Substation Maintenance Procedures R1

Transcript

SUBSTATION MAINTENANCE PROCEDURES 33KV VACUUM CIRCUIT BREAKERS 125VDC LEAD ACID BATTERY POWER TRANSFORMERS ON - LOAD TAP CHANGERS STRUCTURES & BUSWORK  POTENTIAL TRANSFORMERS MV DISCONNECTORS MV SWITCHGEARS GROUNDING FEBRUARY 2009 PREPARED BY: ANSEL GARVEY SUBSTATION MAINTENANCE PROCEDURES TABLE OF CONTENTS 1. INTRODUC INTR ODUCTION TION......... .................. ................. ................. .................. .................. .................. .................. .................. ................. ................. .................. ..............1 .....1 1.1 1.2 1.3 GENERAL ................. .......................... .................. .................. .................. .................. .................. ................. ................. .................. .................. .................. .................. .........1 1 DEFINITIONS ................. .......................... .................. .................. .................. .................. ................. ................. .................. .................. .................. .................. ............1 ...1 SAFETY........................ SAFETY................................. .................. .................. .................. .................. ................. ................. .................. .................. .................. .................. ...............2 ......2 2. SUBSTATION SUBSTA TION IN-SE IN-SERVIC RVICE E INSPEC INSPECTION............. TION...................... .................. .................. .................. .................. .................. .........3 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 INTRODUCTION INTRODUCTION ................. .......................... ................. ................. .................. .................. .................. .................. .................. ................. ................. .................3 ........3 INFORMATION, INFORMATION, TOOLS AND MATERIALS................... MATERIALS............................ .................. .................. .................. .................. ............3 ...3 SAFETY REQUIREMENTS REQUIREMENTS ................. .......................... .................. .................. .................. .................. .................. ................. ................. .................3 ........3 DISCONNECT DISCONNECT SWITCH INSPECTION INSPECTION .................. .......................... ................. .................. .................. .................. .................. ...............4 ......4 STATION BUS INSPECTION.............. INSPECTION....................... .................. .................. .................. .................. .................. ................. ................. .................4 ........4 33KV VACUUM BREAKER INSPECTION............. INSPECTION...................... .................. .................. .................. ................. ................. ..............4 .....4 POWER TRANSFORMER TRANSFORMER INSPECTION INSPECTION .................. .......................... ................. .................. .................. .................. .................. ............4 ...4 ON-LOAD TAP CHANGER INSPECTION................ INSPECTION........................ ................. .................. .................. .................. .................. ............5 ...5 INSTRUMENT TRANSFORMER TRANSFORMER INSPECTION............. INSPECTION..................... ................. .................. .................. .................. ...............5 ......5 STRUCTURE STRUCTURE INSPECTION......... INSPECTION................. ................. .................. .................. .................. .................. .................. ................. ................. .................5 ........5 INFRARED INSPECTION................... INSPECTION............................ .................. ................. ................. .................. .................. .................. .................. .................. .........5 5 3. EQUIPMENT EQUI PMENT INSP INSPECTI ECTION/M ON/MINOR INOR MAIN MAINTENA TENANCE............ NCE..................... ................. ................. .................7 ........7 3.1 3.2 3.3 3.4 3.5 3.6 INTRODUCTION INTRODUCTION ................. .......................... ................. ................. .................. .................. .................. .................. .................. ................. ................. .................7 ........7 125 VDC LEAD ACID ACID BATTER BATTERY Y AND AND CHARGER CHARGER INSPECTI INSPECTION ON.... ........ ........ ....... ....... ........ ........ ........ .....7 .7 33KV VACUUM CIRCUIT BREAKER....................... BREAKER................................ .................. .................. ................. ................. .................. ...........8 ..8 POWER TRANSFORMER TRANSFORMER INSPECTION INSPECTION .................. .......................... ................. .................. .................. .................. .................. ............10 ...10 11KV SWITCHGEAR SWITCHGEAR INSPECTION INSPECTION ................. .......................... ................. ................. .................. .................. .................. .................. ............12 ...12 33KV SWITCHGEAR SWITCHGEAR INSPECTION INSPECTION ................. .......................... ................. ................. .................. .................. .................. .................. ............14 ...14 4. EQUIPMENT EQUI PMENT TESTI TESTING........ NG................. .................. .................. ................. ................. .................. .................. .................. .................. .................. ............17 ...17 4.1 4.2 4.3 4.4 4.5 SAFETY OF PERSONNEL................ PERSONNEL......................... .................. .................. .................. .................. .................. ................. ................. .................. ...........17 ..17 SAFETY HAZARDS .................. .......................... ................. .................. .................. .................. .................. .................. ................. ................. .................. ...........17 ..17 TRANSFORMER TRANSFORMER TESTING......................... TESTING.................................. ................. ................. .................. .................. .................. .................. .................. .........18 18 OIL SAMPLE COLLECTION AND TEST .................. ........................... .................. .................. ................. ................. .................. ...........20 ..20 CIRCUIT BREAKER TESTING....................... TESTING................................ .................. .................. .................. .................. ................. ................. ..............21 .....21 5. MAJOR MAIN MAINTENA TENANCE............. NCE..................... ................. .................. .................. .................. .................. ................. ................. .................. ..............23 .....23 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 INTRODUCTION INTRODUCTION ................. .......................... ................. ................. .................. .................. .................. .................. .................. ................. ................. .................23 ........23 MAJOR MAJOR OVERH OVERHAULS AULS ON 33KV 33KV VACUUM VACUUM CIRC CIRCUIT UIT BREA BREAKERS KERS ........ ............ ........ ........ ........ ........ .....23 .23 MAJOR MAJOR OVERHAUL OVERHAULS S 125 VDC LEAD ACID BATTERIE BATTERIES S & CHARGER....... CHARGER........... ........ ........ ....25 25 MAJOR OVERHAULS ON POWER TRANSFORMERS TRANSFORMERS........ ................. .................. .................. .................. ...............28 ......28 MAJOR OVERHAULS ON ON-LOAD TAP CHANGERS CHANGERS ................. .......................... .................. .................. ............31 ...31 MAJOR MAJOR OVERHAUL OVERHAULS S DISCON DISCON SWITCHE SWITCHES S AND ASSOCIA ASSOCIATED TED EQUIPMENT EQUIPMENT.... ........ ....34 34 MAJOR MAJOR OVERHAUL OVERHAULS S ON INSTRUM INSTRUMENT ENT TRANSFO TRANSFORMER RMERS S ........ ............ ........ ........ ........ ........ ........ ........ ......36 ..36 MAJOR OVERHAULS ON 33KV SWITCHGEAR............ SWITCHGEAR..................... .................. .................. .................. .................. ............37 ...37 MAJOR OVERHAULS ON 11KV SWITCHGEAR SWITCHGEAR ................. .......................... .................. .................. .................. ...............39 ......39 SUBSTATION SUBSTATION GROUNDING MAINTENANCE MAINTENANCE ................. .......................... .................. ................. ................. .................. ...........41 ..41 Page i 6. APPENDICES 6.1 6.1 INSP INSPEC ECTI TION ON SHEE SHEETS TS 6.1.1 6.1.1 33kv Vacuum Vacuum Circuit Circuit Breakers Breakers 6.1.2 6.1.2 125 VDC Lead Lead Acid Acid Batte Batteries ries & Charg Charger  er  6.1.3 6.1.3 Power Power Trans Transform formers ers 6.1.4 6.1.4 On-Loa On-Load d Tap Chang Changers ers 6.1.5 6.1.5 Struc Structur tures es & Buswo Buswork  rk  6.1.6 6.1.6 Instrume Instrument nt Transform Transformers ers 6.1.7 6.1.7 MV Disconne Disconnect ct Switche Switchess 6.1.8 6.1.8 MV Switc Switchge hgear  ar  6.1.9 6.1.9 Substa Substatio tion n Ground Grounding ing 6.2 TEST SHEETS 6.3 6.3 SAFE SAFETY TY PROC PROCED EDUR URES ES Page ii 1. 1.1 INT IN TRODUCTIO ION N GENERAL Preven Preventat tative ive mainte maintenanc nancee is a cycle cycle of planned planned inspec inspectio tions, ns, tests, tests, minor minor overhau overhauls ls and servicing activities designed to keep equipment in good operating condition and to reveal the need for reconditioning or major overhaul in time to prevent breakdowns or failure during during operat operation ion.. This This manual manual contai contains ns mainte maintenan nance ce standar standards ds and proced procedure uress for the  preventative maintenance program. The maintenance standards and procedures shall be used in conjunction with manufacturer’s manuals. These Maintenance Maintenance Procedures Procedures identify the Works to be carried carried out for Maintenance Maintenance on the following equipment:          33kV Vacuum Circuit Breakers 125VDC Lead Acid Batteries & Chargers Power Transformers On-Load Tap Changers Structures and bus work  Potential Transformers Medium Voltage Disconnect Switches Medium Voltage Switchgears Grounding This procedure should be used with the attached inspection sheets and test report forms. Ensu Ensure re all all form formss are are compl complet etel ely y fill filled ed out and and a loca locall fiel field d file file is main mainta tain ined ed on this this equipment. 1.2 DEFINITIONS These procedures fall into four categories: Inspections, Minor Overhaul, Major Overhaul and Test Procedures. I nspe nspecti ctions are comprised of visual checks and test operating of station equipment. They may require taking readings and making reports on equipment condition. Usually the work  can can be comp comple lete ted d with with the the equip equipme ment nt in serv servic ice. e. Inspec nspecti tions ons iden identi tify fy when when furt furthe her  r  investigative maintenance is required. Minor Mainte aintenanc nance e is usually non-invasive and involves assessment of the equipment condition by a means of inspections, checks, samples and tests etc. Minor maintenance is used to assess the correct functioning of the equipment and to determine further  maintenance requirements. This procedure does not cover all eventualities; the crew is also expected expected to look for and correct correct defects, which are not anticipated anticipated in this procedure. procedure. Major Maintenance Maintenance is the the repl replac acem emen entt and and or refu refurb rbis ishm hmen entt of an equip equipme ment nt majo major  r  compone component nt or system system.. Major Major overha overhauls uls are usually usually performe performed d when when a minor minor overhau overhaul, l, historical data, modification or system performance deem them necessary. Major overhauls usually include most of the minor overhaul steps. Page 1 Testing/sampling Testing/sampling procedures procedures outline the steps required to indicate equipment condition through testing of the equipment or equipment insulation i.e. Oil Samples, Thermovision (Infra-red) Capacitance and Power Factor etc. These tests can be performed outside of the minor minor or major major overhaul overhaul proced procedure ures. s. The results results of the testin testing g identi identify fy when when furthe further  r  maintenance is required. 