Troubles & Failures Report: Doble Engineering Company

Knowledge Is Power SM
Apparatus Maintenance and Power Management For Energy Delivery
Doble Engineering Company
Troubles & Failures Report

8/1/2004 To 9/30/2004
Arrester - Trouble
Incident #
Incident Date
Report Date
Photo File Name
43921
4/29/2003
10/14/2004
IID200401,02,03
Manufacturer
Joslyn
Model Number
8110D0001J096
KV
Mfgr Year
51-100 kV
Method of Detection
Cause of Failure
No apparent trouble in the system.

Comments
(Photo was unavailable for release in this report.)
Arrester - In-Service Failure

Incident #
Incident Date
Report Date
43922
11/15/2003
10/14/2004
Manufacturer
Joslyn
Model Number
ZE
Photo File Name

KV
Mfgr Year
51-100 kV
NONE
Method of Detection
Cause of Failure
Line down.
Comments
B/O lightning arrester on RNO breaker.
Arrester - In-Service Failure

Incident #
Incident Date
Report Date
Photo File Name
43961
12/25/2003
2/23/2004
SNPD2004_Rept04
Manufacturer
Ohio Brass
Model Number
219576
KV
Mfgr Year
101-150 kV
2001
Method of Detection
Cause of Failure
Unknown - clear day, no moisture found internally.

Troubles Failures Report
Page 1 of 28
Comments
Arrester failed only about 3 months after it was installed as a replacement to an old SiC
arrester. O.B. had identified arresters that had a problem with moisture ingress,
but this S/N was not part of their recall. O.B. performed an analysis, but no cause
was identified. (Photo was unavailable for release in this report.)
Bushing-Condenser (oip) - Trouble

Incident #
Incident Date
Report Date
43924
5/2/2003
10/14/2004
Manufacturer
General Electric
Model Number
PVDB1155202
Photo File Name

KV
Mfgr Year
11-15 kV
2002
Method of Detection
Cause of Failure
Comments

Incident #
Incident Date
Report Date
43969
8/19/2003
3/25/2004
Manufacturer
General Electric
Model Number
550W1600UG
Photo File Name

KV
Mfgr Year
451-500 kV
1981
Method of Detection
Failed Doble power factor test.

Cause of Failure
Comments
Type U 500KV Bushing - evidence of water entering at top terminal gasket.

Incident #
Incident Date
Report Date
Photo File Name
43942
3/8/2004
3/23/2004
sce2004_rept01a,b
Manufacturer
General Electric
Model Number
FK69-3500-1
KV
Mfgr Year
51-100 kV
1962
Method of Detection
Cause of Failure
Comments
Type U bushing on circuit breaker failed. (Picture was unavailable for release in this report.)
Page 2 of 28
Bushing-Condenser (oip) - Failure at Test

Incident #
Incident Date
Report Date
43891
8/13/2004
8/16/2004
Manufacturer
Lapp
Photo File Name
Model Number
POC
KV
Mfgr Year
101-150 kV
Method of Detection
Bushings: C1 Power Factor

Cause of Failure
Bushing
Comments
Cable - Trouble
Incident #
Incident Date
Report Date
Photo File Name
43934
6/4/2003
3/18/2004
MWD2004_Rept01A(thru C).JPG
Manufacturer
Model Number
Rome
KV
Mfgr Year
0-5 kV
1982
Method of Detection
Cause of Failure
Insulation failure due to old manufacturing formulation.

Comments
The hydro plant tripped due to utility excursion. After receiving permission from the utility for
restart, the unit tripped as soon as the breaker closed. A Megger test revealed a problem
with one of the conductors from the unit circuit breaker to transformer. A hole slightly larger
than a quarter was found in the failed cable. (Photos were unavailable for release in this
report.) As preventative measures, the asset owner will survey other 14 hydro plants
for similar old XLP cables and continue cable testing every 5 years; they may also consider
a shorter interval between cable tests, particularly for older cables.
Capacitor - In-Service Failure

Incident #
Incident Date
Report Date
43926
1/5/2004
4/1/2004
Manufacturer
Westinghouse Electric
Model Number
series caps
Photo File Name

KV
Mfgr Year
201-250 kV
1966
Method of Detection
Cause of Failure
Comments
Cap bank was called to bypass. Bypass switch got part way closed causing extended arcing (blowing
up glass & burning up contacts). Bank was installed in 1966. Parts are wearing out and getting hard to get.
Page 3 of 28
Circuit Breaker - Trouble

Incident #
Incident Date
Report Date
43947
8/15/2001
4/15/2004
Manufacturer
Model Number
242-SP-50
Photo File Name

KV
Mfgr Year
251-300 kV
1980
Method of Detection
Cause of Failure
Failed air compressor.

Comments
A DID NOT CLOSE. BREAKER USED UP ENOUGH AR TO LOCK OUT AIR COMPRESSOR. BROUGHT
IN LOW AIR ALARM, AND LOCKED OUT. CLOSING CIRCUIT TO GCB. FOUND BROKEN RINGS ON
PISTON A MECH; ALSO FOUND BROKEN 1" ROLL PIN IN PISTON ROD. BOLTS IN OPENING
VALVE ASEMB.
Circuit Breaker - In-Service Failure

Incident #
Incident Date
Report Date
43962
1/7/2003
2/23/2004
Manufacturer
Siemens
Model Number
FCV-500
Photo File Name

KV
Mfgr Year
11-15 kV
1979
Method of Detection
Cause of Failure
Trip coil failure.

