Failed units are replaced – repairs are not possible.
• Standard ratings are available from most manufacturers
• When making replacements, MOSA’s will be proven technology from industry leaders in reliability. Application
of equipment will be made to meet system operating demands. Installation will include testing and verification
of operation.
103
Surge Arresters: Strategy

The asset strategy for this equipment group is centered primarily on operating the
equipment to functional failure and replacing equipment near its end of life.
• The equipment in this asset group has no parts that are either repairable or
replaceable. The insulation system is permanently sealed and a seal failure
constitutes arrester failure.
• Condition assessment and performance tracking for this asset group is highly
dependent on patrol inspections (visual observation that is recorded) and relatively
infrequent 7-10 years testing when either transformers or bus outages are taken.
• Monitoring (on line recording/measurement) of electrical or functional characteristics
is not practical due to the cost of monitoring vs. equipment value. Some utilities use
counters on their surge arresters but the technology to date does not yet provide
very accurate or valuable results.
• The best performance indicators are in-service failures that show seal degradation
trends or end of life of the SiC or MOSA materials.
104
Surge Arresters: Implementation Milestones

Sparing
• Evaluation of spare inventory for surge arresters was performed in
2011 to provide replacements for 100% of all ratings and voltage
levels in service today.
• EMS has a minimum of 3-6 spare units for each standard arrester size
used on the system as the result of an effort in 2011.
Capital
• By 2018 Replace 500 kV rod gaps on all 500kV line terminals that
will be worked hot using live-line, bare hand maintenance techniques.
• By 2019 Replace 95% of all remaining 230kV SiC gapped arresters,
including associated low side arresters for arresters installed on
transformers and reactors.
• By 2021 Replace 95% of all remaining 69 – 161kV SiC gapped
arresters including associated low side arresters where they are
installed on transformers.
105
Executive Summary
Strategies
• Switchgear
What will it cost?
106
Station Auxiliary: Asset Criticality

Station Auxiliary - Batteries & Chargers, SS Transformers, Engine Generators, SS Cabling, Grounding
• Lower voltage equipment provides AC station service (operating) power for control houses, yard
lighting, control and data acquisition systems, security systems, and communication systems.
• DC Control Batteries - provide backup DC control power for protective relays.
• AC Power – required for normal operation of HV equipment - for control cabinets, breaker
tank heaters, transformer cooling fans, and station yard power for maintenance and
construction AC power for Non Electric Plant (NEP) facilities within a substation including
maintenance buildings, warehousing and similar NEP facilities that may be co-located within
Substations.
• Engine Generators, Transfer Switches – provide back-up power for loss of the primary SS
power source
Station Auxiliary - Criticality

• The criticality of Station Auxiliary Assets is determined by Transmissions priority ranking criteria
combined with the level of redundancy or back-up power sources (local utility, engine generators).
• Key data for this program area:

• Station Auxiliary equipment condition is based on the age, failure rates by type, service
conditions and environment (SS loading, air born contamination, underground/water
conditions, extreme temperatures)
• Failure rates and reduced capacity for DC Control Batteries
• Station Service Transformers and buried SS Cables - Insulation degradation due to loading,
weather
• SS transformers and buried SS cables - Insulation degradation due to electrical effects -
transients (lightning, switching transients, ground faults)
107
Equipment strategies/ Station auxiliary
Station Auxiliary: Performance Objectives

Station Auxiliary: Auxiliary equipment provides operating power for all substation equipment and most non electric plant
(NEP) facilities within a substation. The majority of this equipment does not have maintainable or repairable parts and is
operated to failure or near failure. Station Service transformers are permanently sealed and older units may have PCB’s
that cannot be measured/detected until a leak or failure occurs.
• Station Auxiliary Performance Objectives: Provide reliable operating power to substation equipment to minimize
reliance on back-up and secondary power sources.
DC Control Batteries:
− Measures - Improve overall replacement rate and timeline for DC control batteries (both failed and banks with reduced, ≤ 80%,
capacity)
− End Stage Targets:
 Perform emergency control battery replacement within 4-6 months for installations that do not require control house expansions
or modular enclosures
 Perform 12-15 scheduled control battery replacements per year due to system needs and asset condition
 Start 2 year design / build on all new planned control battery replacements starting in FY13
AC Station Service (SS) equipment: transformers, cables, transfer switches, AC service panels:
− Measures – Improve long-term SS reliability and safety by targeting “whole system” station service equipment
replacements/upgrades. Includes capacity expansions for future growth in stations where likely. Equipment upgrades include
transformers, cables, AC panel upgrades, transfer switch upgrades, replacing single phase switches w/three phase/group operated
switchgear.
− End Stage Targets – Complete 3–5 major SS replacements/upgrades over the next 3 years – focusing on the top 5% of critical SS
with both capacity and safety deficiencies identified in the Submaintenance 2007 report and Facilities Asset Management (FAM)
Facilities Report.
Engine generators:
− Measures – Improve EG reliability and safety by replacing/upgrading systems in the top 5% of station service rated deficient.
− End Stage Targets - Upgrade 3-5 permanently installed EG’s sets and fuel systems annually – based on priorities set in the
Submaintenance 2007 report and Facilities Asset Management (FAM) Facilities Report.
108
Current State of the Assets

