ITC InfraMation - = December 2002

December=20 2002

Volume 3, Issue=20 12

In This=20 Issue:=20 (Use=20 these links for Fast Navigation)

Welcome from the Editor
Keys to a Good Substation Inspection = Program
British Prime Minister Tony Blair gets a lesson on=20 Infrared

Last Month's Brainteaser
Brainteaser of the Month
Upcoming Classes
About the = ITC

Hi,

Welcome to=20 another issue of your newsletter. I want to extend a big thank = you=20 to all of you who responded to our software survey last month. You = input=20 was greatly appreciated and we have already met with the software=20 engineers to implement your suggestions.

We only send=20 surveys to opted in subscribers, so if you want your opinions = included in=20 future surveys, make sure that you update your reader profile by = clicking=20 the unsubscribe/change profile link at the bottom of this = page.

For those of=20 you who can=92t read html email, you have two options, you can = click the=20 following link to view this newsletter on the web:

HTML=20 Version

Or you can=20 click this link to download a pdf version:

PDF Version

To change your=20 preferences for receiving email, click the unsubscribe/change = profile link=20 at the bottom of this page.

Our next issue=20 will be in 2003, so until then, have a great Holiday Season, =

Gary Orlove,
Editor and=20 Publisher

(As many of=20 you have suspected, I have a split personality; I live both IR and = Visible=20 lives.)

Keys to a Good Substation Inspection = Program =20 [top]

By Mark B. Goff, =
Tennessee Valley Authority

Reprinted by =
permission from Transmission & Distribution World, Nov 1, =
2002

A picture is=20 worth a thousand words, especially when inspecting equipment. = However, if=20 the proper procedures are not in place to act on what you are = seeing,=20 potential problems go unresolved. A good inspection program needs = proper=20 tools and documentation. But just as importantly, it also needs a = defined=20 process that evaluates risks, benefits and costs so timely action = can be=20 taken.

For many=20 years, Tennessee Valley Authority (TVA; Chattanooga, Tennessee, = U.S.) has=20 performed substation inspections. The use of infrared began in the = late=20 1980s. By 1991, TVA was using four infrared cameras in = substations. In=20 1991, a bushing failed violently. Old test records revealed an = infrared=20 image indicating a hot bushing connection, yet no guidelines were = in place=20 to act on the information. From that point forward, infrared = became a key=20 predictive-maintenance tool. Soon after, the use of ultrasonic = devices=20 became a part of the predictive tool set.

Early in 1993,=20 the first focal plane array infrared cameras were purchased to = provide=20 sharper images. Later that year, TVA's Transmission Support and = Technology=20 Advancement departments teamed up with the EPRI M&D = (Maintenance and=20 Diagnostic) Center. TVA had the technical tools but was missing = two=20 essential ingredients =97 communication and documentation. = Therefore, TVA=20 developed a comprehensive program, resulting in the following=20 approach.

Communication=20 is the first step. Each substation survey starts with an entrance = meeting.=20 The purpose is to be aware of safety issues, explain the work = scope and=20 address any noted substation concerns. After the survey, an exit = meeting=20 is held with the local transmission service manager and = transmission=20 maintenance coordinator to inform them of any discrepancies. = Thorough=20 documentation is the next key ingredient. After a survey, the team = generates a report and sends it to the local manager and corporate = office.=20 Identifying the potential avoided cost of each discrepancy is a = critical=20 part of the report.

In 1998, TVA's=20 Transmission Support department started the Level 2 Inspection = (L2i)=20 program as a pilot. It was based on lessons learned from the work = with the=20 EPRI M&D Center. TVA formed seven teams, each composed of an=20 electrician from the maintenance side and an engineer from the = testing=20 side. TVA surveyed 106 substations in six months with a potential = avoided=20 cost of US$4.3 million. Bi-weekly teleconferences were held to = discuss=20 better survey techniques and share information. The L2i pilot = justified a=20 team in each of TVA's 18 Transmission Service Centers.

Methods and=20 Technologies

TVA looked=20 into using seven different methods/technologies for doing = inspections to=20 determine what gave the most investment return. The top four types = =97=20 visual, infrared, ultrasonic (airborne) and dissolved gas-in-oil = analysis=20 (Hydran) =97 set the new bases for the L2i program.

**Investment Return = Contribution per=20 Method/Technology**
Visual	21% = *
Infrared	59% = *
Ultrasonic (Airborne) =97 40 = kHz=20 plus	10% = *
Dissolved Gas-in-Oil=20 Analysis	3% = *
Ultrasonic (Contact) =97 40 = kHz to 250=20 kHz	3%
Sonic =97 20 Hz to 20 = kHz	2%
Vibration =97 <1000 = kHz	2%

Cost=20 Benefits

To gain=20 program approval, management requires cost benefits. TVA used the=20 following empirical formula to calculate potential avoided=20 costs:

Avoided=20 Cost =3D (Worst Case Cost)(1%) + (Possible Case Cost)(10%) + = (Probable Case=20 Cost)(89%) - Actual Cost to Fix

The weighting=20 factors (percentages) for each case took into account probability = and=20 failure severity.

After a period=20 of time, average avoided costs were calculated for each group and = used for=20 tracking purposes. Note: Avoided costs are determined only = when the=20 problem is fixed; otherwise, identified problems are shown with = potential=20 avoided costs.