Comments
Circuit switcher operated to clear fault, interrupting service to approx 5,000 customers.
However, circuit switcher would not close again, and motor operator had to be repaired.

Incident #
Incident Date
Report Date
43952
1/17/2003
4/15/2004
Manufacturer
McGraw Edison
Model Number
AHJ-60-138-10000
Photo File Name

KV
Mfgr Year
151-200 kV
1973
Method of Detection
Cause of Failure
Mechanism lubrication dried up.

Comments
FOUND ALL BEARING STIFF, OR NOT MOVING AT ALL IN MECH. R & R TRIP ASS.
REMOVE AND DISASSEMBLE STIFF TRIP LINKAGE, LUBE PINS
AND FREE UP STIFF BEARINGS. NOW THE BREAKER LATCHES EVERY TIME.
Page 4 of 28

Incident #
Incident Date
Report Date
43946
1/22/2003
4/16/2004
Manufacturer
Siemens
Model Number
SPS2-245-40-1
Photo File Name

KV
Mfgr Year
201-250 kV
2001
Method of Detection
Cause of Failure
While being energized, pole 3 went phase to ground.

Comments
Removed SF6 gas & removed pole 3 cover. Found that pole 3 did flash to ground.
Looks like it flashed from the corona ring to the tank. 7 of the same voltage level
and model in the 2000/2001 mfg year were internally inspected.

Incident #
Incident Date
Report Date
43951
2/5/2003
4/15/2004
Manufacturer
Model Number
GO-3D
Photo File Name

KV
Mfgr Year
51-100 kV
1950
Method of Detection
Cause of Failure
Exhaust piston stuck.

Comments

Incident #
Incident Date
Report Date
Photo File Name
43916
2/24/2003
4/4/2004
BPAT200414-19
Manufacturer
ABB
Model Number
550PM 50-30
KV
Mfgr Year
> 500 kV
2003
Method of Detection
Cause of Failure
Restrike
Comments
Breaker sent a trip command via SCADA. A & B phases interrupted approximately 320
Amps. C-phase continued to carry load current for approximately 16 cycles. Breaker
Failure Relay operated and cleared the bus. Breaker was commission tested and in
service less than 6 weeks. (Photo was unavailable for release in this report.)
Page 5 of 28

Incident #
Incident Date
Report Date
43953
3/24/2003
4/15/2004
Manufacturer
McGraw Edison
Model Number
CH-60A-69-3500
Photo File Name

KV
Mfgr Year
51-100 kV
1974
Method of Detection
Cause of Failure
Comments
FOUND CLOSE COIL OPERATOR IN PIECES AND CLOSE COIL BO, REBUILT CLOSING MEC. AND REPLACED COIL.

Incident #
Incident Date
Report Date
43968
4/2/2003
3/25/2004
Manufacturer
Alsthom
Model Number
HGF-1014
Photo File Name

KV
Mfgr Year
201-250 kV
2002
Method of Detection
Cause of Failure
Internal contamination from factory

Comments
Internal fault B Phase to ground 15000amps

Incident #
Incident Date
Report Date
43950
4/15/2003
4/15/2004
Manufacturer
Model Number
Mitsubishi
Photo File Name

KV
Mfgr Year
101-150 kV
2001
Method of Detection
Cause of Failure
B/O closing coil.

Comments

Incident #
Incident Date
Report Date
43954
5/22/2003
4/15/2004
Manufacturer
McGraw Edison
Model Number
AHJ-60-138-1000
Photo File Name

KV
Mfgr Year
101-150 kV
1973
Method of Detection
Page 6 of 28
Cause of Failure
Mechanism lubricants dried out.

Comments
Breaker had problems closing.

Incident #
Incident Date
Report Date
Photo File Name
43939
7/1/2003
10/14/2004
PAC200402
Manufacturer
ABB
Model Number
145PMI
KV
Mfgr Year
101-150 kV
Method of Detection
Cause of Failure
Broken stud that mounts the stationary arcing contact inside the stationary contact assem
Comments
This was likely caused by a stress concentration due to a surface defect such as a crack at
the root of the threads. (Photo was unavailable for release in this report.)

Incident #
Incident Date
Report Date
43948
7/7/2003
4/15/2004
Manufacturer
Model Number
242-SP-50
Photo File Name

KV
Mfgr Year
251-300 kV
1980
Method of Detection
Cause of Failure
Comments
07/07/03 Breaker timing problem. Timed breaker, found out by 15 ms, will need to come
back to adjust. 07/10/03 Adjusted phase-to-phase timing on breaker. Turned
screw on close pilot valve out to speed up tank 3; it is still slower than factory spec.

Incident #
Incident Date
Report Date
43973
8/2/2003
4/6/2004
Manufacturer
General Electric
Model Number
FK-144-250Y
Photo File Name

KV
Mfgr Year
11-15 kV
1956
Method of Detection
Cause of Failure
Fault started at line arrester, breaker did not clear fault.

Page 7 of 28
Comments
Breaker tank ruptured. Breaker was a total loss. (Lightning in area.)