DC Control Batteries = 254 Chargers = 486 Station Service TX's = 910 Total = 1650
Typically “run to failure”

replacement strategy.
SS Average
Age = 30 yrs. However, planned
replacements are needed to
eliminate older PCB
225 contaminated units and to
250 manage failures “emergency
replacements” avoid
178 190 accumulation of failures
Equipment Quantities
(peaks) and overloading of

200 133 123 resources.
92 153
127
150
115 101
100
79
CHAR Average
Age = 16 yrs. 46
50
54 21
5
0 2 Expected Life for
CHAR Average 6 Batteries is 15- 20 years.
Age = 13 yrs. 0-10
Yrs 11 - 20 Resource constraints and
Yrs 21-30 long lead times have
Yrs 31-40 created a backlog in both
Yrs 41-50
51-60
emergency and planned
Equipment Age (Yrs.) Yrs
Yrs 61-71 battery replacements.
Yrs
109
Station Auxiliary: Strategy - Optimal replacements

Station Auxiliary equipment have varying life spans - at the lowest end of the spectrum are DC control
batteries and chargers. Station service transformers and transfer switches have the highest expected
lifespan. Engine generators and power cables tend to fall in the middle to high end of the spectrum.
Optimal Replacement Window – AC Station Service (SS) Equipment - Transformers, Power Cables, &
Service Panels
• SS- Due to varying sizes 2460 VAC up to 34.5 kVAC; dry type and oil filled SS transformers vary in lifespan from
25–45 years depending largely on insulation type with oil filled typically lasting longer.
• Power cables vary from 25-35 year depending on insulation type, environmental conditions, and loading (current)
of the cable.
• Service panels may last 25-35 years depending on the availability of replacement air circuit breakers (ACB) and
loading – station loads usually outgrow the panels’ capacity to add new circuits and carry the additional current.
Optimal Replacement Window – DC Control Batteries

• NiCad Batteries  25 years
• Vented Lead Acid Batteries  15-25 years
• Lead Antimony  15 years
• Lead Selenium  20 years
• Lead Calcium  20 years
• Plante  25 years
• Valve Regulated lead Acid Batteries  10 years
Optimal Replacement Window – Engine Generators (EG’s)

• Engine generators, permanently installed in stations requiring redundant SS sources, can last 20–30 years
depending on service duty, environmental conditions, and fuel type. EG replacements may include upgrading or
replacement of fuel system components, transfer switches, and housing associated with the EG.
• When making station auxiliary replacements they will be replaced to meet current electrical industry standards for
the specific equipment groups.
110
Maintenance Costs – Control Batteries & Chargers

(Excludes Communication Batteries)
111
Maintenance Costs – Station Service Transformers, Voltage

Regulators, & Transfer Switches
112
Station Auxiliary: Assessing Risk
Poor
Fair
Good
113
Station Auxiliary: Strategy

• The asset strategy for this equipment group is centered primarily on replacement vs. maintenance.
The data requirements are focused on inspection results, a small amount of testing or monitoring,
and failure trending. Most of the equipment have only a small number of components that can be
maintained (replaced or repaired).
• Station auxiliary reliability is based on two major components:

1. Spares – stocked in BPA warehouses or through purchase agreements with local vendors.
2. Redundancy or back-up power sources: Alternate SS (i.e. local utility) backs-up BPA SS;
multiple SS sources (redundancy) in some stations can provide (not necessarily 100%) back-
up; engine generators (portable or permanently installed) back-up SS supply’s.
• Replacement priorities are currently based on two major reports completed in 2007 and 2010 that
highlight deficiencies in three major areas - safety (i.e. National Electric Safety Code -NESC),
condition factors, and inadequate capacity. The surveys and corresponding reports were conducted
by independent contractors well versed in “distribution” electric systems. BPA will continue to
incorporate this type of expertise for the evaluation of station service assessments. Historically BPA
has concentrated it’s expertise in the design, operation, and maintenance of “transmission” facilities
with much less emphasis on the lower voltage “distribution” type facilities that do not carry
commercial power but provide secondary or supporting power to the main infrastructure. The
utilization of outside expertise will continue to augment BPA’s ability to provide reliable station
auxiliary power.
• Implementing New Standards: In 2010 new standards for SS and EG designs and documentation
were issued to help remedy various station auxiliary issues outlined here: Significant portions of this
asset group are replaced under expense programs and this has, over the years, led to non-standard
installations and undocumented modifications/expansions. Independent contracting for replacement
of some SS electrical equipment and engine generators has also contributed to this problem.
114
Station Auxiliary: Strategy (2)

