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IEEE 3006 STANDARDS:

POWER SYSTEMS RELIABILITY

Historical Reliability Data


for IEEE 3006 Standards:
Power Systems Reliability

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IEEE 3000 Standards Collection™
for Industrial & Commercial Power Systems

Historical Reliability Data for


IEEE 3006 Standards:
Power Systems Reliability

Compiled by the
Technical Books Coordinating Committee
of the
IEEE Industry Applications Society

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Abstract: Reliability data gathered from equipment reliability surveys and analyses over a period
of 35 years or more is summarized in this collection. Equipment surveys conducted prior to 1976,
detailed reports on the surveys and data collection efforts, and extensive lists of references on
equipment reliability are presented. The collection provides the analyst with options for determining
reliability parameters for older electrical systems.

Keywords: commercial power systems, electrical interruptions, IEEE Gold Book™


annex, historical reliability data, IEEE 3006, industrial power systems, outage data, power systems
reliability, reliability analysis, reliability survey

This IEEE-SA publication is not a consensus document. Information contained in this work has
been obtained from sources believed to be reliable and reviewed by credible members of IEEE
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Copyright © 2012 by The Institute of Electrical and Electronics Engineers, Inc.


All rights reserved. Published 9 November 2012. Printed in the United States of America.

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Foreword

Compiled in this collection of historical reliability data is invaluable information supporting the planning
and design of industrial and commercial electric power distribution systems. It is a compilation of historical
survey information collected through the efforts of Don Koval and Charles Heising over a period of
approximately 35 years. This is a tribute to them and all of the contributors that made IEEE Std 493TM
(IEEE Gold BookTM) one of the best in what was the IEEE Color Book® series.

This collection summarizes the reliability information collected from equipment reliability surveys over a
period of 35 years or more. It consists of equipment surveys conducted prior to 1976, detailed reports on the
surveys and data collection efforts, and extensive lists of references on equipment reliability. Selected
reliability and availability numeric from the survey efforts are also presented in this document.

This document provides the analyst with options for determining reliability parameters for older electrical
systems. Data not found anywhere else is the cornerstone of this document, with some surveys spanning
many years. In addition, there is utility numeric critical to facility assessments that identifies available
power.

Robert G. Arno, Senior Member of IEEE

This collection is respectfully dedicated to Don Koval and Charles Heising,


who devoted countless hours to compiling this data for the benefit of the industry.

iv
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Contents
Report on Reliability Survey of Industrial Plants—Parts I, II, and III ............................................................ 1

Report on Reliability Survey of Industrial Plants—Parts IV, V, and VI....................................................... 61

Cost of Electrical Interruptions in Commercial Buildings ............................................................................ 87

Reliability of Electric Utility Supplies to Industrial Plants ........................................................................... 95

Report of Switchgear Bus Reliability Survey of Industrial Plants and Commercial Buildings .................. 100

Working Group Procedure for Conducting an Equipment Reliability Survey ............................................ 109

Report of Transformer Reliability Survey—Industrial Plants and Commercial Buildings......................... 114

Report of Large Motor Reliability Survey of Industrial and Commercial Installations


Parts I, II, and III...................................................................................................................................... 124

Reliability Study of Cable, Terminations, and Splices by Electric Utilities in the Northwest .................... 151

Summary of CIGRE 13.06 Working Group World Wide Reliability and Maintenance Cost Data
on High Voltage Circuit Breakers above 63 kV....................................................................................... 161

Report of Circuit Breaker Reliability Survey of Industrial and Commercial Installations ......................... 170

Reliability Survey of 600 to 1800 kW Diesel and Gas-Turbine Generating Units ..................................... 187

Reliability/Availability Guarantees of Gas Turbines and Combined Cycle Generating Units ................... 203

Transmission Line and Equipment Outage Data ......................................................................................... 221

Interruption Costs, Consumer Satisfaction, and Expectations for Service Reliability ................................ 258

Survey Results of Low-Voltage Breakers as Found During Maintenance Testing ..................................... 266

Survey of Reliability and Availability Information for Power Distribution, Power Generation, and
HVAC Components for Commercial, Industrial, and Utility Installations .............................................. 271

v
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Report on Reliability Survey of Industrial Plants
Part I
Reliability of Electrical Equipment

Part II
Cost of Power Outages, Plant Restart Time, Critical Service Loss
Duration Time, and Type of Loads Lost Versus Time of Power Outages

Part III
Causes and Types of Failures of Electrical Equipment,
the Methods of Repair, and the Urgency of Repair

