’ } Q ——NATIONAL PETROLEUM REFINERS ASSOCIATION —— ie g, IMPROVING ELECTRICAL DISTRIBUTION SYSTEM RELIABILITY by W. 6. Morrison E. I, du Pont de Nemours & Company, Inc. Wilmington, Delaware Presented at the REFINERY AND PETROCHEMICAL PLANT MAINTENANCE CONFERENCE February 8-10, 1978 Hyatt Regency Hotel Houston, TexasMC-78-2 Page 1 IMPROVING ELECTRICAL DISTRIBUTION SYSTEM RELIABILITY THE NEED TO IMPROVE RELIABILITY In recent years there has been an ever-increasing interest in improving the reliability of the electrical distribution systems on our industrial plants. This marks a departure from past practice when the name of the game was to run production equipment until it failed. Many people took the electrical system for granted - expecting the lights to come on each time the switch was turned on - or expecting the motor to start each time the button was pressed. When these things didn't happen, blame was placed on the vendor's equipment or the power company. Words like "voltage dips", "surges", "spikes", and "lightning" were used to account for any unexplained outages. In many cases words like these were used, unknowingly, to cover up the real cause of failure. Thus, there would be no real search for the cause, and many times the same type of failure would reoccur. As the plants grow older so do the electrical systems, and as these systems age, the problems increase. I have been on plants where 40% of the available electrical manpower, on days, was set aside for priority I breakdown repair, and where it was not unusual for each electrician to spend an average of one month on overtime emergency repair every four months. When situations like this exist I don't think anyone can question the need to improve the reliability of the electrical systems. These are several reasons for wanting to improve this situation. The following I consider very important. A, Safety - All aspects of safety have historically been Of prime importance at Du Pont. For plants not so indoctrinated, OSHA regulations and inspections have become prime motivators in this area. Reduced Maintenance Costs - Breakdown maintenance is the most expensive type - any improvement in reliability helps this situation. A reliable system lends itself to planned maintenance where the costs can be controlled. C. Reduced Pro Costs - Maintenance costs are a part of tI £ production. In addition, the high cost of energy is another incentive to have reliable, efficient systems.Il. CEL Mc-78-2 Page 2 These reasons, alone, should be enough to cause us to take action to improve the reliability of our electrical systems. The fact still remains that if any improvement is to take place certain steps must be taken. A reliable system doesn't happen by accident or because we desire it - several factors have to work together to achieve this goal. These factors can be grouped in five general categories: A, Attitude B. Design C. Installation D. Preventive Maintenance EB, Organization MANAGEMENT ATTITUDE I regard this as the most basic factor, because invariably I have found that, when a plant has a reliable system you will find a positive attitude concerning reliability at all levels of management. The opposite is also true. The fact that the electrical system represents a relatively small percentage of the dollar investment, or the plant space, or that the electrical system does not directly produce an end product that can be sold, are not valid reasons for neglect- ing it. The importance of the electrical system to your plant can be compared to the importance of the heart to our human bodies. Just as the heart pumps life-giving blood to all parts of our bodies, so the electrical system supplies energy to all parts of a plant. Failure of either one carries disastrous results. Management needs to recognize this importance, and act accordingly. Happily, as T said earlier, there are signs that this is taking place. Now I would like to discuss some of the practical steps that can be implemented to improve the reliability of your electrical systems, DESIGNING TO IMPROVE RELIABILITY The reliability of any electrical system begins with design. It is important that reliability be a basic consideration when you design for new facilities, or existing facilities are modified. Electrical design should be comprehensive enough to include the following aspects. A, Selection of Components B, Arrangement of Components C. Existing and Future FacilitiesB. MC-78-2 Page 3 D. Maintainability + Equipment Specifications F. Adequate Alarms G. Up-To-Date Drawings Selection of Components Quite often the only factor that is considered when selecting new components is cost. This is a dangerous concept. Instead, I feel that other factors such as reliability and maintainability are more important. This does not mean that the most expensive equipment is always purchased; cost should always be a consideration. It does mean that an evaluation, should be made of how each component fits into the overall production scheme. In other words, how critical is it to your operation? What are the consequences of failure? How often can it be shutdown for inspection? In the case of low voltage circuit breakers used as motor starters — how often will the motor be started or stopped? These are all questions that need to be considered. Another factor that affects component selection is the environment. Does the equipment