The document discusses factors driving the market potential for substation maintenance, including aging infrastructure and reliability concerns. It then provides examples of the size of utility companies' substation networks and key components. The rest of the document outlines what makes substation painting unique, including safety considerations working in high voltage environments, surface preparation techniques like flow coating, and coating selections. It also provides examples of large power transformers and specifications for painting projects.

4. Factors Driving MarketFactors Driving Market
PotentialPotential
►Aging T&D system averages 40Aging T&D system averages 40
years.years.
►Competitive markets drivingCompetitive markets driving
maintenance –vs- newmaintenance –vs- new
expenditures.expenditures.
►Renewed emphasis onRenewed emphasis on
maintenance to ensuremaintenance to ensure systemsystem
reliability.reliability.

5. Market SizeMarket Size
►Ameren UEAmeren UE
►325 Substations325 Substations
►1000 Power Transformers1000 Power Transformers
►3000 Circuit Breakers3000 Circuit Breakers
►Alabama PowerAlabama Power
►4000 Power Transformers4000 Power Transformers
►10,000 Circuit Breakers10,000 Circuit Breakers

6. SUBSTATION APPARATUSSUBSTATION APPARATUS
►TransformersTransformers
►Circuit BreakersCircuit Breakers
►Voltage RegulatorsVoltage Regulators
►Structural SteelStructural Steel
►Control BuildingsControl Buildings

12. WHAT MAKES SUBSTATIONWHAT MAKES SUBSTATION
PAINTING UNIQUE?PAINTING UNIQUE?
► SURFACE PREPARATIONSURFACE PREPARATION
► FLOW COATINGFLOW COATING
►Maintain viscosityMaintain viscosity
►Apply uniform 2.5-3.0 mils dft along entireApply uniform 2.5-3.0 mils dft along entire
length of radiatorlength of radiator
► SAFETY IN A HIGH VOLTAGESAFETY IN A HIGH VOLTAGE
ENVIRONMENTENVIRONMENT

13. Surface PreparationSurface Preparation
All prices are for total cost to clean, blast, and paint on a per square foot basis.All prices are for total cost to clean, blast, and paint on a per square foot basis.
Before painting equipment, customer and contractor will make field inspections to determine condition ofBefore painting equipment, customer and contractor will make field inspections to determine condition of
equipment and square footage.equipment and square footage.
DEFINITIONS GENERAL PAINT SCOPEDEFINITIONS GENERAL PAINT SCOPE
Good: Less than 25% surface rust spot blast, spot prime, 2 coatsGood: Less than 25% surface rust spot blast, spot prime, 2 coats
Fair: 25% to 50% surface rust spot blast, spot prime, 2 coatsFair: 25% to 50% surface rust spot blast, spot prime, 2 coats
Poor: greater than 50% surface rust full blast, 3 coatsPoor: greater than 50% surface rust full blast, 3 coats
Equipment Type Condition of EquipmentEquipment Type Condition of Equipment
Good Fair PoorGood Fair Poor
Transformer Tanks – Medium- 15 to 40 MVA 4.15 5.65 7.55Transformer Tanks – Medium- 15 to 40 MVA 4.15 5.65 7.55
+36% +82%+36% +82%
Radiators ( flo-coating) .85 1.05 1.45Radiators ( flo-coating) .85 1.05 1.45
+24% +71%+24% +71%
230 KV Breakers 3.45 4.25 6.10230 KV Breakers 3.45 4.25 6.10
+23% +77%+23% +77%
7.2 KV Regulators 4.80 5.35 6.007.2 KV Regulators 4.80 5.35 6.00
+11% +25%+11% +25%
Approximate price for a 40 MVA TransformerApproximate price for a 40 MVA Transformer
Tank: 1008 square feet: $7717.00 $10,060.00 $13,639.00Tank: 1008 square feet: $7717.00 $10,060.00 $13,639.00
Radiators: 4158 square feet:Radiators: 4158 square feet:

19. WHAT MAKES SUBSTATIONWHAT MAKES SUBSTATION
PAINTING UNIQUE?PAINTING UNIQUE?
► SURFACE PREPSURFACE PREP
► FLOW COATINGFLOW COATING
►Maintain viscosityMaintain viscosity
►Apply uniform 2.5-3.0 mils dft along entireApply uniform 2.5-3.0 mils dft along entire
length of radiatorlength of radiator
► SAFETY IN A HIGH VOLTAGESAFETY IN A HIGH VOLTAGE
ENVIRONMENTENVIRONMENT
► COATING SELECTIONCOATING SELECTION