By
Reliability Subcommittee
Industrial and Commercial Power Systems Committee
IEEE Industry Applications Society

W. H. Dickinson, Chair
P. E. Gannon C. R. Heising A. D. Patton
M. D. Harris D. W. McWilliams W. J. Pearce
R. W. Parisian

Industrial and Commercial Power Systems Technical Conference


Institute of Electrical and Electronics Engineers, Inc.
Atlanta, Georgia
May 13–16, 1973

Published by
IEEE Transactions on Industry Applications
March/April 1974

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Report on Reliability Survey of Industrial Plants


Part IV
Additional Detailed Tabulation of Some Data Previously Reported
in the First Three Parts

Part V
Plant Climate, Atmosphere, and Operating Schedule, the Average Age
of Electrical Equipment, Percent Production Lost, and the
Method of Restoring Electrical Service after a Failure

Part VI
Maintenance Quality of Electrical Equipment

By
Reliability Subcommittee
Industrial and Commercial Power Systems Committee
IEEE Industry Applications Society

A. D. Patton, Chair
C. E. Becker P. E. Gannon R. W. Parisian
W. H. Dickinson C. R. Heising S. J. Wells
D. W. McWilliams

Industrial and Commercial Power Systems Technical Conference


Institute of Electrical and Electronics Engineers, Inc.
Denver, Colorado
June 3–6, 1974

Also published
IEEE Transactions on Industry Applications
July/August and September/October 1974
Part IV, pp. 456–462
Part V, pp. 463–466
Part VI, pp. 467–468, 681, 469–476

Reprinted from pp. 113–136


in 74CH0855-71A, 1974 I&CPS Technical Conference

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HISTORICAL RELIABILITY DATA

85
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IEEE
HISTORICAL RELIABILITY DATA

86
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IEEE
HISTORICAL RELIABILITY DATA

Cost of Electrical Interruptions in Commercial Buildings

By
Power Systems Reliability Subcommittee Industrial and
Commercial Power Systems Committee
IEEE Industry Applications Society

P. E. Gannon, Coordinating Author


A. D. Patton, Chair
C. E. Becker M. D. Harris D. W. McWilliams
M. F. Chamow C. R. Heising R. W. Parisian
W. H. Dickenson R. T. Kulvicki S. J. Wells

Industrial and Commercial Power Systems Technical Conference


Institute of Electrical and Electronics Engineers, Inc.
Toronto, Canada
May 5–8, 1975

Reprinted from IEEE Conference Record


7SCH0947-1-1A, pp. 123–129

87
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IEEE
HISTORICAL RELIABILITY DATA

88
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IEEE
HISTORICAL RELIABILITY DATA

89
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IEEE
HISTORICAL RELIABILITY DATA

90
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IEEE
HISTORICAL RELIABILITY DATA

91
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IEEE
HISTORICAL RELIABILITY DATA

92
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IEEE
HISTORICAL RELIABILITY DATA

93
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IEEE
HISTORICAL RELIABILITY DATA

94
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IEEE
HISTORICAL RELIABILITY DATA

Reliability of Electric Utility Supplies to Industrial Plants

By
Power System Reliability Subcommittee
Industrial and Commercial Power Systems Committee
IEEE Industry Applications Society

A. D. Patton, Chair
C. E. Becker P. E. Gannon D. W. McWillams
M. F. Chamow C. R. Heising R. W. Parisian
W. H. Dickinson M. D. Harris S. J. Wells
R. T Kulvicki

Industrial and Commercial Power Systems Technical Conference


Institute of Electrical and Electronics Engineers, Inc.
Toronto, Canada
May 5–8, 1975

Reprinted from IEEE Conference Record


75CH0947-1-1A, pp. 131–133

95
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IEEE
HISTORICAL RELIABILITY DATA

96
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IEEE
HISTORICAL RELIABILITY DATA

97
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IEEE
HISTORICAL RELIABILITY DATA

98
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IEEE
HISTORICAL RELIABILITY DATA

99
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IEEE
HISTORICAL RELIABILITY DATA

Report of Switchgear Bus Reliability Survey


of Industrial Plants and Commercial Buildings

By
Power Systems Reliability Subcommittee
Power Systems Support Committee
Industrial Power Systems Department
IEEE Industry Applications Society

P. O. O'Donnell, Coordinating Author


P. E. Gannon, Chair
J. W. Aquilino C. R. Heising A. D. Patton
C. E. Becker D. Kilpatrick C. Singh
W. H. Dickinson D. W. McWilliams W. L. Stebbins
B. Douglas R. N. Parisian H. T Wayne
I. Harley S. J. Wells