contain material that is incompatible with your environment? For example, some switchgear insulation coverings will deteriorate in the presence of moisture and petroleum vapors. Component Arrangement When radial circuits are used to serve more than one production unit the equipment will be difficult to maintain, It is important that the loads connected to each feeder be associated with production facilities that can be shutdown at the same time. Where this guideline is followed, the electrical facilities can be maintained during normal production shutdowns with minimum effect on operations. Where this is not the case, there is a major stumbling block to maintenance until steps are taken to rectify the situation. In some cases loop systems can be used to advantage, but care should be taken to make certain that taps off the loop are designed so that they can be safely isolated for maintenance without affecting the system or en- dangering personnel.MC-78-2 Page 4 Existing and Future Facilities Each time a major change is made to a plant, the existing electrical system should be checked from an engineering standpoint to determine the effect of the change on the rest of the system. This is particularly true when it involves electrical protective devices such as relays, fuses, and circuit breakers. These devices must coordinate with each other if they are to function as designed. The following diagram will illustrate what T mean. agg [nee sal ee fl Bi Cs uu a FAS Gra LA zu Diagram A Por example, if a fault occurs at the motor, breaker B4 should operate before breakers B2 or Bl, or fuse Fl. For a fault at L2, fuse P3 should clear the fault with no effect on the rest of the system. Since the source of the fault current in transformer Tl and the system which supplies Tl, several devices "see" the fault current. They must be properly coordinated for the system to be reliable. As stated, this should be a consideration each time a major change is made to your Plant, but another point of consideration is that a series of small changes over the years can have the cummulative effect of destroying system coordination. Therefore, in order to be assured that a system remains coordinated, it should be reviewed every 7 to 10 years.MC-78-2 Page 5 Maintainability Designing for maintainability means that consideration should be given to the fact that equipment needs to be opened for inspection and testing. This means attention should be given to the size of equipment covers - the way the covers are mounted - to the fact that large covers need to be equipped with some type of handles. Enclosures should be large enough to accommodate cables without sharp bends. They should be large enough so that a minimum of taping is required. Particular attention should be given to conduit entrances. Circuit breakers and protective relays should be of the drawout type. When equipment has a dual feed it should be arranged in such a manner that the cables feeding one section can be maintained without having to shutdown the rest of the equipment. These are just a few of the considerations that fall under the heading of maintain- ability. There are many others, but suffice it to say this is a major consideration. Equipment Specifications Under this general heading are such items as making certain that all switchgear is supplied with adequate heaters and that all heater circuits are monitored with ammeters. Indicating light do not serve the purpose adequately. All transformers should be supplied with Pressure gauges as well as temperature gauges. In addition all transformers should be equipped with rupture discs. Splicing method specifications should be developed for high voltage terminations and splices. It is not enough to rely on the general type of instruc- tions supplied by the manufacturers or on the splicer's knowledge. Alarms Alarms should be provided to monitor critical equipment such as batteries and battery chargers. These devices are critical to protective relay systems and attention should be given to monitoring their condition. Switch gear vendors traditionally wire their circuits so that various indicating lights serve as a monitor on the condition of the trip circuits. The same philosophy should be followed in any design involving protective circuits.Iv. NC-78-2 Page 6 G. Drawings Up-to-date drawings of the electrical system are a must if the system is to be safely switched. These drawings should be posted at each substation so they are avail- able when needed. In addition all circuits should be properly identified in such a way that there is no confusion as to the equipment affected when switches are operated. INSTALLING TO IMPROVE RELIABILITY Electrical equipment, regardless of how good it is, will eventually fail if it is abused during installation. This means that if we want reliability in our electrical systems we must pay attention to how it is treated during instal- lation. Contractors who do this work must be selected with care and you, the customer, must take an active part in the job through continuing monitoring and inspection. The *turnkey" type of approach is a "ready-made" disaster in terms of reliability. The following is a list of things important if reliability is to be achieved: A, Equipment Storage B, Adequate Specifications C. Qualified Splicers D. Testing E. Inspection F. Checkout A, Storage All equipment that