The U.S. power grid is a sprawling, intricate web of thermal power plants, renewable energy installations, substations, and battery energy storage systems, all working in concert to deliver electricity to homes and businesses. Ensuring the reliability and resilience of this network is a monumental task, requiring collaboration among utilities, power generators, and engineering groups. Engineering Design & Testing Corp. (EDT), a forensic engineering group, has provided valuable insights into enhancing the reliability of the nation’s electricity delivery system. Their team of professional engineers highlighted several key areas for improvement.
Britt C. Hager, one of the consulting engineers at EDT, emphasized the importance of design and maintenance in ensuring the reliability of electrical systems. He pointed out that a system designed without considering operation and maintenance will inevitably fail. For instance, a rooftop commercial solar design that maximizes output but leaves no room for maintenance can shorten the system’s life. Regular maintenance is equally crucial; neglecting to clean a central inverter in a solar field can lead to reliability issues. Hager also noted the importance of testing alternate power sources and ensuring that tie breakers in Main-Tie-Main type distribution systems are regularly maintained and tested. “The automatic transfer function of the system is also easily missed in testing. It is not uncommon to find a transfer switch bypassed or set to manual unknowingly until a power outage when it does not transfer,” Hager said.
Chris S. Spies, another consulting engineer at EDT, highlighted the importance of condition monitoring systems (CMS) in wind turbines. These systems can provide early identification of anomalies, allowing operators to address minor issues before they become major problems. Spies also stressed the necessity of timely completion of preventive maintenance (PMs) and the analysis of drained lubricants to gain insights into the health of gearbox components. “When CMS systems generate alerts, a prompt response by the operators can be the difference between a minor and a major repair,” Spies said.
Scott S. Cramer, a consulting engineer at EDT, drew attention to the aging of step-up, MPT, and Substation Transformers across the U.S. He emphasized the need for a proactive plan to replace these aged transformers to avoid long-term outages and decreased operating options. Until replacement, Cramer suggested one-line monitoring, conventional oil testing, IR scanning, vibration testing, and partial discharge testing to ensure the transformers are not on the brink of catastrophic failure. “Until replacement, one-line monitoring of the critical transformers and conventional oil testing is essential in order to confirm that the transformers are not on the brink of catastrophic failure and are staying as cool and dry as possible,” Cramer said.
The conversation also touched on the role of automation in maintenance. Hager suggested that the solar industry is a prime candidate for automated maintenance, with drones already being used for infrared scanning and solar module cleaning. Online monitoring devices could also be used for automated monitoring and alerting to problems in electrical apparatus. Cramer proposed online gas-in-oil analysis as a form of automation that could predict the health of transformers.
Gary W. Mullis, the district engineering manager and consulting engineer at EDT, highlighted the necessity of redundancy in power plant and power grid operations. He noted that the U.S. power grid is 99.959% reliable, placing the U.S. at the bottom of industrialized nations for power reliability. Mullis suggested that improving the reliability of the electric utility system to the “five 9s” gold standard will require a multi-faceted approach involving legislation, capital for modernization, and front-line engineering improvements. “The effort required to meet the five 9s gold standard will involve legislation empowering regulators, executive leadership freeing capital for modernization, front-line engineers improving protection and coordination schemes, and tree-trimming companies keeping the right-of-way clear,” Mullis said.
This news underscores the urgent need for a comprehensive approach to enhancing the reliability of the U.S. power grid. It highlights the importance of design, maintenance, automation, and redundancy in ensuring a stable and resilient electricity delivery system. The insights from EDT’s team of professional engineers provide a roadmap for utilities, power generators, and engineering groups to work together towards this goal. The conversation also sparks debate on the role of legislation and regulation in improving power grid reliability, challenging the sector to think beyond technical solutions and consider the broader governance and policy landscape.