Industrial and Commercial Power Systems Technical Conference


Institute of Electrical and Electronics Engineers, Inc.
Cincinnati, Ohio
June 5–8,1978

Published by
IEEE Transactions on Industry Applications
March/April 1979, pp. 141–147

100
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IEEE
HISTORICAL RELIABILITY DATA

101
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IEEE
HISTORICAL RELIABILITY DATA

102
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IEEE
HISTORICAL RELIABILITY DATA

103
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IEEE
HISTORICAL RELIABILITY DATA

104
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IEEE
HISTORICAL RELIABILITY DATA

105
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IEEE
HISTORICAL RELIABILITY DATA

106
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IEEE
HISTORICAL RELIABILITY DATA

107
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IEEE
HISTORICAL RELIABILITY DATA

108
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IEEE
HISTORICAL RELIABILITY DATA

Working Group Procedure for Conducting


an Equipment Reliability Survey

By
Power Systems Reliability Subcommittee
Power Systems Technology Committee
Industrial Power Systems Department
IEEE Industry Applications Society

Procedure I

Compiled December 8, 1980; Approved May 4, 1981

109
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IEEE
HISTORICAL RELIABILITY DATA

110
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IEEE
HISTORICAL RELIABILITY DATA

111
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IEEE
HISTORICAL RELIABILITY DATA

112
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IEEE
HISTORICAL RELIABILITY DATA

113
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IEEE
HISTORICAL RELIABILITY DATA

Report of Transformer Reliability Survey—


Industrial Plants and Commercial Buildings

By
James W. Aquilino

IEEE Transactions on Industry Applications


September/October 1983, pp. 858–866

114
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IEEE
HISTORICAL RELIABILITY DATA

115
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IEEE
HISTORICAL RELIABILITY DATA

116
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IEEE
HISTORICAL RELIABILITY DATA

117
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IEEE
HISTORICAL RELIABILITY DATA

118
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IEEE
HISTORICAL RELIABILITY DATA

119
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IEEE
HISTORICAL RELIABILITY DATA

120
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IEEE
HISTORICAL RELIABILITY DATA

121
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IEEE
HISTORICAL RELIABILITY DATA

122
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IEEE
HISTORICAL RELIABILITY DATA

123
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IEEE
HISTORICAL RELIABILITY DATA

Report of Large Motor Reliability Survey of


Industrial and Commercial Installations
Parts I, II, and III

By
P. O’Donnell

Motor Reliability Working Group


Power Systems Reliability Subcommittee
Power Systems Engineering Committee
Industrial and Commercial Power Systems Department
IEEE Industry Applications Society

IEEE Transactions on Industry Applications


Parts I and II, July/August 1985, pp. 853–872
Part III, January/February 1987, pp. 153–158

124
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IEEE
HISTORICAL RELIABILITY DATA

125
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IEEE
HISTORICAL RELIABILITY DATA

126
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IEEE
HISTORICAL RELIABILITY DATA

127
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IEEE
HISTORICAL RELIABILITY DATA

128
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IEEE
HISTORICAL RELIABILITY DATA

129
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IEEE
HISTORICAL RELIABILITY DATA

130
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IEEE
HISTORICAL RELIABILITY DATA

131
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IEEE
HISTORICAL RELIABILITY DATA

132
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IEEE
HISTORICAL RELIABILITY DATA

133
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IEEE
HISTORICAL RELIABILITY DATA

134
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IEEE
HISTORICAL RELIABILITY DATA

135
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IEEE
HISTORICAL RELIABILITY DATA

136
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IEEE
HISTORICAL RELIABILITY DATA

137
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IEEE
HISTORICAL RELIABILITY DATA

138
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IEEE
HISTORICAL RELIABILITY DATA

139
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IEEE
HISTORICAL RELIABILITY DATA

140
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IEEE
HISTORICAL RELIABILITY DATA

141
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IEEE
HISTORICAL RELIABILITY DATA

142
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IEEE
HISTORICAL RELIABILITY DATA

143
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IEEE
HISTORICAL RELIABILITY DATA

144
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IEEE
HISTORICAL RELIABILITY DATA

145
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IEEE
HISTORICAL RELIABILITY DATA

146
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IEEE
HISTORICAL RELIABILITY DATA

147
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IEEE
HISTORICAL RELIABILITY DATA

148
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IEEE
HISTORICAL RELIABILITY DATA