Station service transformers & cables:
• Inspections - Thermovision, visual (oil leaks), electrical & insulation tests
• Monitoring/testing – Station service supply voltage, grounding (dc grounds, neutral shift)
• Analyze
• Monitor/Test - Substation Auxiliary Parameters to be monitored and recorded:
− Test/Measure – SS TX Power factor, winding ratios, etc. (as required by PMG’s) Voltage & Current measurements
where applicable and feasible
− Measure - Thermovision
− Inspection - Oil leaks, broken/damaged bushings
− Cables – voltage, resistance, connector condition on URD/insulated cables, grounds
DC control batteries:
• Inspections – battery leaks, bulges, temperature, vapors
• Monitoring/testing – voltage, battery capacity (load test or impedance test), fluid – specific gravity
(as applicable)
− For electrical equipment – DC Battery – Cell failures/replacements and charger replacements/failures
− Oil Leakage rates and mitigation efforts
Engine Generators:
• Inspection/Monitoring/testing
− Hours of operation for EG’s
− Voltage stability, output capacity (loading), fuel consumption/emissions, start-up
Analyze – All SS Equipment

• Failure rates/trends by model, voltage, and design type
115
Station Auxiliary: Implementation Milestones
• By 4th QTR 2012 complete the 3 remaining carry-over replacements of

2009 & 2010 battery and chargers projects.
• By 4th QTR 2014 replace the two remaining DC control batteries that are
beyond 30 years of age and thus beyond their expected useful life.
• By 4th QTR 2015 complete 6 AC station service projects with “systems”

ranked in “poor” condition based on safety, capacity & condition factors.
116
Executive Summary
Strategies
• Switchgear
What will it cost?
117
Substation Bus & Structures: Asset Criticality
Substation Bus & Structures – Bus, Insulators, Towers, and Supports

• Includes electrical and non-electrical supporting infrastructure for HV electrical
equipment in substations: Dead-end (line termination) transmission towers; supports
and foundations for disconnect switches, instrument transformer, electrical bus, etc.;
substation bus and insulators, seismic hardening, fuel storage systems and enclosures
for engine generators.
• These supports and structures provide the required electrical clearances or spacing
between energized equipment (phase-to-phase); energized equipment to ground, and
safe working distances for personnel and HV electrical equipment to work and operate
safely.
Substation Bus & Structures – Criticality

• The criticality of Substation Bus & Structures is determined by Transmissions priority
ranking criteria. The failure of these items can cause electrical faults and damage to
other substation equipment or personal injury if failures occur while workers are
present.
118
Equipment strategies/ Substation bus and structures
Substation Bus & Structures: Performance Objectives

Substation Bus & Structures: The Substation Bus & Structures is a new replacement program that requires
development of performance factors. There has been a small program for the past 5 years targeting the upgrade of bus
connections on critical equipment to seismic connections.
• Substation Bus Performance Objective: Capital & Maintenance – Replace substation rigid or flexible bus that
is underperforming as follows:
− Measures:
 Upgrade underrated Bus – substation bus or bus sections that are not rated for the continuous current
(bottleneck)
 Bus Hot spots – Thermovision (bus connections), high resistance - Poor electrical contact (electrical
compound –NO-OX problems)
 Corrosion (steel & copper bus), galvanic corrosion
 Fitting fatigue, ice damage, bad compression for pressed fittings (mechanical failure) – visual
inspection;
 Seismic zones combined with system critical equipment
 Replace all remaining steel bus by 2016.
 Replace all cracked pressed bus fittings within one year of discovery or sooner depending on severity
 Upgrade 10% of all remaining non seismic bus connections annually
• Structures Performance Objective: This equipment is subject to predominantly structural and mechanical
failures modes and requires performance criteria to be developed
− Measures:
 Structural condition – corrosion, metal damage – criteria needed
 Foundation – spalling, cracking, uneven settling/frost heave (site conditions) – criteria needed
 1st QTR 2013: Develop Measurement/Inspection criteria for assessing condition of structures, supports
& foundations
 3rd QTR 2013: Develop repair criteria and a coordinated replacement approach for structures and
footings to minimize station service interruption and cost.
119
Substation Bus & Structures: Assessing Risks
Substation Bus & Insulator Failure Modes
• Bus – Overheating of older steel & copper bus due to increased loads,
corrosion, deteriorating fittings - issues due to age and limited manufactures of
replacement fittings for steel & copper bus.
• Bus – Aluminum pressed fittings – failures due to degradation of the filler
compound, ingression of moisture, cracking due to moisture ingression and
subsequent freezing, internal corrosion leading to high resistance connection,
heating/annealing, stretching & thinning of conductors
• Porcelain Insulator failure - due to tracking (electrical), cracking, pin & cement
failure between sheds
• Polymer insulator failure – Loss of hydrophobicity (ability to shed water and
contaminants) leads to tracking, arcing, and loss of insulation quality.
Separation between polymer and end fittings due to high voltage electric field
stresses.
120
Substation Bus: Strategy