23. WHAT MAKES SUBSTATIONWHAT MAKES SUBSTATION
PAINTING UNIQUE?PAINTING UNIQUE?
►SURFACESURFACE PREPARATIONPREPARATION
► FLOW COATINGFLOW COATING
►Maintain viscosityMaintain viscosity
►Apply uniform 2.5-3.0 mils dft along entireApply uniform 2.5-3.0 mils dft along entire
length of radiatorlength of radiator
► SAFETY IN A HIGH VOLTAGESAFETY IN A HIGH VOLTAGE
ENVIRONMENTENVIRONMENT
► COATING SELECTIONCOATING SELECTION

24. Safe Working DistancesSafe Working Distances
VOLTAGE MINIMUM
DISTANCE
50 - 1,000 Avoid Contact
1,100 - 15,000 2’ 2”
15,100 - 36,000 2’ 7”
36,100 - 46,000 2’ 10”
46,100 - 72,500 3’ 6”
72,600 - 121,000 4’ 3”
138,000 - 145,000 4’ 11”
161,000 - 169,000 5’ 8”
230,000 - 242,000 7’ 6”
345,000 - 362,000 12’ 6”
500,000 - 550,000 18’ 1”
OSHA Standards (29 CFR 1910.269)

27. WHAT MAKES SUBSTATIONWHAT MAKES SUBSTATION
PAINTING UNIQUE?PAINTING UNIQUE?
► SURFACE PREPSURFACE PREP
► FLOW COATINGFLOW COATING
►Maintain viscosityMaintain viscosity
►Apply uniform 2.5-3.0 mils DFT along entireApply uniform 2.5-3.0 mils DFT along entire
length of radiatorlength of radiator
► SAFETY IN A HIGH VOLTAGESAFETY IN A HIGH VOLTAGE
ENVIRONMENTENVIRONMENT
► COATING SELECTIONCOATING SELECTION

28. SUBSTATION STRUCTURALSUBSTATION STRUCTURAL
STEEL & FENCESTEEL & FENCE
►One coat of Induron’sOne coat of Induron’s
Induraguard 9200 Tower PaintInduraguard 9200 Tower Paint
@ 8 to 12 mils DFT.@ 8 to 12 mils DFT.
►Single Component (no pot life).Single Component (no pot life).
►Easy application by brush orEasy application by brush or
mittmitt
►20 year service life.20 year service life.

29. SUBSTATION EQUIPMENTSUBSTATION EQUIPMENT
COATING SYSTEMCOATING SYSTEM
►Full prime BodyFull prime Body
Induron’s P-30 Primer RedInduron’s P-30 Primer Red
►Full Intermediate CoatFull Intermediate Coat
Induron’s P-30 Primer TanInduron’s P-30 Primer Tan
►Full Finish CoatFull Finish Coat
Induron’s Indurasil Silicone EnamelInduron’s Indurasil Silicone Enamel

32. BIGGEST MAINTENANCEBIGGEST MAINTENANCE
PROBLEM IS TRANSFORMERSPROBLEM IS TRANSFORMERS
►Most expensive ($1,000,000Most expensive ($1,000,000
plus)plus)
►Hardest to replace (6 monthHardest to replace (6 month
lead time)lead time)
►Most critical for system loadMost critical for system load
and reliability.and reliability.

33. Transformer Coating SystemTransformer Coating System
► Full prime BodyFull prime Body
Induron’s Induramastic 85 orInduron’s Induramastic 85 or
Induron’s P-30 Primer RedInduron’s P-30 Primer Red
► Full prime RadiatorsFull prime Radiators
Induron’s P-30 Primer RedInduron’s P-30 Primer Red
► Full Intermediate CoatFull Intermediate Coat
Induron’s P-30 Primer TanInduron’s P-30 Primer Tan
► Full Finish CoatFull Finish Coat
Induron’s Indurasil Sky GrayInduron’s Indurasil Sky Gray

34. General Electric 40 MVAGeneral Electric 40 MVA
TransformerTransformer
► Tank Surface Area = 1008 sq. ft.Tank Surface Area = 1008 sq. ft.
► Radiator Surface Area = 4158 sq. ft.Radiator Surface Area = 4158 sq. ft.

35. Westinghouse 120 MVA TransformerWestinghouse 120 MVA Transformer
► Tank surface area = 1862 sq. ft.Tank surface area = 1862 sq. ft.
► Radiator surface area = 18,630 sq. ft.Radiator surface area = 18,630 sq. ft.