is scheduled for installation indoors should be stored in dry, heated indoor locations. All heaters should be connected to temporary power sources as soon as the equipment arrives, regardless of where it is stored. Equipment with moving parts such as circuit breakers should be stored in dry, heated buildings. Rust and moisture are the enemies of reliability. B. Adequate Specifications Supply the contractor with rigid specifications that cover such things as storage of equipment, installation of cables, termination of high voltage cables, and testing and checkout requirements. Then make certain they are followed.MC-78-2 Page 7 Qualified Splicers Only let people who are “certified" in high voltage splicing perform this work. There are several schools around the country that provide this type of training. Du Pont's effort in this area alone is one of the prime reasons we enjoy one of the most reliable cable systems in the country. Testing The following is a list of tests that should be per- formed during construction. ‘Tables I, II and III which are attached to this paper tabulate some of the test values for DC testing. 1. DC high potential test on all high voltage cables, switchgear, circuit breakers, and large motors. + X-ray examination of each high voltage splice or termination. 3. Calibration of all protective relays and direct acting low voltage circuit breakers. 4. Test all oil-filled transformers, circuit breakers, and other auxiliary power equipment with a power factor or Doble test. 5. Test all insulating oil for color, dielectric strength, acidity, and interfacial tension. 6. In large transformers the insulating oil should be tested for dissolved combustible gas content. 7. All intermediate size motors should have a di- electric absorption test performed using either a 500, 1000 or 2500 volt megger. It goes without saying that all of these test results should be recorded and filed for future use. Inspection All electrical connections should be inspected for tightness. This includes current transformer and potential transformer connections supplied by the vendor. All enclosures should be inspected to makeNC-78-2 Page 8 certain that moisture cannot enter. A note of caution is in order here - b conduits that go from heated areas to unheated compartments or vice versa. Moisture can enter through condensation, Make certain clearances are adequate and that varmints can not enter outdoor switchgear. Checkout There are several areas that require thorough functional testing and checkout if you are to achieve system reliability. 1. Prestart-up checks on large motors for air gap clearances, bearings, and bearing insulation. 2, Start-up checks on large motors for vibration, lubrication, and heating. Complete functional checkout of all motor control circuits. 4. Make certain that all protective relays are func- tioning correctly to operate the various circuit breakers concerned. Make certain all protective relays actually receive current and potential as required. These tests should be made using a phase angle meter and am- meters or voltmeters. In some cases it is advisable that these tests be performed prior to start-up using primary injection methods. This is partic- ularly true where the "correct condition" is no secondary current. 6. Make certain that all protective relays are con- nected correctly when current and potential trans- former polarity is a factor. Again it is advisable to use a phase angle meter for this check. MAINTAINING TO IMPROVE RELIABILITY After a system is designed and installed with reliability in mind, a good preventive maintenance program is required to maintain this reliability, These are 6 aspects to any good PM program. They are as follows:Mc-78-2 Page 9 A. Routine Patrols B. Planning and Scheduling C. Good Procedures D. Adequate Testing E. Good Visual Inspection F. Good Housekeeping G. Good Record system Routine Patrols The first and most basic part of any preventive mainte- nance program is training people to use their God-given senses - sight, smell, touch, hearing. When we use these "tools" in a regular manner any. maintenance program is off to a good start. For example we should: 1. Inspect all transformers for leaks, levels, tempera- ture, and pressure. Sudden increases in temperature or failure of the pressure to vary with temperature are signs of impending trouble such as moisture entering the tank, All readings should be recorded (weekly). 2, Feel transformer cooling fins to detect unusual temperature variations (weekly). . Feel motor bearings for temperature or vibration levels (daily). 4, Listen for unusual noises in motors, transformers, and switchgear (daily). 5. Observe all switchgear indicating lights to make certain all trip circuits are functioning (daily). 6. Observe all protective relay indicating targets. Record and reset (daily). 7. Inspect batteries and battery chargers for signs of leaks or malfunctioning (weekly). 8. Observe all switchgear heater ammeters to make certain all heaters are functioning. (Red-line all ammeters at the normal circuit value to make this job easier) (daily).Be E. NC-78-2 Page 10 9. Feel all molded case circuit breakers and low voltage power switches for overheating (daily). 