The asset strategy for substation bus centers around periodic inspection and replacement of individual
fittings or small bus sections when a mechanical or electrical failure occurs. Bus that is found to be
underrated will be upgraded to meet the minimum continuous current ratings (path rating). Planned
replacements of large bus sections or bus in multiple bays may be required for older steel or copper bus
where replacement fittings and bus are no longer available.
Optimal Replacement Window – Bus & Insulators
• Substation bus has a reported 45 year expected life span based on accounting practices but
routinely exceeds that figure. Very few stations at BPA still have mostly steel or copper bus.
Those remaining are plagued with corrosion issues; overheated connections; and connectors
prone to breakage.
• When making bus and fitting replacements the installations shall meet all applicable material
and workmanship standards. In particular bus fittings shall be selected to avoid galvanic
corrosion (when metals of dissimilar material come in contact with one another). All fittings
whether bolted or pressed shall be the appropriate type and amount of conductive/filler
compounds to assure good (low resistance) long lasting electrical connections.
Substation Bus - Asset strategy development needed - Inspect/Record/Analyze Data
• There are presently no centralized systems in place to record data associated with the
inspection, condition, and failure of these assets. These facilities have no unique identifiers.
Some of these components are capitalized when replaced and others are expensed.
• A method of component identification and asset health & condition data storage is needed.
121
Substation Insulators: Strategy
The asset strategy for insulators centers around periodic inspection and replacement of
individual insulators at the time of failure. A high percentage of failures may drive planned
replacements of a large population of insulators where degradation due to age or poor
manufacturing is causing excessive failures and reducing reliability.
Optimal Replacement Window – Bus & Insulators

• Porcelain insulators have an expected lifespan of 35 years and routinely exceed that figure.
• Polymer (non ceramic) insulators, up to this time, are not used in AC substations. Their expected
life span is currently 25 years and only a few vendors have had polymer insulators in continual
service for that many years.
• When insulators are replaced they shall meet all applicable industry standards for electrical
insulation strength (flashover, puncture, water/contamination shedding, etc.) and mechanical
strength for the intended application.
Insulators - Inspect/Record/Analyze Data

• There are presently no centralized systems in place to record data associated with the
inspection, condition, and failure of these assets. These facilities have no unique identifiers.
Some of these components are capitalized when replaced and others are expensed.
• A method of component identification and asset health & condition data storage is needed.
122
Substation Bus & Structures: Assessing Risks

Substation Structures & Foundations – Failure Issues
This is a relatively new Asset group in terms of treating these facilities in formalized
program. This asset group currently lacks a tracking method or system and condition
assessment criteria. The condition of these assets were superficially addressed in a report
published in 2007 focusing on Substation NEP and Supporting infrastructure. The most
significant finding regarding structures and foundations was that almost 1/3 of the facilities
(stations) were at or exceeded 50 years of age and were exhibiting distinct signs of age
related degradation.
• Steel supports and towers – Corrosion, rust, metal fatigue, broken bolts, bent or twisted
members
• Steel – Assess repair options: replacing individual members, adding structural reinforcement
• Foundations – Spalling (flaking, chipped, pitted) may be repaired/patched to avoid further
degradation of concrete and foundation failure due to loss of rebar (rust/corrosion)
• Foundation – Cracking: mild superficial surface – may be repaired/patched to avoid further
degradation (water ingression/ice); severe- due to rebar or concrete failure (replace)
• Foundation – Uneven settling, frost heave – can damage electrical equipment particularly
insulator failure, and misalignment of disconnect switches.
Critical Takeaways:
1. While asset groups such as SPC, PSC, AC SUB’s (electrical), and Transmission Lines have dedicated
staff that work, at least part time, on maintenance standards and condition assessment criteria very
few resources currently exist to focus on Substation Structures & Foundations condition assessment.
2. Clear and consistent condition assessment criteria needs to be developed to help make replace vs.
maintain (repair) decisions.
3. Assessment methods and a data repository needs to be developed to begin recording and tracking
condition data and repairs.
123
Bus & Insulators: Strategy

Bus & Insulators - Inspect/Record/Analyze Data
• Key data for this program area Inspect/Record/Analyze Data :
Bus & Insulators

• Visual and Thermovision inspection of bus condition (corrosion, high resistance hot spots, cracking or fatigue of fittings &
jumpers, conductor separation)
• Bus & Fitting types – Copper, Steel, Aluminum; bolted, welded, pressed
• Visual and Thermovision inspection of insulators (cracking, tracking, corona, water shedding).
• Insulator age
• Site conditions for Insulators – contamination (industrial, agricultural); weather – precipitation, icing, UV
Structures, Supports & Foundations Condition

• Visual and physical inspections to ascertain condition of structures (corrosion, cracking, metal fatigue); foundations
(cracking, crumbling, frost heave, settling)
• Site conditions – Soil type and condition, frost depth, seismic zone, climate
• Galvanic corrosion of structures
1. Clear and consistent condition assessment criteria needs to be developed to help make replace vs. maintain (repair)
decisions for this asset group.
2. A method or system needs to be developed (perhaps in CASCADE) to begin recording and tracking condition data and
repairs. This may need to begin with just a station by station assessment.
3. Replacement methods, techniques, and options need to be developed to address the highly disruptive nature of replacing
structures and foundations in substations while minimizing disruption to service