36. ABB 400 MVA SINGLE PHASEABB 400 MVA SINGLE PHASE
TRANSFORMERSTRANSFORMERS
► Tank Surface Area = 4006 sq. ft.Tank Surface Area = 4006 sq. ft.
► Radiator Surface Area = 77,600 sq. ft.Radiator Surface Area = 77,600 sq. ft.
(each)(each)
► 95% of surface area in the radiators95% of surface area in the radiators

37. MAINTENANCMAINTENANC
EE
PLANNINGPLANNING
PROGRAMPROGRAM

38. MAINTENANCE PLANNINGMAINTENANCE PLANNING
PROGRAMPROGRAM
► Physical survey of all substations.Physical survey of all substations.
► Rank items in order of priority.Rank items in order of priority.
► Photograph of high priority items.Photograph of high priority items.
► Test for lead in coatings.Test for lead in coatings.
► Survey 7-10 subs per day.Survey 7-10 subs per day.
► Typical Cost: $1200 per day of survey timeTypical Cost: $1200 per day of survey time
plus travel expenses.plus travel expenses.

40. PAINTING SPECIFICATIONS
BY
UTILITY SERVICE & MAINTENANCE, INC.
for
SOUTHERN ILLINOIS POWER COOPERATIVE
ELIZABETHTOWN SUBSTATION
ITEM 1 PRIORITY
1
TRANSFORMER, GENERAL ELECTRIC
30/40/56 MVA
161,000-69,000 VOLTS
Serial Number: L252271
Company Number: TR#2
REMOVE FANS, CLEAN, PRIME, BODY AND FINISH COAT, REPLACE ON TRANSFORMER AND TOUCH UP AFTER
REMOUNTING.
HIGH PRESSURE WASH TANK, ACCESSORIES AND RADIATORS TO REMOVE GLOSS/CHALK AND TO NEUTRALIZE.
REMOVE RUST AND/OR LOOSE PAINT FROM ALL TANK AREAS (HAND SAND, POWER SAND, SCRAPE, SPOT BLAST OR
WATER BLAST).
SPOT PRIME ALL BARE METAL AREAS.
FULL BODY COAT TANK AND ACCESSORIES.
FULL BODY COAT RADIATOR TUBES (FLOW COAT).
FULL SPRAY FINISH COAT TANK AND ACCESSORIES.
FINISH COAT RADIATOR TUBES (FLOW COAT).
NOTE:
SIPCOOP TO PROVIDE WATER AT SITE.
SPOT PRIME BOLT HEADS. COVER ALUMINUM FAN BLADES.
SIPCOOP TO PROVIDE GROUNDING.
USM TO REMOVE AND REPLACE FANS.
MATERIALS
PRIMER -- INDURON INDURAMASTIC 85 EPOXY MASTIC
BODY COAT -- INDURON P-30 PRIMER, TAN
FINISH COAT –- INDURON INDURASIL SILICONE ALKYD, SKY GRAY, ANSI 70
PRICE --------------------------$18,484.53

41. MAINTENANCE PLANNINGMAINTENANCE PLANNING
PROGRAMPROGRAM
Benefits to CustomerBenefits to Customer
► Provides individual specifications forProvides individual specifications for
each itemeach item
► Prepares budgetPrepares budget
►By substationBy substation
►For entire systemFor entire system
► Prioritizes all painting needsPrioritizes all painting needs
► Report with photos for Top Priority itemsReport with photos for Top Priority items

42. Lead in Paint
 Generator/Owner responsible for lead paint chips
“cradle to grave”.
 Most states require contractor to be licensed by the
state in lead removal.
 Always contact your Environmental Department,
different states have different rules.
 Some states require “chain of custody” forms for test
samples.
 Two governmental agencies with lead requirements:
EPA – Environmental
OSHA – Worker Safety

43. EPA
 Generator – Any person, by site, whose act or process produces
hazardous waste identified or listed in 40 CFR Part 261 or whose
act first causes a hazardous waste to become subject to
regulation.
 Sampling of debris the responsibility of the generator. 40 CFR Part
262.11
 TCLP – Toxicity Characteristics Leaching Procedures, if waste
tested has a leachable lead concentration of greater than 5 ppm it
is considered hazardous under the RCRA Act.( Resource
Conservation and Recovery Act )
 One 55 gallon drum = approximately 200 kg, less than 100 kg per
month you are considered a conditionally exempt small quantity
generator.
 Storage times of 180 days or will be considered “operators of a
hazardous waste storage facility”.

44. Lead In Paint
 OSHA Definition: any coating containing
ANY amount of lead triggers the
standard, then the exposure levels
determine the level of
implementations/worker protection.

45. OSHA
 1993 - Lead Exposure in Construction Standard 29 CFR 1926.62
 Worker safety responsibility of the contractor.
 Must have a written compliance program.
 Employee training is triggered when employee exposures equal or
exceed the Action Level on any one day.
 Action Level: 30 micrograms per cubic meter, 8 hour time
weighted average.
 PEL – Permissible Exposure Limit: 50 micrograms per cubic meter
8 hour TWA.
 Competent Person –must be able to identify existing and
predictable lead hazards in the work area and have the authority
to take prompt measures to eliminate such problems