149
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IEEE
HISTORICAL RELIABILITY DATA

150
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IEEE
HISTORICAL RELIABILITY DATA

Reliability Study of Cable, Terminations, and Splices


by Electric Utilities in the Northwest

By
William F. Braun

IEEE Transactions on Industry Applications


January/February 1987, pp. 144–153

151
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IEEE
HISTORICAL RELIABILITY DATA

152
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IEEE
HISTORICAL RELIABILITY DATA

153
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IEEE
HISTORICAL RELIABILITY DATA

154
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IEEE
HISTORICAL RELIABILITY DATA

155
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IEEE
HISTORICAL RELIABILITY DATA

156
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IEEE
HISTORICAL RELIABILITY DATA

157
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IEEE
HISTORICAL RELIABILITY DATA

158
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IEEE
HISTORICAL RELIABILITY DATA

159
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IEEE
HISTORICAL RELIABILITY DATA

160
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IEEE
HISTORICAL RELIABILITY DATA

Summary of CIGRE 13.06 Working Group


World Wide Reliability and Maintenance Cost Data
on High Voltage Circuit Breakers above 63 kV

By
C. R. Heising, A. L. J. Janssen, W. Lanz,
E. Colombo, E. N. Dialynas

IEEE-IAS Industrial Application Conference


Denver, Colorado
October 2–5, 1994

Reprint from IEEE Conference Record


94CH34520, pp. 2226–2234

161
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HISTORICAL RELIABILITY DATA

162
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IEEE
HISTORICAL RELIABILITY DATA

163
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IEEE
HISTORICAL RELIABILITY DATA

164
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IEEE
HISTORICAL RELIABILITY DATA

165
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IEEE
HISTORICAL RELIABILITY DATA

166
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IEEE
HISTORICAL RELIABILITY DATA

167
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IEEE
HISTORICAL RELIABILITY DATA

168
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IEEE
HISTORICAL RELIABILITY DATA

169
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IEEE
HISTORICAL RELIABILITY DATA

Report of Circuit Breaker Reliability Survey of


Industrial and Commercial Installations

By
A.T. Norris

IEEE Industrial and Commercial Power Systems


Technical Conference
Chicago, Illinois
May 8–11, 1989

Reprinted from IEEE Conference Report


89CH27738-3, pp. 1–16

170
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IEEE
HISTORICAL RELIABILITY DATA

171
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IEEE
HISTORICAL RELIABILITY DATA

172
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IEEE
HISTORICAL RELIABILITY DATA

173
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IEEE
HISTORICAL RELIABILITY DATA

174
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IEEE
HISTORICAL RELIABILITY DATA

175
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IEEE
HISTORICAL RELIABILITY DATA

176
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IEEE
HISTORICAL RELIABILITY DATA

177
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IEEE
HISTORICAL RELIABILITY DATA

178
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IEEE
HISTORICAL RELIABILITY DATA

179
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IEEE
HISTORICAL RELIABILITY DATA

180
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IEEE
HISTORICAL RELIABILITY DATA

181
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IEEE
HISTORICAL RELIABILITY DATA

182
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IEEE
HISTORICAL RELIABILITY DATA

183
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IEEE
HISTORICAL RELIABILITY DATA

184
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IEEE
HISTORICAL RELIABILITY DATA

185
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IEEE
HISTORICAL RELIABILITY DATA

186
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IEEE
HISTORICAL RELIABILITY DATA

Reliability Survey of 600 to 1800 kW Diesel and


Gas-Turbine Generating Units

By
Clayton A. Smith, Michael D. Donovan, and Michael J. Bartos

Conference Record of the IEEE Industrial and


Commercial Power Systems Technical Conference
Chicago, Illinois
May 8–11, 1989

IEEE Transactions on Industry Applications


July/August 1990, pp. 741–755

187
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IEEE
HISTORICAL RELIABILITY DATA

188
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IEEE
HISTORICAL RELIABILITY DATA

189
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IEEE
HISTORICAL RELIABILITY DATA

190
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IEEE
HISTORICAL RELIABILITY DATA

191
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IEEE
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Reliability/Availability Guarantees of Gas Turbines and


Combined Cycle Generating Units

By
Thomas E. Ekstrom

IEEE Transactions on Industry Applications


Vol. 31, No. 4, July/August 1995, p. 691–707

203
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Transmission Line and Equipment Outage Data

Part I

An IEEE Survey of U.S. and Canadian


Overhead Transmission Outages at 230 kV and Above

By
R. B. Adler, S. L. Daniel, Jr., C. R. Heising,
M. G. Lauby, R. P. Ludorf, T. S. White