• Structures and foundations have an expected lifespan of 45 years and many cases exceed that figure.
• Repair and reinforcement options need to be developed and applied consistently to provide short term mitigation of
potential failures that can impact reliability, damage equipment, or cause injury if workers are present
• When making concrete and structure replacements they will be replaced to meet current seismic standards as applicable.
In addition all materials shall meet the applicable quality standards for materials, workmanship, and installation methods.
124
Structures & Foundations: Strategy

Structures & Foundations - Inspect/Record/Analyze Data
Critical Takeaways - Inspect/Record/Analyze Data:
1. Clear and consistent condition assessment criteria needs to be developed to help make replace vs. maintain
(repair) decisions for this asset group.
2. A method or system needs to be developed (perhaps in CASCADE) to begin recording and tracking condition
data and repairs. This may need to begin with just a station by station assessment.
3. Replacement methods, techniques, and options need to be developed to address the highly disruptive nature
of replacing structures and foundations in substations while minimizing disruption to service
• Structures and foundations have an expected lifespan of 45 years and many cases exceed that figure.
• Repair and reinforcement options need to be developed and applied consistently to provide short term
mitigation of potential failures that can impact reliability, damage equipment, or cause injury if workers are
present
• When making concrete and structure replacements they will be replaced to meet current seismic standards as
applicable. In addition all materials shall meet the applicable quality standards for materials, workmanship,
and installation methods.
Seismic Bus Riser Replacements
• 500kV seismic bus riser replacements are 25% complete

− Remaining 75% will be completed 4-5 per year according to the capital forecast. This work is coordinated with TLM scheduled
line outages.
125
Structures & Foundations: Implementation Milestones

• By 4th QTR 2012 develop “emergency replacement” template for structure
and foundation replacements to address substation steel structure
corrosion and failing foundation problems.
• By 3rd QTR 2012 complete the following:
1. Criteria and processes to evaluate how and when substation structures should
be repaired vs. replaced – this will become part of the next Bi-annual asset
strategy.
2. Alternative methods or designs for major substation bus replacements to allow

continuity of service, i.e. mobile substation use during construction; temporary
bus support systems; yard expansion/new bay construction in lieu of replacing
existing bays; new structure designs alternatives/standards for major
replacement of older structures, etc..
• By 4th QTR 2012 complete technical evaluation on structures at Ashe

Substation under the new corrosion assessment criteria and recommend a
repair/replacement timeline based on the findings.
• By 1st QTR 2013 complete the bus pedestal replacement at Satsop

Substation.
126
Executive Summary
Strategies
• Switchgear
What will it cost?
127
Forecast Planning Levels

Momentum Strategy
Historically capital replacements have been based on relatively short planning cycles, 3-5
years that dealt primarily with highly visible failure issues or chronic maintenance problems.
The philosophy was predominantly an operate to failure approach. The legacy strategy was
weak in long term tracking and trending failures rates for equipment and parts for all but the
highest value equipment. Repair history, failure rates, and analysis was largely uncentralized
and prioritization of replacements was mostly subjective due to lack of consistent supporting
data.
This historical approach led to three significant issues that this strategy aims to remedy
1. Periodic spikes or peaks in equipment failures requiring emergency replacements. The Run to
Failure approach is reasonable and cost effective when correctly applied but when misapplied
leads to inefficient use of resources (i.e. maintenance & construction) and risks both reliability and
the timely completion of planned work.
2. Periodic accumulation or bow wave of urgent replacements making it difficult to coordinate (ramp-
up) financial and staffing resources needed to accomplish the required replacements.
3. Increased demand on maintenance and supply chain resources to maintain, repair, stock,
contract for services (emergency & planned) and acquire parts to continue repairing equipment
well beyond it’s peak life cycle.
128
Historical Funding Levels – Capital Replacements

The table below provides an estimation of past funding levels for replacements that today fall into the AC
Sustain Asset program. Past reporting practices may have captured some system replacement projects
under an “upgrades and additions” capital program and, in the case of smaller equipment such as
instrument transformers, surge arresters and station service equipment, may have been reported as
expense rather than capital.
AC Sustain (Replacement of High Voltage AC Substation Facilities) - Historical (Direct capital expenditures in nominal dollars)
Major Equipment Categories FY2001 FY2002 FY2003 FY2004 FY2005 FY2006 FY2007 FY2008 FY2009 FY2010 FY2011
Circuit Breakers & Switchgear (4454) 204 8,104 18,487 12,246 7,384 8,955 6,352 5,981 7,609 5,038 5,614
Transformers & Reactors (5131) 375 183 220 1,900 -1 10 292 5,117 30,139 1,679 616
SUB Capacitors - Shunt (5517) 0 0 78 8,133 762 60 2,134 30 62 425 93
SUB PT/CT/CVT & Arresters (5140) 0 0 56 144 55 1,816 618 742 514 802 1,286
SUB Low Voltage Station Auxiliary (5679) 55 258 525 493 44 49 1,528 3,592 2,230 2,442 3,437
SUB Bus & Structures (5680) 39 153 7 387 105 -4 506 1,526 551 498 396
AC Sustain Totals 674 8,698 19,373 23,302 8,349 10,885 11,430 16,989 41,104 10,885 11,442
Notes:
• Changes in financial reporting occurred in the 2003/4 timeframe that may affect the accuracy of the data before and
during this transition period. Mainly due to changes in capital vs. expense reporting.
• In 2009/10 the addition of many new capital replacement equipment categories for financial reporting and the
transfer of projects from “miscellaneous” and “upgrades & additions” categories to the newer more specific
equipment categories may also affect the data accuracy.
• Negative numbers -X show where projects from previous years were completed and under budget; and the cost of
any new projects in that same year were offset by the returned funds.
129
Forecast Planning Levels – Capital Replacements
Momentum Plan funds replacements at an increased rate compared to the past 10-12 years. Increases in funding levels target specific assets
within the major equipment categories that can no longer be maintained due to end of life, lack of spare parts, diminishing vendor support and
significant increases in maintenance costs for certain equipment types and models.
130
Risks of constrained budget