10. Examine indoor switchgear enclosures for signs of building leaks (weekly). Planning and Scheduling All electrical equipment needs to be shutdown for more detailed inspection and testing. If this is to be effective it should be done on a regular basis. Table IV has some suggested frequencies for some types of equipment. If the maintenance program is to be econom- ical this work needs to be planned and scheduled in advance - sometimes as much as 5 years. It should be planned so that it coordinates with planned production outages. In order to do a thorough job, detailed plans and procedures need to be developed prior to the shut~ down. Good Procedures As I mentioned in the previous section, procedures are a necessity for effective maintenance. Many jobs are repetitive in nature which presents you the opportunity for developing a file of preventive maintenance proce~ dures. These should incorporate all vendor information and be kept current with each plant experience. In addition it is important to develop switching procedures for removing equipment from service. Adequate Testing All testing that was mentioned in the section under installation should be an integral part of the mainte. hance program. The only exception is x-raying which is generally a one-shot test. Personnel performing the tests should be properly trained. Good Visual Inspection As a part of the test program, develop the habit of inspecting for signs of moisture, tracking, and heating. Remove covers to all switchgear and cable compartments involved in any testing and look for these signs. Clean all insulation surfaces. Tighten all power connections. Lubricate all moving parts in circuit breakers.VI. vir. MC-78-2 Page 11 F, Good Housekeeping Develop the habit of keeping all switchgear compart- ments, substations, battery rooms, and electrical control rooms clean and orderly. These rooms should not be used for material storage, offices or lunch rooms. Good housekeeping goes a long way in developing a positive attitude among mechanics toward good mainte- nance. G. Good Record System Keep records of all test results. This is the main tool for knowing the condition of your electrical equipment. In addition, make it a habit to keep all electrical drawings up-to-date. Develop a system that assures that this is accomplished. ORGANIZING TO IMPROVE RELIABILITY To accomplish the program that I've discussed requires an organization that is structured with maintenance in mind. The first requirement of this organization is to clearly define areas of responsibility. This certainty includes supervisory personnel, but it also includes your mechanics, particularly in the area of routine patrols. Another requirement is the assignment of an engineer or engineer- type to the program. Foremen, with their personnel respon- sibilities, do not have the time to do all the planning and scheduling required. My experience has shown that such a person. should be in the maintenance organization and not in Design. He should work very closely, on a consulting basis, with Design engineers when changes are made to the system. He should work with contractors doing electrical work in the plant. During periods of heavy project work it will probably be necessary to augment his efforts with other People who can work on a daily basis with the contractors. CONCLUSION All of this sounds expensive and is apt to discourage many plants from making any changes from their current program. Before you make a final decision I would like to make one final comparison. The initial expense in any maintenance Program can be compared to an investment in something like a Mutual Fund or a Savings Account. You will receive dividends - the amount depends on how much you invest and how wisely you invest. That is one of the payoffs of a good organization - it makes us wiser in making our investments. The dividend is increased reliability - lower ultimate maintenance costs - increased production - better yields and higher profits.MC-78-2 Table 1 (896T 380d) ATUQ SeTqeo Mens ose ore | ogz |} ost | ove or69] 6 ose |} 99T Sot} st" 00z o0z O€T | Olt or 97 002 { o9Tt o9T SOT Om 6 Set | Site STE 3 Ost oet oet SB ott || o£ 6 oge" or €@ sei ort ozt | et $8 OTT |} o2 16 oge* |[-T-r pect Sa°4T sq ott ott | ott Sh oot £9 ze | oe" |i1r geet “7° 4T ei 2, ago] ott |} 29 06 | Stz" f 06 06 09 og ot z9 | Set |[tr goot ‘e°9t| % a 56 OL OL Ss OL Te a] stt" we Ly Se zz of 060° Ss ss ov SS Se 1€ 060° aT Ss St ev c<4 slo" SE Se Sz SE Se mE Ge € pT L'e | GNIVW| “TLSNT (4) “NT LNT “TEsNT| | ENTvML -tisnr|fanrew] “Tasnr] (4) “NT at Parada “SNXHL | *AWES TVWUON|"AUaS “TWHYON "SNMHL|| (GSLON SV Ldaoxa “SNI I_ssvi9 | «*SNT} “TT Zoot Ova ONY Wadd S8ddl 1aVO TIV “TAbna* GNA THAR TOd Wu. (ANSTAdOUd ANG TAHLA “AM NI ONILVE SEOVEION ISHL Fava CaCTaLAS SHDVLIOA LSHL 1GVD WAMOdMC-78-2 TABLE 2 UNSHIELDED CABLE TEST VOLTAGES INS. |_TEST VOLTAGE KV DC INSULATION | VOLTAGE | CONDUCTOR |THKNS. INIT. | TYPE SIZE INC. |FACTORY|INST.| MAINT. | Rubber RHW | 600 |#1 - 4/0 |.078 12 9.6} 7.2 RH 15412 10 RW 525-1000 |.109 | 18 {14.4°] 11 O-B Butyl 3kv 17 - 4/0 |.125 3465 427.6 | 22 225-1000 |.141 39 432 a 5 kv |8 = 4/0 |.156 42 134 25 225-1000 |.172 46.5 136 26 EP 5 kv [8 - 4/0 lo 42 34 25 225-500 +120 42 34 25 525-1000 |.130 | 42 |34 | 25 THW, TW, T | 600 4/0 }.078 12.5 |10 765 ne 225-500 | .094 15° {12 10 THWN 600 j1- 4/0 |.050 12.5 |10 25 225-500 | .060 15° {12 10 225-500 | .060 EE} = jC 13 Polyethylene 600 |1 - 4/0 |.050 22 12 9 | 5 kv |8 - 4/0 |.110 45 136 27 225-500 |.120 | 45 136 27 525-1000 [+130 | 45 136 27MC-78-2 Table 3 ELECTRICAL EQUIPMENT TEST VOLTAGES FIVE-MINUTE TEST VOLTAGES (KV) FOR D-C_HIGH-POTENTIAL TESTING RATED TEST VOLTAGE EQUIPMENT VOLTAGE 7 L (CLASS) | FACTORY | INSTALLED | NANCE. Switchgear Assemblies, 0.6 ee 2.3 2.3 Including Bus and 24 | 2h 15 15 Internal Transformers 2 4 2 20 20 (1 Min, or 120% for 1 Sec} - Interrupter Sws. Only alpen 27 27 All Other Gear 2 51 38 38 §_| 5 38 38 a >? 