Incident #
Incident Date
Report Date
Photo File Name
43937
8/10/2003
5/18/2004
MWD2004_Rept04A(and B).jpg
Manufacturer
Siemens
Model Number
SPS-38-23-1
KV
Mfgr Year
36-50 kV
1995
Method of Detection
Cause of Failure
Comments
This CB has been leaking since installation. Utility personnel spent a couple of days
troubleshooting this CB using conventional gas detection methods but were not successful.
The amount of leak was very minimal; about 5 pounds of SF6 gas was added once a yr.
GIS came to the power plant on 10/27/03 to perform laser imaging on the breaker. The
camera detected a leak on the supply line fitting of A-Phase; no other leaks were found.
Utility personnel performed soap bubble test to confirm the leak and then adjusted the fitting.
Re-shot of the fitting showed no more SF6 leak. (Photo unavailable for release in this report.)

Incident #
Incident Date
Report Date
43949
8/17/2003
4/15/2004
Manufacturer
Model Number
242-SP-50
Photo File Name

KV
Mfgr Year
251-300 kV
1980
Method of Detection
Cause of Failure
Comments

Incident #
Incident Date
Report Date
Photo File Name
43923
9/10/2003
10/14/2004
IID200304,05,06,07,08,09
Manufacturer
Siemens
Model Number
BZO121406
KV
Mfgr Year
151-200 kV
1984
Method of Detection
Tested the bushings and found variable capacitance.

Cause of Failure
Page 8 of 28
Comments
Replaced the breaker. (Photos unavailable for release in this report.)

Incident #
Incident Date
Report Date
43966
10/2/2003
2/16/2004
Manufacturer
I.T.E.
Photo File Name
Model Number
242-GA63-30C
KV
Mfgr Year
201-250 kV
1981
Method of Detection
Cause of Failure
Deterioration of capacitor.
Comments
Replacement Capacitors not available-Pole 2 destroyed.

Incident #
Incident Date
Report Date
Photo File Name
43915
10/18/2003
4/4/2004
BPAT200412,13
Manufacturer
ABB
Model Number
550PM 40-30
KV
Mfgr Year
> 500 kV
2003
Method of Detection
Cause of Failure
Comments
Breaker sent a trip command via SCADA. A & B phases interrupted approximately 250
Amps. C-phase continued to carry load current for approximately 16 cycles. Breaker
Failure Relay operated and cleared the bus. (Photos were unavailable for release in this report.)

Incident #
Incident Date
Report Date
43960
10/28/2003
2/23/2004
Manufacturer
Siemens
Photo File Name

KV
Mfgr Year
11-15 kV
1979
Model Number
FCV500
Method of Detection
Cause of Failure
Trip coil burned, breaker did not operate, took substation off line.
Comments
Failure caused interruption of service to approx. 5000 customers.
Page 9 of 28

Incident #
Incident Date
Report Date
Photo File Name
43943
11/10/2003
3/23/2004
sce2004rept_02
Manufacturer
ABB
Model Number
72PMI31-12
KV
Mfgr Year
51-100 kV
2000
Method of Detection
Cause of Failure
Shorted B-phase close coil causing.

Comments
Close signal was initiated via automatic capacitor controls, B phase close coil
leads were shorted. X relay contacts welded closed causing cb to pump until A phase
interrupter failed. It appears the cb close-opened. (Photo unavailable.)

Incident #
Incident Date
Report Date
Photo File Name
43909
11/16/2003
4/4/2004
BPAT200401, BPAT200420
Manufacturer
Brown Boveri Company
Model Number
72 PM
KV
Mfgr Year
51-100 kV
1988
Method of Detection
Cause of Failure
Bird droppings from an overhead structure washed down onto the bushings by the rain.
Comments
2 entrance bushings failed. Repair of the breaker required an internal inspection, replacement bushings and
unknown internally damaged parts to be replaced. Time to repair was longer than replacing the breaker
from stock so bkr was replaced. Additionally, the load lost needed to be restored. (Photos unavailable.)

Incident #
Incident Date
Report Date
43940
11/26/2003
12/1/2003
Manufacturer
High Voltage Breakers
Model Number
HVB362
Photo File Name

KV
Mfgr Year
301-350 kV
2003
Method of Detection
Cause of Failure
Defective material in the dashpot piston.

Comments
New breaker not in service. Relay doing final trip testing. Got pole disagreement
alarm. Found bent linkages in the mechanism of one phase. HVB sent factory people
to investigate. Found damage to linkages in mechanism, the aluminum cast support
conductor that holds the puffer piston, the puffer piston, the Teflon nozzle, and
the stationary contacts. HVB removed and replaced the whole phase. Took damaged
Page 10 of 28
phase to factory for investigation. HVB acted quickly and performed all repairs
at no cost to utility. Report available.

Incident #
Incident Date
Report Date
43925
12/20/2003
4/1/2004
Manufacturer
I.T.E.
Model Number
VRK-15-12
Photo File Name

KV
Mfgr Year
11-15 kV
1972
Method of Detection
Cause of Failure
Failure of mag latch and mech to keep breaker in the tripped position.
Comments
ITE VRKs have a history of mag latch failures and parts are no longer available.

Incident #
Incident Date
Report Date
43913
1/6/2004
4/4/2004
Manufacturer
Pennsylvania Transformer
Model Number
RHE-84L
Photo File Name

KV
Mfgr Year
201-250 kV
1965
Method of Detection
Cause of Failure
Latch valve failed due to lack of lubrication.

Comments
Trouble: OCB failed to reclose. Temperature -32 degrees. Mechanism does not move.
Corrective action - Removed and cleaned latch valve. Cleaned and lubed mechanism.