Potential impacts from not fully funding the proposed asset strategy
 Asset Performance Objectives and Targets

• Corrective maintenance costs will rise or remain high on aging and equipment in poor health
 Asset Failure
• Vendor support for some equipment is becoming scarce or non reliable
• May cause more emergency replacements of circuit breakers and circuit switchers
• Will risk a “run to failure” approach on some assets thus replacing under emergency
conditions at higher cost than a planned replacement
 Other Risks
• Retaining an inventory of obsolete parts for equipment that is scheduled to be replaced
increases warehousing costs
• Vendor support for spare parts is becoming scarce or non reliable
 Replacement Backlogs
• Would continue to keep obsolete and aging equipment in service thus affecting reliability.
131
AC Substation – Momentum Maintenance Costs
132
Forecast Maintenance Costs

Capital investments will continue to offset increases in maintenance costs but the current forecasted rates of
investment are not expected to result in a net decrease in substation maintenance costs. Variations in the offset
depend on several major factors:
1. The rate of system expansion for which the full impact of the maintenance cost for new equipment will not be
seen for several years. Following the initial investment (equipment is installed) the first major maintenance
services may not be conducted for a period of 2 – 7 years depending on the equipment type.
2. The cost of procuring and warehousing (BPA or contracted warehousing) spare parts for maintenance and
repair.
3. The cost and skill levels of labor resources (in house and contracted services).
4. A reduction in the number of units (substation equipment) that require maintenance, or
simplification/optimization of the existing maintenance procedures. These are further clarified below:
• The sale of delivery facilities and other changes in facility ownership can reduce the number of pieces
of equipment BPA has to maintain. The potential gains are small due to slowed sales of delivery
facilities and fewer remaining facilities eligible under this policy.
• Changes in equipment technology that require less maintenance by design. Historically this has led to
more frequent replacements due to shorter life cycles and sometimes increased costs in replacement
parts by eliminating the ability to replace lower cost subcomponents vs. higher cost component
systems.
• Capital investments in newer technology, not only the high voltage equipment itself, but also monitoring
equipment holds significant potential for implementing RCM principles. Reliability Centered
Maintenance is heavily dependent on equipment performance factors such as failure trending at both
the unit and subcomponent level particularly for power circuit breakers. With today’s technology smart
relays and similar data acquisition systems will be employed to help trend and project where
maintenance is most needed based on the duty severity a piece of equipment is subjected to.
133
AC Substation – Momentum Maintenance Costs

Substation Maintenance
40,000
35,000
30,000
$1,000s Expense
25,000
20,000
15,000
10,000
5,000
0
FY3 FY4 FY5 FY6 FY7 FY8 FY9 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21
Fiscal Year
Preventative Maintenance Corrective Maintenance Other Maintenance Engineering Administration
134
Executive Summary
Strategies
• Switchgear
What will it cost?
135
FY10 Program Accomplishments

FY10 Program Work Planned Work Accomplished Explanation for Variance
0004454 Circuit Design on 22 pieces of - 22 designs complete Kitsap Sub replace 1 breaker moved to FY11
due to combining work with other onsite
Breakers and switchgear -1 breaker installed projects.
Switch Gear Fault Duty Switchgear - 5 disconnect switches Kitsap Bus Tie breaker moved to FY11 due to
•Circuit Breakers material issues.
Maintenance - 7 disconnect switch Ashe sub replace two 230KV PCB & two
•Circuit Switchers Replacements projects completed that were 500KV CS moved to FY12 due to material
•Disconnect Switches started in FY09 or before. delays.
Ross fog test replace breaker delayed to
Emergency Replacements: - 6 fault duty circuit breakers FY11 due to emergency work priorities.
 Walla Walla disconnect -3 fault duty disconnect Ross EHV lab delayed to FY11 due to
switch switches emergency work priorities.
Paul sub replace pantograph switches – 2 of 3
 Covington 500kV - All emergency switchgear replaced, 1 delayed into FY12 due to outage
disconnect switch replacements complete. constraint.
136