33 33 5 85 64 6h 5 {113 85 85 148 iii All Transformers 0.1.-1 Min. fai) 10 10 (or 90% of these values 2.5 | 15 15 15 for 5 minutes) 5.0_| 19 1 19 8.7 26 26 26 1 rm 3h 3a 7 50 30 50 3k 5 70 70 70 46 a 4 9 Transformers, Dry-1 Min. 3 $ (or 90% of these values e t 2 g for 5 minutes) 6.7 “is 9 25 nd 32 Motors & Generators 6 3.6 2.4 2h 9.3 6.2 ye al 10 Tee 2k 16 1.5 39 26 13.8 i 30 Trans. & Distrib. 2oh 15 15 Systems - Open 42 20. 20 7.2 7 23.8 38 38 oh 5 ti 6h, 34.5 85 85 16 aii shi Current-Limiting Reactors | 2.5 | 19 19 19 5.0 | 26 26 | 26 a. 36 6 36 15 50 50 50 24.5 | 70 70 70 be Q 95NC-78-2 TABLE 4-A ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS OUTSIDE ELECTRIC _UNI Inspection Interval Poirol lines ond inspect following parts: (Use binoculars where necessary) to 6 months 1. Poles for: (See Procedure PM 8, Details, Wood Pola Maintenance) - Leoning 'b._ Washout around base Splitting d. Woodpecker holes . Lightning damage (also toon ofter outage during lightning storm) 2. Crossarms for 3. Guys and Anchors for: a. Twisting 2, Broken strands b. Splitting b. Corrosion & Decoy «looseness ond slippage 4d. Loose or missing braces d, Adequate clearance from conductors ®. Loose pins Loose clamps f. Tracking or burning {Anchor eye above ground 4. Insulators and Bushings for 5. Lightning arresters for: 1. Cracks (require careful inspection) 1. Breaks, cracks, and chips b. Chips or bad brooks b. Ground connection & Unserewed 4. Leaning ot bad angle @. Cleanliness Note: If atmosphere is contaminated with conducting material, i might be necessary to clean and coat porcelain surfaces with silicone annually or biannually Conductors for: 7. Hordware for: ©. Broken strands ©. Loosenest Bb, Blisters or burned spots b. Corrosion «Excessive or uneven sagging d. Loose connections 8. Ground wires for: Horizontal and vertical clearances 4. Troes that touch or can fall across lines a. Breaks b,_Attachment 10 pole ‘Make climbing Inspection of poles for detailed observation of above items, Tight Bio 5 yoors hardware and make repairs found necessary. Aerial bucket truck is especiolly adopted for pole-op inspections ond rapairs. ‘Make ground line and above-ground inspeciion® of wood poles, Sound, teal bore, Bio 10 years in Inspect to 20 inches below ground ond treat with preservative, Above-ground wood southern states preservative treatment may be necessary. Install pole topper, see Standard E28D. 10 to 12 years in northern states. Inspec for 1. External decoy below ground b. Above ground and roof decay «Hollow heart rot Shell rot @. Crossarm decay and charring Termites DC high-potential proof test lines tad tical Equipment Tesling and Stor!-Up Manual, Accession No. 4905, Measure ground resislance every 3 10 5 years. follures that ore net apparent by visual Inspection. RefMC-78-2 Table 4-B ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS 250-600 “VOLT SAFETY SWITCHES AND DISTRIBUTION PANELS Type Inspections ond Tests Intervel indoor i closures with hand to datect overheating. If 20, determine load, If overloaded, reduce lood, repair switch or install larger switch or wire (or both) if required, I switch Note: If overheoted switch is not overloaded (80 percent of nameplate ompere rating) de-energize switch and inspect fuses, fuse clips, terminals, etc for tightness, If spring clips have lost their temper, replace same. Tighten hinge bols, clean ll joints ‘and clips. Apply thin coat of good general-purpose lubricen! to metal parts only (not on insulation). Operate switch several times before replacing in service. Tes! wth Biddle Ducter, or equivalent, to delarmine contact resistance. [3 months or more offen (Shuidown required only for corrective action) Clean, inspect and test with 1000-vall megger, or equivalent, Inspect fuses for proper type. Rafer to Slandord DE3M. Use of standard NEC fuses is no! permitted. IS to 6 years, (Shuidown required.) ‘Ovideor Same os Indoor type abave and inspect for evidence of conden: sation ond water leaks. MOLDED CASE CIRCUIT BREAKERS Inspections and Tes Feel enclosures with hand for overheating Note: If operating above normal temperature, check lood. overloaded, reduce load or install larger breaker and wire. If not overlooded, de-energize and repair or replace breaker Moke certain terminals are tight, (Shutdown required.) T month recommend! | wook desirable. (Con be done ropidly by personnel while In Jare on other tosis.) Clean and inspec! breaker, Tighten Ferminals. Tes! Insulation of breaker and wiring with maggar, or equivalent. Tes! overload trip elements with Mulli-Amp Jr fester, or equal Test with Biddle Duct resistance, oF equivalent, to determine contact Tio 6 years. (Swuidewn required) Nok A high incidence ‘occurred during the pe 1 of molded cose circuit breaker failure from overheating of terminals and contacts has as! few years. Feeling upper portion of breaker enclosure with hand will detect overheating condition. Maximum interval of one manth recommended; weekly interval