1.3 SAFETY It is the responsibility of every employee to avoid unnecessary risks by following safety rules, approved work procedures and practices. Before undertaking any procedures in this manual manual,, proper proper work work protect protection ion must must be establ establish ished ed as requir required ed by GRENLE GRENLEC C Safety Safety Policy and Procedures. In addition, safety hazard identification must be an integral part of  every everyday day work. work. It is the the resp respon onsi sibi bili lity ty of the the pers person on in char charge ge of the the work work and and each each crewmember to constantly be on the lookout for safety hazards and to take definite steps to eliminate or control the hazards. Safety Safetyof of Personne rsonnell In order to ensure human safety, all personnel involved with the works shall be briefed on all aspects of the work prior to the commencement of any maintenance work or testing, and the follow following ing safety safety procedu procedures res adhered adhered to. Particu Particular lar emphas emphasis is should should be placed placed on  personnel hazards haz ards and the safety precautions prec autions associated with these hazards. haz ards. Work Work Protection ction Proper work protection shall be established in accordance with the requirements of  GRENLEC Safety Policy and Procedures. Ensure the Controller is notified when a station inspection is being performed. Safety SafetyII dentifica ntifi cation tion A safety identification exercise and safety basics procedure to identify all hazards shall be  performed. Page 2 2. SUBS BSTA TATI TIO ON IN IN--SER ERV VIC ICE E IN INSP SPEC ECTI TION ON 2.1 INTRODUCTION 2.1.1 This Maintenance Procedure details the work to be carried out during Substation Inspections. The maintenance crew is also expected to identify and correct defects, which are not anticipated in this procedure. This procedure is performed to: (i) Assess Assess substation substation structures, structures, bus work and equipment equipment condition; condition; (ii) Verify the correct functioning of the equipment and determine maintenance requirements. 2.1.2 The substation inspection should be carried out by trained maintenance personnel and in accordance with this procedure and the manufacturer’s instructions. 2.1.3 The Substation Inspection Sheet should be completed during the site inspection. 2.2 2. 2 INF IN FOR ORMA MATI TION ON,, TO TOOL OLS S AN AND D MA MATE TER RIA IALS LS 2.2.1 Planning In planning the work, refer to: - Manufacture Manufacturer’s r’s instruction instruction books, technical technical drawings, drawings, etc. etc. - Trai Traini ning ng lesso lessons ns - Previo Previous us statio station n insp inspect ection ion report reportss - Copy of of any special special GRENLEC GRENLEC orders orders or manufacturer manufacturerss technical technical bulletins bulletins 2.2. 2.2.2 2 Specia Spec iall Tool Toolss and and Mate Materi rial alss - Bino Binocu cula lars rs - Infr Infrar ared ed Camer Cameraa 2.3 SAFETY REQUIREMENTS During a station inspection and thermovision testing the electrical equipment will be inservice and in an energized state. Proper work clearances must be maintained at all times. Operating and testing of equipment must be approved and coordinated by the controllers. Binocul Binoculars ars should should be used used for detail detailed ed inspec inspection tion of live live equipm equipment ent.. Infrar Infrared ed Camera Camera should be used to check for and record hot joints. All personnel involved shall be briefed on all aspects of the work prior to the start of any maintenance or testing activity. Particular emphasis should be placed on personnel hazards and the safety precautions associated with these hazards. Proper working clearances must  be maintained at all times. time s. Make yourself aware of close-by live apparatus while conducting the inspection. Page 3 2.4 2. 4 DISC DI SCON ONNE NECT CT SW SWIT ITC CH IN INSP SPEC ECTI TION ON 2.4.1 Visually check that the switches are in their required operating position - either fully closed with blades in proper position or fully open with proper clearances. 2.4.2 Check if the insulators are chipped or cracked. Check for signs of flashover, excessive dirt, foreign material, copper splash. Check cementing and fasteners. 2.4.3 Check linkages, operating handles for damage and correct positioning. 2.4.4 Visually check the motor mechanism for deterioration, corrosion or damage. 2.4.5 . Check the anti-condensation heater in Motor Control Panel 2.5 STATION BUS INSPECTION 2.5.1 Check bus support insulators for chips, cracks, flashover burns, excessive dirt, foreign material, copper splash, copper wash, correct cementing and fasteners. 2.5.2 Check bus connections for damage, deterioration or signs of heating. 2.6 2. 