IEEE PES Transactions on Power Delivery


Vol. 9, No. 1, January 1994, pp. 21–39

Part 2

Frequency of Transmission Line Outages in Canada

By
Don O. Koval

Conference Record of the 1994 Industry Application’s


Conference Twenty-Ninth Annual Meeting
Denver, Colorado
October 2–3, 1994
Volume III, pp. 2201–2208

Part 3

Transmission Equipment Reliability Data from


Canadian Electrical Association

By
Don O. Koval

IEEE Transactions on Industry Applications


Vol. 32, No. 6, November/December 1996, pp. 1–9

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Interruption Costs, Consumer Satisfaction, and


Expectations for Service Reliability

By
Michael J. Sullivan, Terry Vardell,
B. Noland Suddeth, Ali Vojdani

Paper No. 95 SM 572-8 PWRS


IEEE-PES Summer Power Meeting
Portland, Oregon
July 23–27, 1995

258
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Survey Results of Low-Voltage Breakers as


Found During Maintenance Testing

By
Pat O’Donnell

IEEE Industrial and Commercial Power Systems


Technical Conference
New Orleans
May 6–9, 1996

Reprint from IEEE Conference Record


96CH35920, pp. 1–4

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Survey of Reliability and Availability Information for Power
Distribution, Power Generation, and
HVAC Components for Commercial,
Industrial, and Utility Installations

By
Peyton S. Hale, Jr., and Robert G. Arno

IEEE Industrial and Commercial Power Systems


Technical Conference
Clearwater, Florida
May 7–11, 2005

Reprint from IEEE Conference Record


ISBN 0-7803-5843-0, Copyright © 2000 IEEE

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HISTORICAL RELIABILITY DATA

SURVEY OF RELIABILITY AND AVAILABILITY INFORMATION


FOR POWER DISTRIBUTION, POWER GENERATION, AND
HVAC COMPONENTS FOR COMMERCIAL, INDUSTRIAL,
AND UTILITY INSTALLATIONS

Mr. Peyton S. Hale, Jr.


U.S. Army Corps of Engineers
Special Missions Office
Power Reliability Enhancement Program (PREP)
10115 Gridley Road
Fort Belvoir, VA 22060-5859

Mr. Robert G. Arno


Reliability Analysis Center (RAC)
201 Mill Street
Rome, NY 13440-6916

Abstract (containing over 6,000 records of operational and


maintenance data) and the contact information
This paper presents the culmination of a 24,000 man- (containing over 3,500 records identifying information
hour effort to collect operational and maintenance data sources). The levels of data quality and maintenance
on 204 power generation, power distribution and quality were assessed during the analysis phase of the
HVAC items, including gas turbine generators, diesel project.
engine generators, electrical switchgear, cables, circuit
breakers, boilers, piping, valves, pumps, motors and The results indicated that the maintenance quality
chillers. The data collection process and the resultant level was a major predictor of equipment availability,
data are the subject of this paper. therefore, the availability values presented represent an
average maintenance program across all the data
The Power Reliability Enhancement Program sources. In addition, the information obtained can aid
established the data collection effort to determine the facility designers and engineers in evaluating different
effects of “new technology” equipment, i.e., equipment designs to minimize production/mission failure and to
installed after 1971, on reliability and availability. estimate the down times associated with various systems
Previous data collection efforts were completed in the or sub-systems. Facility types that require more
early 1970’s using data collected in the 1950’s and maintenance time and systems that may benefit from
1960’s. The primary purpose of the data collection redundancy or replacement can also be identified.
effort was to provide more current equipment
reliability and availability data when performing a The U.S. Army Corps of Engineers, Power Reliability
facility reliability/availability assessment. Information Enhancement Program, located in Fort Belvoir, VA,
was obtained on a variety of commercial and industrial sponsored this two-year program. The work was
facility types (including office buildings, hospitals, accomplished by the Reliability Analysis Center (RAC)
water treatment facilities, prisons, utilities, in Rome, NY.
manufacturing facilities, school universities and bank
computer centers), with varying degrees of maintenance I. INTRODUCTION
quality.
The U.S. Army Corps of Engineers, Power Reliability
Data collection guidelines and goals were established Enhancement Program (PREP) sponsored a study of the
to ensure that sufficient operational and maintenance reliability, availability and maintainability characteristics of
data were collected for statistically valid analysis. 204-power generation, power distribution, and Heating
Minimums of 3.5 million calendar hours were Ventilation and Air Conditioning (HVAC) items. This
established for each component. Time-to-failure data, paper describes the data collection and summarization of all
helpful in model development, were collected, when 204 items. The Reliability Analysis Center (RAC), a DoD
available, to determine device failure characteristics. A Information Analysis Center operated by IIT Research
database system, with flexible output capabilities, was Institute, in Rome New York, began the work in October
developed to track both the equipment information 1991 and delivered the final report in early 1994.