Incident #
Incident Date
Report Date
43912
1/6/2004
4/4/2004
Manufacturer
Pennsylvania Transformer
Model Number
RHE-84-230-15000
Photo File Name

KV
Mfgr Year
201-250 kV
1965
Method of Detection
Cause of Failure
Comments
Trouble: OCB failed to reclose. Temperature -32 degrees. Mechanism does not move.
Corrective action - Removed and cleaned latch valve. Cleaned and lubed mechanism.
Page 11 of 28

Incident #
Incident Date
Report Date
43964
1/29/2004
2/23/2004
Manufacturer
Siemens
Model Number
FCV500
Photo File Name

KV
Mfgr Year
11-15 kV
1979
Method of Detection
Cause of Failure
Trip coil burned, circuit breaker failed to operate on distribution circuit fault.
Comments
When the 12 kV circuit breaker failed to operate, backup relaying sensed the fault
and opened the 115 kV circuit switcher, interrupting service to approximately 5000
customers. This was the 3rd incident in 4 months where failure of a FCV-500 trip
coil caused a station to trip off line.

Incident #
Incident Date
Report Date
43956
3/19/2004
4/15/2004
Manufacturer
Allis-Chalmers
Model Number
FC-500-A1
Photo File Name

KV
Mfgr Year
11-15 kV
1974
Method of Detection
Cause of Failure
Trip mechanism frozen; lubrication dried up.

Comments
ACB WAS OVERHAULED 2 YRS AGO. PLAN TO REVISE LUBRICATION PROCEDURES ON BREAKER
MECHANISMS. THIS ACB FAILED TO OPEN ON A FEEDER FAULT CAUSING THE

BUS OVERCURRENTS TO CLEAR AN ENTIRE BUS SECTION (5 ADDITIONAL CIRCUITS)

Incident #
Incident Date
Report Date
Photo File Name
43888
7/6/2004
8/4/2004
3449164710432161.JPG
Manufacturer
ASEA-Brown Boveri
Model Number
242PMG50-30
KV
Mfgr Year
201-250 kV
2000
Method of Detection
Visual Inspection
Cause of Failure
Leak/Gasket
Comments
Moisture trapped in the mechanism housing caused massive corrosion damage and multiple
breaks on the disc springs on this AHMA-11 mechanism. The mechanism is not repairable
and is a total loss. Some water found an access into the mechanism housing, apparently
through some inadequate sealing procedures during installation. The drain hole
Page 12 of 28
was removed and over one quart of water poured out from the mechanism. A new mechanism
was installed and proper installation and sealing procedures were followed.
Circuit Switcher - Trouble

Incident #
Incident Date
Report Date
43971
7/3/2003
3/25/2004
Manufacturer
S&C Electric
Model Number
2040
Photo File Name

KV
Mfgr Year
51-100 kV
1988
Method of Detection
Cause of Failure
Voids & unmelted plastic in Delrin Spring Carrier allowing Red Target to actuate even though there was no SF6 leak.
Comments
We have had 30 or so of these Red Target-Low Gas problems and have been sending
back the Interrupters for a porcelain credit. We were told by the factory that units
between 1988 and 1991 did have manufacturing problems with the carrier, but, no
trouble since 1991. Then we had several 1992 and 1995 failures and contacted them
again. Recently we had the S&C Factory research this problem thoroughly and they
have a new repair kit that we can install in the field.
Page 13 of 28

Incident #
Incident Date
Report Date
43928
7/31/2003
4/1/2004
Manufacturer
S&C Electric
Model Number
Mark IV
Photo File Name

KV
Mfgr Year
301-350 kV
1978
Method of Detection
Cause of Failure
Unknown. Shipped failed interrupters back to S&C.

Comments
Interrupters on south pole failed to interrupt. Opened circuit with air break arms.
Circuit Switcher - In-Service Failure

Incident #
Incident Date
Report Date
Photo File Name
43927
11/1/2003
11/1/2003
IPC2004_Rept03
Manufacturer
S&C Electric
Model Number
S&C 2020
KV
Mfgr Year
51-100 kV
1994
Method of Detection
Cause of Failure
Comments
Problem with this design, if the circuit switcher fails to trip, (trip coil failure)
the agastat times out and the disconnects open even though the SF6 bottles do
not. The clearances on the open 69 kv disconnects are too close and the energized
line was flashing over phase to phase. This C/S needs a redesign, or we could roll
the C/S 180 so the open disconnects would not be energized when the gas bottles
were closed. (Photo not available for release in this report.)

Incident #
Incident Date
Report Date
Photo File Name
43914
2/3/2004
4/4/2004
BPAT200403,04,05,
Manufacturer
S&C Electric
Model Number
Mark IV
KV
Mfgr Year
> 500 kV
1979
Method of Detection
Cause of Failure
Mechanical failure of the interphase linkage.