0005131 500kV Shunt Reactor - Malin 230 KV transformer complete Pushed Malin shunt reactor to FY11 due
Transformers & Fuse replacements complete: to coordination with PGE on anchoring the
230kV Transformer – Langlois  Burbank reactor to the pad prior to dismantling.
Reactors
 Scootney Dixie fuse replacement moved to FY11
•Power Transformers  Cascade Locks due to outage.
8 Fuse Replacements
•Reactors Hood River fuse replacement moved to
FY12 due to outage.
•Fuses 2 transformer retirements
Retire Transformers – Fidalgo & Sandpoint Fuse replacement moved to
Lopez Island complete FY11 due to outage constraint.
Scootney moved to FY12 due to outage
7 Type U Bushing Replacements and resources constraint
1 Type U bushing
Ringold moved to FY12
complete
137

0005140 Arrester replacements – 9 Projects Arrester projects Goshen moved to FY12 due to
Instrument sites completed - outage availability
 Sandpoint
Transformers and  Kalispell Libby moved to FY12 due to design
 LaClede
Arresters  Columbia
 Kalispell issues.
 Sandpoint
•VT/CVT  Goshen St Johns moved to FY12 due to
 LaClede
•CT  Libby outage availability.
 Sickler (design completed, construction in
 Redmond FY11)
•Arresters Redmond moved to FY11 due to
 Sickler
 St Johns
material delay.
 11 Emergency VT replacements – 4
 Columbia
complete
VT replacement – 1  9 Emergency CT replacements – 4 complete
site
 1 Emergency Arrester replacements -
complete
138

0005517 Shunt Add surge arresters to  Design complete in FY10 for 4 All seven sites moved to FY11 or
Capacitors fuseless shunt capacitor out of 7 sites. beyond due to outage issues.
•Shunt Capacitors banks - 7 sites
 Addy
(Fairmount, La Grande, and
 Alvey
 Ashe
Santiam did not spend any dollars
 Redmond in FY10)
 Fairmount
 La Grande
 Santiam
139

0005679 Low FY09 Batteries - 7 Completed 4 FY09 batteries FY10 Steilacoom and Badger Canyon moved
to FY11 due to construction resource
Voltage Aux. FY10 Batteries – 12 Completed batter replacements:
availability.
 Norway
•Batteries & Ellensburg moved to FY12 due to scope
 Walton change
Chargers FY09 SS Replace – 11  Wren Drain install SS equip. moved to FY11 due to
•SS Transformers material delay.
•SS Cabling Transfer Switch -
Tillamook transfer switch completed Santiam replace. Bank #4 control cable moved
to FY13 to save $ & resources.
•Engine Generators Tillamook St Johns 115KV SS PVTS delayed to FY13
EMERGENCY
•Grounding due to design work
Batteries 10 Keeler SS upgrade moved to FY11 due to
Chargers 5 resource availability
Station Service 2 Lookout Point replace steel Bus & SS XFMRS
delayed to FY13 due to construction resources.
SS XFMRs 3
Ovando battery replacement moved to FY12
Cable Replacements 1 due to construction resource availability.
140

0005680 Bus & Rigid Bus Riser Seismic Projects completed in FY10 Ashe completed on 5/13/11 due to
Structures Hardening – 8 sites  Echo Lake loss of outage. Original planned
•Bus  Raver #1& #4  Grizzly complete date was 9/15/10.
 Schultz  Raver #1 & #4
•Bus Supports  Allston  Schultz
•Dead-end Towers  South Tacoma Rock Creek Bus Phasing
 Allston
•Lightning Masts  Echo Lake  South Tacoma
corrections schedule to complete
 Grizzly 3/2011 but completed late due to
•Foundations loss of outage.
•Insulators Bus Pedestal
•Engine Generator Replacement – Ashe Emergency Bus Riser
Fuel System & Replacements – 3 sites
Housing
Rock Creek Bus Phasing
Corrections
141

0004454 Circuit Design on 20 pieces of - All design complete Ross fog test replace breaker delayed again
to FY12 due to emergency work priorities.
Breakers and switchgear - FY10 breakers complete:
Ross EHV lab delayed again to FY12 due to
Switch Gear  Kitsap breakers
Fault Duty Switchgear emergency work priorities.
 Langlois & Toledo replacements
•Circuit Breakers Maintenance Replacements Ross disconnect switch moved to FY12 due to
complete.
outage constraints.
•Circuit Switchers  Cardwell
Tahkenitch delayed to FY12 due to
 Drain
•Disconnect Switches Emergency Replacements: construction.
 Fairview Libby & Hatwai delayed to FY13 due to
 McNary - multiple
 Hood River construction resource availability.
 Satsop
 Hanford All emergency switchgear
 Troy replacements complete.
142

0005131 Fuse Replacements (FY10) Malin Shunt Reactor complete Not all Type U bushing
Transformers & FY10 fuse replacements: replacements complete due to
Reactors  Ringold outage constraints
Type U Bushing Replacements  Sandpoint
•Power Transformers (FY10)  Dixie
•Reactors U Bushing replacements (FY10): Not all fuse replacements
•Fuses  Addy completed
GIC Transformer Monitors  Allston
(construction in FY12):  Keeler
 Bell  McNary Did not complete design on
 Sacajawea  Pasco one GIC Transformer Monitor
 Tillamook  Port Angeles
 Vantage GIC Transformer monitors completed
design 3 of 4
2 Emergency Transformers (spare)
500kV & 230KV
143