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II. BACKGROUND PC. The database can now be placed on a CD and


transferred to anyone with Microsoft Office Access.
The Power Reliability Enhancement Program
established a utility system availability goal of 0.999999 Database Information
(31.5 sec/yr. downtime) at Command, Control, In order to collect statistically valid data it was important
Communication, Computers and Intelligence facilities that a stratified survey of different facility categories,
worldwide. The methodology PREP used in calculating the applications and operating conditions be conducted.
system reliability and availability was a Boolean algebra Guidelines were developed to assist in the selection of
based modeling technique using individual equipment potential sites. These guidelines include:
reliability values to produce the system model. 1. Locations surveyed were required to have varying
degrees of maintenance practices.
Prior to this study, PREP based its predictions on 2. A number of sites for each facility category were
component reliability and availability information predetermined; this was required to eliminate any
developed in the early 1970’s that had been compiled from skewing of the data caused by the influence of
multiple sources. However, PREP had discovered limited data.
problems with using this information source since the 3. Component size was also a basis of site selection to
information contradicted itself and contained some ensure that similar technologies were being
confusing data. In addition, the database did not fully compared.
address maintenance. Therefore, it became apparent that 4. Equipment age was also considered to ensure that
the data needed to be updated. data from both the newer high-efficiency generation
of equipment and the older technology generation
III. DATABASE DEVELOPMENT were included.

A computerized system named PREPIS (Power The first of these was included because it is known that
Reliability Enhancement Program Information System) was maintenance policies and practices directly affect
developed to assist technical staff in organizing, tracking, equipment availability. High levels of maintenance lower
analyzing, and reporting all of the technical and contact availability, but have the potential to increase reliability.
information during the execution of this PREP program. Too little maintenance raises availability, but has the
The two major components in PREPIS are: potential to decrease reliability. During a prolonged period
1 . Contact records: contains site information; it is of operation time with little maintenance, availability and
comprised of 6208 contact records. reliability both decrease drastically. The amount of
2 . Equipment records: contains performance and maintenance performed can drastically affect the
maintenance information; it includes 4043 performance parameters being collected.
equipment records.
3. This comprehensive database system was organized A process of identification and certification of data was
functionally to support the following tasks: developed to ensure that each data collection trip was
- Record individual site information successful. Minimum requirements for data were
- Prioritize site visits established to ensure a sound statistical basis for the
- Collect and organize site data analysis:
- Data input and verification • A minimum of five years of operational data was
- Data summarization and analysis collected.
- Report generation • A minimum sample size of 40 with a maximum site
allocation of 10 items each was imposed.
The output record generator contains several “canned” • A minimum of 3.5 million calendar hours total for
reports designed for data summary and availability each component was established.
calculations. Some of the reports are designed to allow the
user the flexibility to select a multitude of query topics. Data Contacts
The format of the report generator allows easy construction Contacts were the key to the success of this program.
of custom reports for individual needs. The cooperation and support of the people involved from
the many facilities, even during times of budget and
This database, developed in 1991, was adequate for the personnel reduction is demonstrated in the quality of data
task. As new, more efficient database tools were developed received to support the PREP.
it became apparent that a more portable, user friendly
database tool was needed. In addition several inquiries of A concerted effort was employed to develop an
the database resulted in a significant effort to recreate data extensive contact database using manufacturers, facilities,
reports to satisfy requests. A better method was sought to societies, and locations of any potential data contributor
minimize this time. utilizing PREP components. Manufacturers were contacted
not only for contacts, but also for any warranty data that
RAC began the arduous task in 1998 of creating a may be available. A total of 25 manufacturers participated,
common database and has transferred the data into including Caterpillar, Westinghouse Electric, EMD, and
Microsoft Office Access database allowing the user the MFG Systems Corporation. A total of 25 professional
ability to develop customized data extraction scenarios on a societies were contacted, including:

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- American Gas Association determine numerous performance parameters. This