Comments
While attempting to close circuit switcher via SCADA, the reactor and bus LOR's
operated. South bus LOR reset. Operator reported only two phases closed and linkage
between phases on the ground. (Photo unavailable.)
Page 14 of 28
CT - In-Service Failure
Incident #
Incident Date
Report Date
43967
11/27/2003
2/15/2004
Manufacturer
Haefely
Model Number
IOSK-245
Photo File Name

KV
Mfgr Year
201-250 kV
1985
Method of Detection
Cause of Failure
Internal fault
Comments
CT Column caught on fire & failed due to A Phase to Ground fault. This is a free-standing
oil-filled CT.
CT - In-Service Failure
Incident #
Incident Date
Report Date
Photo File Name
43890
11/27/2003
8/16/2004
27131316710412281.ppt
Manufacturer
Trench Electric
Model Number
IOSK-245
KV
Mfgr Year
201-250 kV
1984
Method of Detection
Other (See Comments), Relay Operation

Cause of Failure
Deteriorated Insulation
Comments
This is for a 230kV free standing CT that failed catastrophically while in service.
Page 15 of 28
Insulator - Trouble
Incident #
Incident Date
Report Date
Photo File Name
43936
10/21/2003
3/18/2004
MWD2004_Rept03A(thru H).JPG
Manufacturer
Model Number
Other
KV
Mfgr Year
201-250 kV
1933
Method of Detection
Cause of Failure
Unknown cause but note age of equipment.

Comments
One insulator stack pulled completely away, littering the station floor with insulator
material. (Photo unavailable.)
PT - Trouble
Incident #
Incident Date
Report Date
43935
6/10/2003
3/18/2004
Manufacturer
General Electric
Model Number
JVM
Photo File Name

KV
Mfgr Year
0-5 kV
1979
Method of Detection
Cause of Failure
Failure attributed to age of the equipment.

Comments
Both units tripped offline. From investigation, both fuses on the primary side
were found blown. TTR revealed shorted turns in the faulty P.T. The P.T. was replaced
with an old spare; new P.T.'s were ordered and will be changed-out at the next scheduled
maintenance. As preventive measures, other hydro plants will be surveyed for
the same type and manufacture P.T., of the same vintage, and consideration given to
performing insulation resistance tests on older P.T.'s during annual shutdowns.
Reactor - In-Service Failure

Incident #
Incident Date
Report Date
43899
2/21/2004
9/14/2004
Manufacturer
Trench Electric
Model Number
Shunt
Photo File Name

KV
Mfgr Year
26-35 kV
1981
Method of Detection
Other (See Comments)

Cause of Failure
Page 16 of 28
Deteriorated Insulation
Comments
After the reactor circuit breaker tripped, a lockout alarm indication was given.
A turn-to-turn failure occurred on the inside package of the reactor. Trench stated
that switching surges over long term operation can cause a shorted turn that creates
a high circulating current blowing out the winding. At 23 years old Trench stated
that it served its useful life. Inspection of other units was suggested. Reactors
of this age don't have arresters. New ones do to protect from TOVs during switching.
Consequently, we will be adding arresters to the other reactors in service.
Regulator - In-Service Failure

Incident #
Incident Date
Report Date
Photo File Name
43938
6/3/2004
3/25/2004
PAC200401a,b,c
Manufacturer
Siemens
Model Number
JFR
KV
Mfgr Year
16-20 kV
2002
Method of Detection
Cause of Failure
Spring failure - Siemens has redesigned the spring to a compression type.

Comments
We have seen several new model JFR regulators with this problem. Usually when a
drive spring breaks the operating mech jams. However this regulator tried to go
through the neutral position with only motor drive and caused an open circuit at the
reversing switch. (Photo was not available for release in this report.)
Relay - In-Service Failure

Incident #
Incident Date
Report Date
43963
1/28/2004
2/23/2004
Manufacturer
Basler
Model Number
BE1-51
Photo File Name

KV
Mfgr Year
N/A
1996
Method of Detection
Cause of Failure
Relay housing did not short CT circuit when relay was pulled for maintenance.
Comments
When the relay technician was removing a Basler BE1-51 relay for maintenance, the
shorting device did not make a connection to the CT circuit. When the paddle was
removed, technician heard buzzing noise (from CT opening), then differential relay
operated, opening circuit switcher. Service interrupted to about 5000 customers
for several minutes until relay re-installed and station put back on line.
Page 17 of 28
Switch - Trouble
Incident #
Incident Date
Report Date
Photo File Name
43911
5/14/2003
4/4/2004
BPAT200402
Manufacturer
(No MFR Listed)
Model Number
TA-3A
KV
Mfgr Year
251-300 kV
1964
Method of Detection
Cause of Failure
C-phase of the disconnect mechanically failed & stayed in the harp while operating the
disconnect switch. A-phase and B-phase opened normally.
Comments
This Schwager-Wood disconnect had a history of problems, likely associated to the

instability of the ground conditions at the site. The C-phase blade was found loose,
in the harp, in a rotated position. The crank arm at the hinge end was fully rotated
in the full open position. It does not appear that the blade left the harp during
operation. (Photo unavailable for release in this report.)
Switch - In-Service Failure

Incident #
Incident Date
Report Date
43910
5/16/2003
4/4/2004
Manufacturer
Allis-Chalmers
Photo File Name

KV
Mfgr Year
> 500 kV
1968
Model Number
Pantograph
Method of Detection
Cause of Failure
Mechanical failure of pantograph-type blade on the disconnect.