desirable, This can be done by per sonnel when in area for other tasks. UGHTING PANELS Inspections end Teste Tntorvel covers of switches and Visual exiernal inspection ond fe breckers for overheating ‘Check panel directory for condition and completeness, [é monthe Complete cleaning end inspaction of interior, Tighten terminals Test insulation with 500-valt megger, or equal. Tes! branch breakers with MultiAmp Jr taster, or equivalent. Check panel directory for accuracy; reploce, if necessary. Rearrange disorderly wiring 6 years. (Shuldows required.) GROUNDING SYSTEMS Type Inspections ond Teste Interval Eleciic system, |Inapectfor loose connediions and breaks. Test with ground megger [6 10 12 months. (Shut lightning and (refer to Standard £13.1P). Jdown roquired in static hazardous areas.) Fault return Inspect for loose connections ond breaks. 12 months Test with Ducter, or equivalent. Refer to Standard DE4P, 3 to 6 yoors. (Shuidewn required for Ductar tost ing in hazardous areas.)MC-78-2 TABLE 4-C ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS AIR-BREAK MOTOR STARTERS AND CONTROL CENTERS (600 V AND BELOW) Inspections ond Tests Taterval Visual inspection of individual starter inferiors and machanisms [1 yeor. More offen if {for cleanliness, terminal tightness, contac! burning, overheating | conditions require uses, evidence of condensation, water laoks, rodents ond over- | (Shutdown of individual heating of main switch, ferminals, ele(se0 Notes 1 and 2). Test | load required.) oad and control wiring with 1000-volt meggor. Note: Fi ling upp with hand every throe months, or more oft method far detecting overheating of main switch or breaker. portion of an operating storter enclosure Is © good Complete cleaning ‘and inspeciion of main buses, swilch, contactor, |3 to 6 years (Shuidown terminals and wiring, Test insulation with 1000-volt megger, or | of MCC or starter rack ‘equal. Tes! overload relays with Mult-Amp Jr overload relay required) tester, or equivaler Note 1. Space heators are req They should be operated continvously. Note 2. Check connection bos for tighinoss as soon os possibl Note 3. Visuolly inspec! shielded cable AIRBREAK MOTOR STARTERS (2.4 AND 5 KV) 1d in motor control centers located outdoors and in unheated indoor oreas, (not over six months) after totel lood is applied. rminations for cleanliness ond tracking at leas! once o year. Tspections and Tests Interval ‘Some a: 600-volt sioriers cbove, except lest insulation wih Tio 3 years (Shuidews 2500-voll meager, of equal. If slorler is equipped with induction | required.) type relays, es! wilh MulliAmp reloy test sel. See Notes 1, 2, ‘and 3 above, AC MOTORS AND TURBO.GENERATORS {All2.4, 5 and 15 KV Class; Large 600 Volt Clas Type Tnspoclions and Tests Interval rip Timiled inspection for cleanliness and general condition. Gio 12 months depend proof, splashy Check space heater oparation on molars located ouldoors. ing on ombient condi weather protected. | Note: Inspect slip rings and brushos, f so equipped, every ions. (Shutdown, three months, ar less. (Shutdown may be required.) required) Totally enclosed Visual inspection of {freedom of cooling alr movement or to prevent dirt buildup and assure [3 10 6 monthe rail Tngpeclion of windings, oll rings, bearings, rotor, and [2 lo 6 years depending including slip rings and brushes, Iso equipped. It may | upon ambient and sary to drill hree occoss holes in outer frame of TEFC | operating conditions motors to check alr gaps, thers holes should be threaded and | (Shutdown required} plugged. Clean windings, if necessary, uting oir blasl, Freon®, ete [Moke dielaciric absorption or sep volioge tesi with 2500-vall 2 io 6 yoors or more megger or OC high-potential tester, Perform Schleif teston 5 | often if frequent shut jond 15 ky class machines. downs permit. Refer to ESD Elect Maintenance Group for dotailinforma: tion on these tests, Corsory chock of stator and bearing lomporalures, oil levels, (Monthly, ot feos), loperotion of ol rings, vibration, and unusual noises. weakly preferred. Place hand on motor housing and bearing housing for check fof temparature ond vibration. Note for molors equipped with air vent fillers: Inspect for cleanliness of fills avery thrae months, or more often W conditions dictate. Clean ond treo! permanentlype fillers; replace renewable-type fillers as required by dust buildup.NC-78- Table 2 4-0 ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS LOW.VOLTAGE SWITCHGEAR (600 V_AND BELOW) Type Ingpections and Tests Taterval Indoor ‘Visual inspection of paris made accessible by opening front and [3 10 6 months rear doors; fe, fronts of breakers, raor of meters and relays, ferminal blocks, wiring, buses, insulators. Inspec! for cleanliness ‘ond evidence of water ond rodents. Visval inspection of doshpots ‘on overcurrent trip devices for il leakage. Chack for proper ‘operation of space heaters in unheated reas. See Note 3, Check CT wiring by means of ammeter switch where available Inspect bus joints and cable terminals for evidence of hecting. See Notes | and 4 Complete cleoning and delciled inspection of al switchgear Aiinslollation ond Structures, including circu breakers, wiring, buses, disconnect [3 106 yeors depending devices ond insulators, Test with 2500-volt megger, or ‘upon ombiant conditions equivalent (Shutdown required.) Check bus ond cable joints for tightness. Delalled