- National Association of Power Engineers type of data was the most difficult and time
- American Society of Mechanical Engineers consuming to summarize and was only used when
- Association of Physical Plant Administrators no other data sources were available. The PREPIS
- Association of Energy Engineers equipment record database is comprised of 10% to
15% of this type of data.
IV. DATA SUMMARIZATION AND CLASSIFICATION
Maintenance Policy
Data Completeness The major intent of the data collection effort was to
As with every data collection program, there are varying minimize the effects of maintenance policies and
degrees of completeness in the data gathered. Some data procedures on the calculated availability values by
sources had complete records and could give statistics on collecting data from a variety of locations having various
operational characteristics on every piece of equipment maintenance policies. RAC personnel developed a code to
from installation date to that current moment of time. More categorize each facility’s maintenance policies and
often, the only items tracked were major items such as procedures into one of three levels:
cooling towers and boilers. Data for items such as valves Code “1”: Above average maintenance policy. The
and filters were not usually recorded. Other problems facility not only followed a scheduled, preventative
included incomplete or non-current versions of the maintenance policy that was equivalent or similar to the
equipment’s blue prints. Several RAC technicians manufacturer’s suggested policy, but also went beyond it,
manually developed parts lists, recording data from such as using redundant units, specialized equipment tests
nameplates and relying on facility engineers for component (thermograph, vibration analysis, oil analysis), complete
descriptions. spare parts kits for equipment, and so on.
Code “2”: Average maintenance policy. Facility used
It became important to categorize the different levels of either in-house maintenance crews performing scheduled,
data completeness to ensure that the final data collection preventative maintenance according to the equipment
included fair data representation for each component. To manufacturer’s suggested PM schedule or a combination of
quantify this data completion (or quality) index, RAC in-house maintenance crews and outside contractors. In
identified these four levels: both cases, it was verified that they did actually follow a
fairly rigid schedule.
1. Perfect Data: Data needed for a valid, complete Code “3”: Below average maintenance policy. Facility’s
reliability study, including a parts list, failure actual policy was less than average. It may have instituted
history data with time-to-failure statistics, parts a scheduled maintenance policy but not followed it or it
description data, operational periods, and ten may have had no maintenance policy. Symptoms such as
continuous years of recorded data. No engineering leaky valves with rags tied around them, dirty air filters,
judgment or data extrapolation is required. The squeaky bearings, lose belts, and general house keeping
PREPIS equipment record database is comprised of because of unavailable manpower were typical signs that
10% to 20% of this type of data. maintenance at a facility was less than desirable.
2. Not Perfect Data: Data with no serious flaws, but
the data collection process demanded additional Each location was then compared to each other and to
time to ensure useful information was gathered. the average maintenance policy. Overall, the facilities that
Examples include parts list determined by RAC visited practiced an average level of maintenance;
inspection, incomplete blueprints or less than ten that is, they adhered to the manufacturers recommended
years of data. The PREPIS equipment record maintenance policy. RAC looked at approximately the
database contains 35% to 40% of this type of data. same number of facilities that had below average
3. Verbal/Inspection Data: Data with serious gaps that maintenance policies as those facilities that had an above
required additional documentation and verification average maintenance policy.
prior to its inclusion in the database. Items
included were typically major items, such as Results
generator sets and boilers. Senior maintenance Attached to this paper are the 204 components
personnel were interviewed to extract the necessary representing the PREP database. It is presented in a
information to fill the data gaps. These interviews hierarchical structure to provide the analyst with numeric
were used as support documentation to recorded options if the exact component is not identified. As an
data, not as data source information. About 25% of example, the CATEGORY of Accumulator is comprised of
this type of data exist in the PREPIS equipment two CLASSES (Pressurized and Unpressurized). Each of
record database. the CLASSES is comprised of individual data points.
4. Soft Data: Data that relied on the memories of Reliability numeric is derived for each data point listed
experienced maintenance personnel from the within a CLASS and displayed in columns in the database
participating facility; it was often extracted from report.
log books containing maintenance personnel
entries, filing cabinets with work order forms, and The numeric is then rolled-up to the CLASS level to
repair records when outside repair support was indicate a combination of information within each CLASS.
needed. Engineering judgment was often used to Subsequently the data from the CLASS level is rolled-up

274
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IEEE
HISTORICAL RELIABILITY DATA

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275
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IEEE
HISTORICAL RELIABILITY DATA