Comments
It has been determined that this disconnect is not needed on the system anymore due
to system configuration changes. It is scheduled to be removed. Removal of this
disconnect will allow us to have spare parts for the remaining 8 pantograph disconnects
on our system pending replacement.
Switch - Failure at Test

Incident #
Incident Date
Report Date
43894
7/20/2004
8/30/2004
Manufacturer
(No MFR Listed)
Model Number
EV-1
Photo File Name

KV
Mfgr Year
> 500 kV
Method of Detection

Cause of Failure

Comments
The equipment was a Southern States EV-1 500-kV disconnect switch. The part that
Page 18 of 28
failed was the VM-1, slave, motor operator on A-phase. When the
MOD (Motor Operated Disconnect) was operated, A-phase motor operator continued
to turn after the blade was fully open. This caused the coupling between the gear
box and the shaft connected to the rotating stack to fail. After this occurred,
the motor operator continued to spin, breaking off all open and close stops on the
motor operator. The motor operator was finally stopped when the DC control knife
switch was pulled. It was found that the 1" stainless steel gear shaft was cracked
vertically.
The entire motor operator was replaced.
Transformer - In-Service Failure

Incident #
Incident Date
Report Date
43917
5/17/2003
4/4/2004
Manufacturer
Wagner Electric
Model Number
HAL 24
Photo File Name

KV
Mfgr Year
101-150 kV
1951
Method of Detection
Cause of Failure
Winding failure due to lightning.

Comments
Through Fault

Incident #
Incident Date
Report Date
43958
6/6/2003
2/23/2004
Manufacturer
Federal Pacific Electric
Model Number
Transformer, LTC
Photo File Name

KV
Mfgr Year
101-150 kV
1968
Method of Detection
Cause of Failure
A high-current, three phase, through fault occurred and the transformer failed.
Comments
Failure caused interruption of service to 3000 customers including several large

industrials. This vintage of FPE transformer is prone to failure. We purchased
5 of these in 1968 and all five have now failed. Most of them failed during a through-fault.

Incident #
Incident Date
Report Date
43929
6/19/2003
4/1/2004
Manufacturer
Model Number
Wagner Electric
Photo File Name

KV
Mfgr Year
101-150 kV
1970
Method of Detection
Page 19 of 28
Cause of Failure
Poor design.
Comments
Through-fault during lightning storm (windings failed).

Incident #
Incident Date
Report Date
43908
6/20/2003
4/23/2004
Manufacturer
Model Number
Photo File Name

KV
Mfgr Year
101-150 kV
1964
Method of Detection
Cause of Failure
Possibly Lightning
Comments
Hoop failure (progressive turn-to-turn fault); replaced the transformer.
Transformer - Trouble
Incident #
Incident Date
Report Date
Photo File Name
43944
7/3/2003
3/23/2004
sce2004_Rept03
Manufacturer
Model Number
KV
Mfgr Year
Unknown
1954
Method of Detection
Cause of Failure
Probably age related.

Comments
Contact leaf spring failed. (Photo unavailable.)

Incident #
Incident Date
Report Date
Photo File Name
43959
7/5/2003
2/23/2004
SNPD2004_Rept02a,b,c
Manufacturer
General Electric
Model Number
Transf, w LTC
KV
Mfgr Year
101-150 kV
1975
Method of Detection
Cause of Failure
Squirrel contacted 12 kV bus on source side of circuit breaker. Corroded wiring prevented
circuit switcher from tripping. Sustained fault caused much damage
Comments
Fault started when a squirrel contacted the source side of an outdoor 12 kV breaker.
Page 20 of 28
The fault grew and involved all three-phases. Relays saw the fault properly, and
provided signal to circuit switcher to trip. Circuit switcher did not trip due
to corroded wiring inside conduit (not visible from ends). Fault and fire damage
was extensive. Two breakers and bus support structure were burned. Transformer
failed during the through-fault. Service interrupted to 5000 customers. (Photo unavailable.)

Incident #
Incident Date
Report Date
43972
7/10/2003
4/22/2004
Manufacturer
Model Number
Virginia Transformer
Photo File Name

KV
Mfgr Year
51-100 kV
1993
Method of Detection
Cause of Failure
Unknown
Comments
Turn to turn failure on the secondary winding. Performed complete rewinding of all coils,
testing and tank refurbishment, repair of load tap changer, installation of new remote
temperature gauges, new insulating oil, install tap changer filter unit, desiccant drier breather.

Incident #
Incident Date
Report Date
43931
8/4/2003
4/2/2004
Manufacturer
Model Number
General Electric
Photo File Name

KV
Mfgr Year
451-500 kV
Method of Detection
Cause of Failure
Comments
This transformer has Trench 287 kV high-voltage composite bushings.

A flashover occurred between the bottom plate and the tank wall of the transformer
and another fault between the upper part of the oil impregnated paper winding and
the flange of the composite insulator. All high-voltage bushings were replaced.

Incident #
Incident Date
Report Date
43970
8/19/2003
3/25/2004
Manufacturer
General Electric
Model Number
367 MVA
Photo File Name

KV
Mfgr Year
451-500 kV
1981
Method of Detection
Page 21 of 28
Cause of Failure
Lightning strike to bushing (H S bushing)

Comments
Bushing failed due to low oil level resulting in lower BIL, water had entered bushing
on top terminal gasket. Due to internal damage, replaced transformer.
Incident #
Incident Date
Report Date
43965
9/10/2003
3/2/2004
Manufacturer
Ferranti, Ltd.
Photo File Name
Model Number
Transformer LTC
KV
Mfgr Year
101-150 kV
1995
Method of Detection
LTC was severely coked and producing high levels of ethylene.

Cause of Failure
Poor design and/or quality of LTC

Comments
Problems were uncovered during routine DGA of the tap changer oil. The first test
showed extremely high levels of ethylene, about 100 times normal. We suspected
the test was faulty, so a second sample was drawn, and it had 145,000 ppm ethylene.
The Doble lab reported this ethylene level was the highest they have ever recorded
in a DGA sample. The tap changer was maintained less than 2 years ago and has an
oil filtration unit installed. When opened up, the reversing switch had severe
coking. Movable and stationary contacts also required replacement.