Communication

Good=20 communication was the glue binding the different teams together = and=20 keeping management engaged. The following guidelines were = used:

Conduct an=20 entrance meeting before starting the inspection to review=20 test/maintenance records and discuss areas that might need a = closer=20 look.
Discuss=20 safety concerns.
Discuss=20 equipment concerns including those out-of-service pieces, which = will=20 need inspection at a later date.
Provide=20 immediate notification of critical discrepancies as soon as they = are=20 found.
Hold an exit=20 meeting after completing the inspection to cover loose ends and = set=20 priorities for maintenance activity.
Hold regular=20 teleconferences with all of the inspection teams to review = lessons=20 learned.
Communicate=20 the cost savings to management.

Documentation

Good=20 documentation follows good communication hand in hand. Seven steps = are=20 recommended to provide high-quality reports:

Develop and=20 document guidelines for cost benefits.
Use a=20 digital camera and an infrared camera with digital image=20 storage.
Develop and=20 document guidelines for severity criteria.
Capture=20 ultrasound data on a digital recorder.
Use a=20 database for collected information.
Make hard=20 copies for the maintenance crews to use in the field.
Document=20 cost savings.

Successful=20 substation inspections require a formal and comprehensive program. = The=20 program needs the right equipment and technical expertise to = perform the=20 inspections, while standing on good communication and = documentation, and=20 headed by cost benefits. Ultimately, the program must provide all = of the=20 information necessary to make timely and prudent business=20 decisions.

Two=20 Examples: Discrepancies and Avoided Costs=20

The oil level=20 can be seen on a transformer bushing. The normal oil level in the = bushing=20 is near the top. The oil level in the bushing shown is less than = halfway=20 down.

In this=20 example, the qualitative images and actual temperatures are not as = significant as the thermal profile.

Low = Oil	$1000
Pegged Low = (Oil gauge=20 reading below scale)	$2000
Level greater = than halfway=20 down in the porcelain	$Cost of the=20 transformer

A breaker does=20 not exhibit iron and copper losses like those seen in = transformers.=20 Therefore, a breaker's temperature typically runs slightly greater = than=20 ambient. If a temperature rise is seen in a breaker, it must be = coming=20 from a high contact resistance inside. Small temperature rises can = be=20 significant because the actual contacts are enclosed and the = actual=20 contacts cannot be viewed directly. By comparing the tanks, it was = noted=20 that the tank on the left was only 10=B0C (18=B0F) delta greater = than the=20 other two. Closer examination revealed severely burnt contacts = that would=20 have led to a breaker malfunction.

In this=20 example, the quantitative images and actual temperatures are as=20 significant as the thermal profile. Temperature rise is not based = on=20 ambient. Compare temperatures of all three phases, across the = apparatus=20 and with similar devices in like conditions.

Severity=20 Rating	Potential = Avoided=20 Cost
Critical = >10=B0C=20 delta	$20,000
Serious 5=B0C = to 10=B0C=20 delta	$10,000

Definitions=20 of Limits

Critical

Immediate=20 investigation with the possibility of removing the equipment = from=20 service, depending upon the investigation.
Serious

Investigate=20 as soon a possible and increase the frequency of scanning, = depending=20 upon the investigation.
Intermediate

Trend at=20 regular scanning frequency. In power plant switchyards, multiply = the=20 potential avoided costs by factors of four (fossil and hydro) = and eight=20 (nuclear), respectively.

=A9 2002,=20 PRIMEDIA Business Magazines & Media Inc. All rights reserved. = This=20 article is protected by United States copyright and other = intellectual=20 property laws and may not be reproduced, rewritten, distributed,=20 redisseminated, transmitted, displayed, published or broadcast, = directly=20 or indirectly, in any medium without the prior written permission = of=20 PRIMEDIA Business Corp. =

Upcoming=20 Classes =20 [top]

Click the=20 links below to see our course calendars.

Americas

International

Germany

France

About the = Infrared=20 Training Center =20 [top]

The Infrared Training Center offers training and = certification in=20 all aspects of infrared thermography use. Our world-class training = facilities are located near Boston, Massachusetts, USA and = Stockholm,=20 Sweden and have the world's most extensive hands on laboratories = for=20 infrared applications. Please join us in exploring the fascinating = world=20 of the infrared!

Your comments and suggestions about this newsletter are = welcomed=20 and encouraged. If you have an interesting application or case = study to=20 share, we encourage you to submit it for publication. Published = articles earn credit towards = recertification.

Please e-mail Gary = Orlove or=20 send regular mail to the Americas office.

Visit our website:

ITC Americas, BOSTON

16 Esquire Road
N. Billerica, MA 01862, = USA

Tel: +1-978-901-8405
Toll free:=20 = +1-866-TRAINIR
&= nbsp; =20 (866-872-4647)
Fax: +1.978.901-8832
E-mail: mailto:info_us@infraredtraining.com

ITC International, SWEDEN

Rinkebyv=E4gen 19
SE-182 11 Danderyd, = Sweden

Tel: +46 (0) 8 753 25 00
Fax: +46 (0) 8 753 26 = 01
E-mail:=20 mailto:itc@flir.se

THIS DOCUMENT IS FOR INFORMATIONAL = PURPOSES ONLY.=20 INFORMATION PROVIDED IN THIS DOCUMENT IS PROVIDED 'AS IS' WITHOUT = WARRANTY=20 OF ANY KIND. The user assumes the entire risk as to the accuracy = and the=20 use of this document. The Infrared Training Center newsletter may = be=20 copied and distributed subject to the following conditions: 1. All = text=20 and images must be copied without modification and all pages must = be=20 included; 2. All copies must contain the Infrared Training Center=20 copyright notice and any other notices provided therein;
3. = This=20 document may not be distributed for profit

=A92002 Infrared Training Center - All rights=20 reserved