V. CONCLUSIONS REFERENCES

Information collected in this study is useful in determining the site [1] GO, available from Electric Power Software Center,
reliability or availability. The actual value that is predicted for a University Computing Company, 1930 Hi Line Drive, Dallas,
specific system may not be totally definitive, but the comparisons TX 75207.
between systems is of greater value. [2] Design of Reliable Industrial and Commercial Power
Systems, IEEE Standard 493-1990.
The data and procedure can be used in different manners to aid the [3] Dickinson, W.H., Gannon, P.E., Heising, C.R., Patton, A.D.,
facility designer and facility engineer. The designer can use the data and McWilliams, D.W., “Fundamentals of Reliability
to evaluate different designs. The designer can estimate the length of Techniques as Applied to Industrial Power Systems,”
downtime by adding the failure time to the production or mission loss Conference Record 1971, IEEE Industrial Commercial Power
and can estimate the total length of time from line stop to line start as Systems Technical Conference, 71C18-IGA, p. 10-31.
a result of failures. New designs or redesigns can be evaluated to [4] Singh, C. and Billinton, R., System Reliability Modeling and
minimize the production/mission failure with estimates on money Evaluation, Hutchinson Educational, London, England, 1977.
saved by avoiding downtime. The engineer can estimate the down [5] IEEE Standard 493-1980, IEEE Recommended Practice for
times associated with the systems or sub-systems and compare these the Design of Reliable Industrial and Commercial Power
results to the actual times. This could identify problem areas that Systems, Table 2. In general, failure duration is actual hours
may need more (or less) maintenance time and systems that may downtime per failure based on industry averages. Data from
benefit from redundancy or replacement. “All Equipment Failures” are used, as opposed to median
plant averages, which use data of all plants that reported
VI. WHERE TO GET ADDITIONAL INFORMATION actual outage time on equipment failures.

Additional information including list of contacts and specific BIOGRAPHIES


maintenance information may be obtained from:
Peyton S. Hale, Jr. received his B.S. in Mechanical Engineering,
U.S. Army Corps of Engineers from the University of Virginia in 1983. He received his Masters
Special Missions Office Degree in Engineering Management from George Washington
Power Reliability Enhancement Program (PREP) University in 1993. His principal responsibilities include performing
10115 Gridley Road reliability/availability analyses, leading site field surveys and
Fort Belvoir, VA 22060-5859 preparing recommended system improvement documents for
(703) 704-2777 electrical and mechanical systems for critical Command, Control,
Communications and Intelligence (C3I) facilities.
Reliability Analysis Center
201 Mill Street Robert G. Arno received his B.S. in Electrical Engineering from
Rome, NY 13440-6916 State University of New York at Utica/Rome in 1982 and is currently
(315) 337-0900 a member of ASQC, Mohawk Valley Chapter. Mr. Arno has worked
in the reliability field for 23 years, joining IIT Research Institute in
Rome, NY in 1977. His principal responsibilities include program
management, electrical and mechanical system analysis and
modeling, and data collection and analysis. He managed the
described data collection program.

276
Copyright © 2012 IEEE. All rights reserved.
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PREP DATABASE /Version 4.2
The header below represents the header in the database. Each column heading is explained in the text boxes. The formulas, representing the column heading, are contained in the
table in Section V above.

Average Average time


Unit Years represents the time to
number of calendar hours Average between
time maintain for maintenance and
collected for each item divided each
by 8760. between repair actions
failures occurrence
in hours

PREP Roll up Report by Category, Class and Item


Category Class Reliability Inherent Operational Unit Failures Failure Rate MTBF MTTR MTTM MDT MTBM Hrdt/Yr.
Availability Availability Years (Failures/Yr

Represents the The number


of failures

277
IEEE

category of the Average time


item; Example - recorded for equipment is
This column represents each item
Boiler the probability of the not available
during the
item failing in one year data
due to
collection maintenance
and repair.
HISTORICAL RELIABILITY DATA

Represents the Class period


of the item;

Copyright © 2012 IEEE. All rights reserved.


Example – Boiler, Inherent Availability
Hot Water. considers down time as a Operational Availability Failure Rate
The number
result of a failure. No considers down time as a based on a year.
of hours item
maintenance down time result of maintenance is down per
is considered. Ref: RAC and failure. Ref: RAC year
publications, Reliability Average time
publications, Reliability including
Tool Kit, page 12. to repair for
Tool Kit, page 12. repair and
each
maintenance.
occurrence in
hours.
*Time Truncated, Chi Squared, 60% Single Side Confidence Interval

Authorized licensed use limited to: Northeastern University. Downloaded on October 30,2014 at 22:31:30 UTC from IEEE Xplore. Restrictions apply.
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