inspection and cleaning of power oir circuit Breaker Kr installation, T yeor units, and callbrotion and testing of evercurrent trip devices clter installation and with MultiAmp Company fest equipment (see Note 5), Test 3 years thereafter, ond ‘with 2500-volt megger, or equivalent. Tes! with Biddle Ducte cotter brecker opens or equivalent fo determine contact resistance. Under fault conditions. (Shutdown of affected ‘Annual functional trip testing of power alr circult breakers is feeder required) highly desirable to determine if binding parts or defective wiring would prevent a breaker from tripping open to clear © fault or overload condition. [Outdoor Visual inspection of parts made accessible by opening external | 3 months doors; sama as for indoor type above and evidence of conden- sation, overheating, water leaks, roden', und reptiles. Check for unsealed underground condults which can be a source of, vapor. Check oir filters for cleanliness (clean or renew). Check spoce heaters which should operate continuously Inspection after prolonged rain preferred to locate leaks. Inspect ‘overheod coble entrances for water leaks. Inspect cable terminals for evidence of water running through conductors from connection ton overhead lines, which is often the point of entry. Complete cleaning ond detalled inspection of all ewilchgeor Byears. More offen structures, including circuit breakers, same as for Indoor type if conditions require above. (Shutdown cequired.) Detailed Inspecion, cleaning and feeling of Grcull breaker unils, | Al inatollalion, T yeor ‘same os for indoor gear above. tlter installation, ond 3 years thereafter, ond ‘after breaker opens ‘under foult conditions. (Shutdown of affected feeder required.) Note 1. Heating of cable terminals often is encountered in low-voltage switchgear. This Is caused by loosening of connections due to cold flow and distortion of the copper, or aluminum, and load cycling. Experience indi Cotes that tightening bolis ond connectors after total load has been applied for several months! (not over 6 months) operation prevents heating trouble, Therefore, low-voltage switchgear should be shut down after ‘obout six months’ operation so all bus joint bolls and cable terminals can be tightened. Note 2. A high incidence of molded cose circull breaker failure from overhealing of terminals ond contocts hos ‘occurred during the post few years, Fasling upper portion of breaker enclosure with hond will detect over- eating condiion. Meximum interval of one month recommended; weekly interval desirable, This can be done by personnel when in areo for other tosks. Note 3. Space Heaters are required in switchgear located outdoors and in unheated indoor locations. They should be operated continuously. Note 4. Porteble infra-red hermometar may be used to check connection temperature withou! de-energizing. Note 5. Overcurrent irp devices should be tatted and calibrated by competant and adequately trained personnel who perform this work at frequent intervals so as to remein fully acquainted with the detailsate an ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS 3=15_KV_INSULATED CABLES (ALSO 600-VOLT_MAIN FEEDERS) Type Inspections ond Tosts Interval | Indoor, outdoor, | Visual Inspeclion of cables al condull ends, splices, supporis ond | 1 yoor | underground, poles for deformation due lo pressure. Visual inspection of PILC serial, in conduit, | cable ot same points for oll or compound leaks. Visual inspection Intray, In duct, and_ | of terminations for dust, tracking, deformation, water streaks, otc direct burial and being loo close to grounded metal ports, Complete inspection some os above, cleaning offerminalions | Ar installolion, ond DC high:potential testing ‘annually for two years after installation, then every 6 years a fll maintenance tes! voltages. Or, every 2 ‘years of reduced main tenance tes! voltoges. (Shutdown required.) 5-15 KV METAL ENCLOSED SWITCHES (INCLUDES 2.3 KV) Type Inspections and Teste Tatorval Indoor Visual inspection of Interior through Inspection windows (I 310.6 months provided) for cleanliness, evidence of condensation, water leoks, rodents, reptiles etc, same as metalclad switchgear. See Notes 1, 2, and 3. Complete cleaning, detailed inspeciion ond DC highpotential [A nslalalion, | teal; same os for metalclad switehgacr, annually for two years ‘after installation, then ‘every 3106 yo Outdoor Visual, some as for indoor type above ond for evidence of F months condensation, water leaks and rodents. Check air filters for cleanliness (clean or renew). | epee | | See Notes 1, 2, and 3. | Complete cleaning, detolled inspeclion and test, some oF for ‘A installation, | metal-cod switchgear. ‘onnually for two years after installation, then every 3 years. Check air filters for cleanliness (clean or renew). More often if conditions require. (Shutdown | required.) | Note 1. Space heaters are requirad in matal enclosed switches located outdoors and in unheated indoor areas. They should bo operated continuously. Note 2. Check connection bol for tightness as soon as possible (not over six manths) after normal load is applied. Note 3. Visually inspect cable terminations for cleanliness and tracking at least once @ year.MC-78-2 Table 4-F ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS POWER TRANSFORMERS Type Inepections and Tests Inferval (Ol, gas, and) Visual external inspection of gages, bushings, and for leaks. T month askoral illed Approximately zero pressure over wide range of loads is Remove transformer evidence of a leak ina sealed oll or askarel filled transformer. | throat covers annually Steady gage pressure over wide range of loads indicates valve | to inspect bushings between gage and tank is closed or gage Is nonoperative, located therein. Low gos pressure al normal operating load or loss of gos pressure at no load is evidence of c leak in a gos filled transformer. Oil level in nonsealed oF conservator ype transformers must be ‘within limits shown on gages or sight lasses. Oil level in oll filled bushings must be within limits shown on gages or sight glasees. Oil filled Test oil for dielectric, acidity, and inferfacial tension. 