Incident #
Incident Date
Report Date
43941
10/1/2003
10/22/2003
Manufacturer
General Electric
Photo File Name

KV
Model Number
LRT-200-2
Mfgr Year
Unknown
Method of Detection
Cause of Failure
Bypass switch assembly misalignment on phase 3.

Comments
Transformer failed due to tap changer failure. Report available.
Incident #
Incident Date
Report Date
43957
10/14/2003
4/15/2004
Manufacturer
Model Number
Federal Pacific Electric
Photo File Name

KV
Mfgr Year
51-100
1974
Method of Detection
Page 22 of 28
Cause of Failure
Low side turn-to-turn failure.

Comments
DGA RESULTS - * The equipment condition code has been abnormal (2-3) since 08/13/2003.
The high CO2/CO ratio may indicate thermal decomposition of cellulose. Exercise
caution. Determine load dependence.
Incident #
Incident Date
Report Date
Photo File Name
43920
11/29/2003
4/4/2004
BPAT200406
Manufacturer
Hyundai
Model Number
BPA001000891
KV
Mfgr Year
101-150 kV
Method of Detection
Cause of Failure
Low voltage leads flashed over to the core.

Comments
The transformer tripped by two sets of differential, the Buchholz and the pressure relief
device operated. The 115 KV breaker at Drummond and the 161 KV breaker at Goshen
(72 miles) isolated the failed transformer within 4 cycles. The quick response from the
relays and breaker may have prevented further damage to the transformer. There were
of combustible gasses in the oil including acetylene, but the transformer tested OK
electrically. The manufacturer reported to the site within one week after the failure,
inspected the transformer and found that there was a dielectric breakdown between the
X1 C-phase and X2 B-phase leads and the core clamping structure through a lead
supporting board for X1, X2 and X3 leads. The failure occurred close to the X1 bushing
after the lead makes a 90 degrees angle from vertical to horizontal. (Photo unavailable.)

Incident #
Incident Date
Report Date
43930
1/13/2004
4/2/2004
Manufacturer
General Electric
Model Number
FOA
Photo File Name

KV
Mfgr Year
451-500 kV
Method of Detection
Cause of Failure
Bushing Failure
Comments
Trench 230kv bushing failure caused total loss of transformer. We are replacing
all of these type composite bushings.
Page 23 of 28
Incident #
Incident Date
Report Date
Photo File Name
43907
1/15/2004
4/23/2004
AVA2004_01
Manufacturer
Model Number
Alsthom
KV
Mfgr Year
> 500 kV
2002
Method of Detection
Cause of Failure
Comments
High voltage winding insulation failed. (Photo unavailable.)
Incident #
Incident Date
Report Date
Photo File Name
43918
1/16/2004
4/4/2004
BPAT200407,08,09,10,11
Manufacturer
Model Number
Allis-Chalmers
KV
Mfgr Year
301-350 kV
1963
Method of Detection
Cause of Failure
Internal fault leading to winding failure.

Comments
(Photos unavailable.)
Incident #
Incident Date
Report Date
43932
2/16/2004
4/2/2004
Manufacturer
ASEA Inc.
Model Number
TFTY1000
Photo File Name

KV
Mfgr Year
201-250 kV
Method of Detection
Cause of Failure
Internal fault caused can to split a welded seam along the lid on low-voltage side of transformer.
Comments
Unit was 8 years beyond design life, paper insulation degradation, 2300 piles driven
into ground in area for new construction, and decrease in insulation distance between
18kv internal delta bus at bottom of transformer tank.
Incident #
Incident Date
Report Date
Photo File Name
43933
2/17/2004
4/26/2004
MID200401,02,03
Manufacturer
Model Number
KV
Mfgr Year
Page 24 of 28
Kuhlman Electric
51-100 kV
1979
Method of Detection
Cause of Failure
Possibly due to previous over tightening of wire connection to collection ring stud.
Comments
An inspection of the LTC was made as part of the regular maintenance when the electrician
noticed the phenolic collector ring panel was burnt. The two studs passing through
the phenolic collector ring panel from the collector ring overheated causing the
board and studs to deteriorate. The 3/4" studs are reduced to 1/2" on the end connecting
to the collector ring. Solder is then sweat into the threads from the other side
(penetrating approx. 1/4"). I suspect the stud had loosened from the collector ring
(possibly due to previous over tightening) and overheated to the point the cable,
with the studs attached, came loose in the electricians hand. (Photo unavailable.)
Incident #
Incident Date
Report Date
Photo File Name
43919
2/20/2004
4/4/2004
BPAT200421, 22
Manufacturer
Model Number
Allis-Chalmers
KV
Mfgr Year
301-350 kV
1963
Method of Detection
Cause of Failure
Internal Fault
Comments
Winding failure. (Photo unavailable.)
Incident #
Incident Date
Report Date
Photo File Name
43945
3/19/2004
3/23/2004
sce2004_Rept04a,b
Manufacturer
Model Number
General Electric
KV
Mfgr Year
Unknown
1951
Method of Detection
Cause of Failure
Tracking and burning of the insulating drum on NLTC allowed the conductor contact points
to be misaligned and become loose. Severe arcing occurred.
Comments
Uneconomical to repair unit. This station is isolated load