0005140 Arrester replacements Arresters complete Arrester replacements not

Instrument  Addy  Redmond July 2011 (from FY10) completed and pushed into FY12.
Transformers and  Keeler  Addy
Arresters  Ostrander  Keeler
 Trentwood design  Ostrander
•VT/CVT
•CT
Rod Gap replacement CT retirement at Keeler complete
•Arresters – 1 site
CT retirement – Keeler Also complete:
PT replacement – 1 10 Emergency VT replacements
site  8 Emergency CT replacements
 Emergency Arrester replacement – Shelton
144

0005517 Shunt Add surge arresters to Construction complete at 5 sites in Ashe overspent by $50K and Alvey
Capacitors fuseless shunt capacitor FY11 over spent by $80k.
•Shunt Capacitors banks - 7 sites  La Grande complete Santiam moved into FY12 due to
 Addy  Fairmount complete
outage availability.
 Alvey  Redmond complete
 Ashe  Ashe complete Addy moved to FY12 due to outage
 Redmond  Alvey complete availability.
 Fairmount
 La Grande
 Santiam
145

0005679 Low FY09 Batteries – 3 F09 battery completed: Franklin battery replacement moved to
Voltage Aux.  Aberdeen FY12 due to design change.
 Steilacoom Madison battery replacement moved to
•Batteries & FY10 Batteries – 9 FY12 due to material issues.
Completed 8 FY10 batteries, In Progress 1
Chargers
Completed 5 FY09 SS replace., In
•SS Transformers FY09 SS Replace – 10 Progress 5 Keeler SS moved to FY12 due to
•SS Cabling 2 Cable Replacements complete: construction issues.
 Rockdale Radio Station Salem replace/upgrade SS moved to
•Engine Generators Cable Replacement – 1  Lane FY12.
•Grounding EMERGENCY
Batteries 8
Station Service 2
SS XFMRs 1
146

0005680 Bus & Rigid Bus Riser Seismic Completed in FY11 No variance
Structures Hardening – 2 sites  Ostrander
 Ostrander  Troutdale
•Bus
 Troutdale
•Bus Supports
 Monroe Bus Pedestal
•Dead-end Towers Bus Pedestal Replacement completed in FY11
•Lightning Masts Replacement – 2 sites
•Foundations  Monroe  Rock Creek Bus Phasing
•Insulators  Ashe Corrections completed in May 2011
•Engine Generator
Fuel System & Emergency Bus Pedestal
Housing Replacement
147

Bonneville-Transmission ACSubstations DAS

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B O N N E V I L L E P O W E R A D M I N I S T R A T I O N

Alternating Current (AC) Substations

Jerry Almos, Program Manager

What equipment is covered?

Strategic environment & drivers

• Substation bus & structures

What will it cost?

Program Accomplishments FY10 & FY11

BPA’s Alternating Current (AC) Substation Assets

 There are approximately 250 alternating current (AC) Substations

 Per a benchmarking study conducted by 1st Quartile in May 2011

Executive Summary, cont.

BPA operates approximately 27,000 major (serial numbered)

Transformers and Reactors

Executive Summary, cont.

• Transmission will continue to promote standardization in the purchase of

Executive Summary, cont.

Criteria For Asset Replacement

Executive Summary, cont.

 Historically, BPA has replaced AC substation equipment based

Executive Summary, cont.

Executive Summary, cont.

 Replace 6 – 500kV, 7 – 230kV and 4 – 115kV

 Maintain the proper level of spare transformers

Executive Summary, cont.

 Emergency spares are maintained at a proper level to have at least one

Executive Summary, cont.

 Replace 1 – 115kV shunt capacitor group

 Spare capacitor cans and fuses are stocked to an

Executive Summary, cont.

 Replace the remaining 1,100 instrument transformers containing

 Emergency spares are maintained at a proper level to have at least

Executive Summary, cont.

 Replace 112 DC control batteries and chargers

 Emergency spares are maintained for station service

Executive Summary, cont.

 Replace the bus at 4 substations

Executive Summary, cont.

Impacts of Constraints on Budget, Resources, Outages, etc.

 Asset Performance Objectives and Targets

Other possible constraints

What equipment is covered?

Strategic environment & drivers

• Substation bus & structures

What will it cost?

Program Accomplishments FY10 & FY11

BPA’s Alternating Current (AC) Substation Assets

 There are approximately 250 alternating current (AC) Substations on the

• Per a benchmarking study conducted by 1st Quartile in May 2011

AC Substation Asset Overview

Criteria for Asset Replacement

AC Substation Equipment Types

2. Switchgear – Power circuit breakers(1,869), Circuit switchers(222) & Disconnects (6,715).

AC Substation Equipment Types

Transmission Net Plant

System Protection Control,

3 Transmission Lines - Wood,

Tools and Equipment Acquisition

Control Center, $17 , 0%