1 year (refer to Procedure PE 8) ‘Askarel filled Test askorel liquid for dielectric and acidity, color, water content, | year refractive index, and general condition, Oil, gas, ond ‘DC high:potentiol test transformers with solid bushings. Consider | 6 years (Shutdown oskarel illed power fatior testing oll ond askoral filled transformers thal are Svar 25 yeors old. Perform comprehensive tests on oil and ttkarel in transformers over 25 years old. Tests include dielectric frengih, ocidity, Interfacial tension, color, molsture content, power factor ot 25 Cand 100 C, corrosive sulphur, and inclusions of cellulose material. Power factor test oll filled bushings. required) (273 yeors) shutdown) (Oil test does not require Note: Make internal inspection, cleaning and corredlive measures os indicated necessary by obove tests Dry open Viswal exiornal inspection of gages ond ventilating louvers T month Check air filters for eleanliness {clecn or renew). Visval infernal inspection ond cleaning of care, cls, insulators, | 1 10 3 yeors, depending ventilating louvers, ond filers. ‘upon ambient conditions (Shutdown required.) 3-15 KV STATION AND ROTATING MACHINE TYPE UGHTNING ARRESTERS Type Inspections and Tosts Talorval Indoor Clean, inspadl, and les! of some fime as associated ewitchgear, | 3 fo 6 years cables, and transformers. (Shutdown required.) Dirt collects on interior surfaces of unseoledtype arresters ond lowers resistonce values. When this occurs, disassembly ond cleaning is necessary. Test resistance with 2500-vall megger or DC high-potential test 5 Power factor fest unsealed type arresters rated 15 kv and above. ‘Ovidoor ‘Same os indoor arresiers above, Outside and diri deposits usvally | 3 years or more often fre more severe thon for indoor orresters. depending upon ‘ambient conditions cand mount of deposit ‘on porceloin surfaces, (Shutdown required.)ELECTRICAL EQUIPMENT, MAINTENANCE INSPECTION AND TESTING INTERVALS 515 KV_METALCLAD SWITCHGEAR (INCLUDES 2.3 KV) Ys? ac Type Inspections and Tests Interval [indoor Visval inspection of parls made accessible by opening external [3 to 6 months doors; i, fronts of breakers, rear of meters ond relays, terminal blocks, wiring, space haatars (see Note 1) etc. Inspect for cleanliness, tracking, evidence of water, rodents, and reptiles, See Note 3, Complete cleaning and deioiled Inspection of all pars, including | AT insiolfation, circult breakers, breaker disconnect studs, Insulators, cable tannvally for two Terminotions, connections, loose bolts, (see Note 2) etc, Test with | yeors after instal Biddle Ducter, or equivalent, to determine brookr contact re lation, then 3 t0 6 sistance, Tes! buses, breakers, PI's, CT's and cables with high years, depending upon potential OC. Tes! transformers and protective reloys, ‘ambient conditions. (Shutdown required.) ‘Outdoor Viswal inspection of parts made available by opening exiernal [3 months doors; same as for indoor gear above and for evidence of con- denzation, water leaks, rodents, ond reptiles. Check ar filters for cleanliness (clean or renew). See Note 1 Complete cleaning ond detailed inspection of oll paris; same as | A Installation, for indoor gear above, Tost buses, breokers, PT's, CI's, cables, ote, with high potential DC. Test transformers ond protective relays. tennvelly for two years after installation, then evory 3 years ‘More often if conditions require, (Shutdown required.) Note 1. Space heater PROTECTIVE RELAYS 1s ore required in switchgear located ovidoors and In unheated indoor areas. They should be operated continuously Note 2. Check connection bolts for tightness ossoon os possible (not over six months) after normal load is opplied. Note 3. Visually inspect cable terminotions for cleanliness and tracking at least once a year. differential, ote Type Tnapections ond Tests Tnterval Overcurrent Viewal inepeciion for proper operation and calibration. Cal 3 years. More offen potential, brote ond test with MultiAmp Company relay test equipment whore dust, moisture, Make functional proof test of relay and wiring with phantom load to trip associated cireull breaker on onnual basis, if possible, This is of special importance on 600-volt power alr cireuit breokers. corrosion, vibration, fr wide variations In temperature ore present. Tripping of breoker will shut down loads con: nected therato, unless alternate supply breaker is provided, See Note 4 Note 4. Relays thould be tested end calibrated only by competant and adequately trained personnel who perform this type of work a frequent intervals so os to remain fully acquainted with the detals.