so a generator had to be installed to off load transformer. (Photo unavailable.)
Page 25 of 28
Incident #
Incident Date
Report Date
Photo File Name
43955
3/30/2004
4/15/2004
Sdge2004Rept10A-G.JPG
Manufacturer
Waukesha
Model Number
KV
LTC PWR XFMR
Mfgr Year
2002
Method of Detection
Cause of Failure
High moisture.
Comments
Before we put the bank in service in April of 2003 , it failed the Doble test. When
we opened it up we found severe rust all over the core. Waukesha came out and cleaned
it up and called it good. It still Doble tested bad. It started gassing so it
was taken out of service. We Doble tested it before Waukesha reps got here to see
if it was worse than the initial test; it was. The CL watts went from 1.543 to 6.619 and the
CHL watts went up to 8.250 from 1.895. We also megger tested it again to see if that
had gotten worse and it did. Low to ground was 10.7 gig ohms and now it only got
89.7 meg ohms. When Waukesha drained it and opened it up on 3-21-04, the rust and
contamination looked worse than it did back in March of 2003. In March of 2003,
Waukesha drained and processed the oil for 24 hours. This was after they got inside
and cleaned up the rust off of the top of the core. The transformer came to us from
Waukesha with oil in it. The only time it was opened up when it was originally put in
service was when the factory rep was here to supervise the installation of the bushings.
Two-Winding Transformer - In-Service Failure

Incident #
Incident Date
Report Date
43898
1/4/2004
9/14/2004
Manufacturer
General Electric
Model Number
Photo File Name

KV
L252778A
Mfgr Year
1981
Method of Detection
Relay Operation
Cause of Failure

Comments
B phase (center) failure - could have been the winding insulation (most likely)
and/or the B phase HV bushing.

Incident #
Incident Date
Report Date
43889
2/4/2004
8/16/2004
Manufacturer
General Electric
Model Number
GE 12/16/20 @55degC
Photo File Name

KV
Mfgr Year
51-100 kV
1981
Method of Detection
Page 26 of 28
Power Factor, TCG

Cause of Failure
Winding
Comments

Incident #
Incident Date
Report Date
Photo File Name
43895
7/2/2004
9/2/2004
5230132810442451.jpg
Manufacturer
General Electric
Model Number
KV
Mfgr Year
D
Method of Detection
Exciting Current
Cause of Failure
Through-Fault
Comments
This unit has X1-X0 winding damage that showed up in TTR and excitation tests.
INTERNAL INSPECTION RESULTS
The coil structure that contains the H1-H3/X1-XO windings shows subtle evidence
that movement occurred in the structure. There are spacers in multiple areas of
the winding that have shifted out of their normal position. The LV leads that exit
the coil structure had ripped the cloth that originally tied some bracing blocks
to the leads. On one location at the bottom of the coil structure the blocking
was out of alignment. No tipping of the HV conductors or core damage could be observed.
Page 27 of 28
Two-Winding Transformer - Failure at Test

Incident #
Incident Date
Report Date
43897
8/24/2004
9/9/2004
Manufacturer
Westinghouse
Model Number
Photo File Name

KV
SL
Mfgr Year
1984
Method of Detection
Partial Discharge
Cause of Failure
Winding
Comments

Incident #
Incident Date
Report Date
43896
8/30/2004
9/9/2004
Manufacturer
ASEA-Brown Boveri
Model Number
SL
Photo File Name

KV
Mfgr Year
1997
Method of Detection
Relay Operation
Cause of Failure
Winding
Comments
Page 28 of 28

Troubles & Failures Report: Doble Engineering Company

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Knowledge Is Power SM

Apparatus Maintenance and Power Management For Energy Delivery

Doble Engineering Company

Troubles & Failures Report

Photo File Name

No apparent trouble in the system.

(Photo was unavailable for release in this report.)

Arrester - In-Service Failure

Photo File Name

B/O lightning arrester on RNO breaker.

Arrester - In-Service Failure

Photo File Name

Unknown - clear day, no moisture found internally.

Bushing-Condenser (oip) - Trouble

Photo File Name

Bushing-Condenser (oip) - Trouble

Photo File Name

Failed Doble power factor test.

Type U 500KV Bushing - evidence of water entering at top terminal gasket.

Bushing-Condenser (oip) - Trouble

Photo File Name

Troubles Failures Report

Bushing-Condenser (oip) - Failure at Test

Photo File Name

Bushings: C1 Power Factor

Photo File Name

Insulation failure due to old manufacturing formulation.

a shorter interval between cable tests, particularly for older cables.

Capacitor - In-Service Failure

Photo File Name

Troubles Failures Report

Circuit Breaker - Trouble

Photo File Name

Failed air compressor.

Circuit Breaker - In-Service Failure

Photo File Name

Trip coil failure.

Circuit Breaker - Trouble

Photo File Name

Mechanism lubrication dried up.

Troubles Failures Report

Circuit Breaker - Trouble

Photo File Name

While being energized, pole 3 went phase to ground.

Circuit Breaker - Trouble

Photo File Name

Exhaust piston stuck.

Circuit Breaker - Trouble

Photo File Name

Troubles Failures Report

Circuit Breaker - In-Service Failure

Photo File Name

Circuit Breaker - Trouble

Photo File Name

Internal contamination from factory

Internal fault B Phase to ground 15000amps

Circuit Breaker - Trouble

Photo File Name

B/O closing coil.

Circuit Breaker - Trouble

Photo File Name

Troubles Failures Report

Mechanism lubricants dried out.