6 33K 33 KV VA VAC CUU UUM M BR BREA EAK KER IN INSP SPEC ECTI TION ON 2.6.1 Perform a general inspection in the operating mechanism/control cabinet and around the  breaker checking ch ecking for deterioration, d eterioration, corrosion or damage. 2.6.2 Check the anti-condensation heater. 2.7 2. 7 POW OWER ER TR TRAN ANSF SFOR ORME MER R IN INSP SPEC ECTI TION ON 2.7.1 Check oil levels in tank and tap changer conservators. conservators. 2.7.2 Check the pressure gauge reading on sealed tank transformers. The gauge should indicate a  positive pressure p ressure with the unit in service. 2.7.3 If the transformer is equipped with a silica gel breather check the color of the silica gel. Blue indicates indicates dry and pink indicates indicates wet. 2.7.4 Check valves, gaskets, gaskets, welds, and fittings fittings for any sign of oil leakage or damage. 2.7.5 Perform a general inspection in the control cabinet and inspect the transformer for  deterioration, corrosion or damage. 2.7.6 Operate the fans to ensure correct operation. Check that the radiators are free from debris that could restrict the flow of air. 2.7.7 Check anti condensation heaters 2.7.8 Check temperature readings (oil and winding temperature gauges) Page 4 2.8 2. 8 ON LO LOAD AD TA TAP P CH CHAN ANG GER IN INSP SPEC ECTI TION ON 2.8.1 Perform a general inspection in the operating mechanism/control cabinet checking for  deterioration, corrosion or damage. 2.8.2 Operate Operate the tap changer raise and lower one tap. Check for irregular operation, operation, noises, etc.  NOTE: Notify controlling authority before operating o perating tap changer. 2.8.3 Check the anti-condensation heater (if applicable). 2.9 2.9 . INST IN STRU RUME MENT NT TR TRAN ANSF SFOR ORME MER R IN INSP SPEC ECTI TION ON 2.9.1 Check valves, gaskets, gaskets, and fittings fittings for any sign of oil leakage or damage. 2.9.2 Perform a general inspection around the instrument transformer checking for deterioration, corrosion or damage. 2.10 2. 10 STR ST RUC UCTU TUR RE IN INSP SPEC ECTI TION ON 2.10.1 Check all foundations and structures for cracking, shifting or deterioration. 2.10.2 Check all equipment ground connections are secure. 2.1 .11 1 INFRA RAR RED IN INSP SPE ECTION 2.11 2.11.1 .1 Scop Scopee of Progr rogram am The objectives of the thermovision testing program are: 1. Detect Detect overheated overheated components components in station station equipme equipment. nt. 2. Monitor Monitor equipment equipment showing showing signs signs of deteriora deterioration. tion. 3. Examine new new installatio installations ns for improper improper or faulty faulty connections connections.. 4. Examine the the condition condition of equipmen equipmentt which has has been repaired. repaired. 2.11 2.11.2 .2 Test Te st Cond Condit itio ions ns 2.11.2.1 2.11.2.1 To obtain obtain the most most reliabl reliablee results, results, it it is recommend recommended ed to arrange arrange station station loading so that the equipment equipment being surveyed will be carrying carrying as large a current current as possible, possible, for one hour prior  to the test. It is recommended that the loading be at least 25% of the equipment rating. 2.11.2.2 2.11.2.2 Prior to making making applicatio application n for equipme equipment nt outages outages and switchi switching ng required required to create the necessary necessary increased increased loading on components, components, a switching switching schedule and test plan should be established for each station. 2.11.2.3 2.11.2.3 Testing Testing should should be carried carried out with the the understandi understanding ng that that equipment equipment may be returned returned to normal operating position, without notifying the test crew. Page 5 2.11.3 2.11.3 Evaluati Evaluation on of Test Results Results (Curre (Current nt Carrying Carrying Compone Components) nts) The thermovision operator will carry out a preliminary evaluation of the test results. Items found to be outside outside the normal limits limits of temperature temperature rise outlined outlined in the operators manual shall be reported to the substation group. The thermovision operator will assign priority for further action, as shown below: A – Emergency, arrange repair immediately B – Repair in the immediate future C – Repair in near future possibly with next planned outage D – Repair in regular maintenance, retest at next thermovision inspection 2.11.4 2.11.4 Evaluati Evaluation on of Test Results Results (Non (Non Current Current Carrying Carrying Compone Components) nts) 2.11.4.1 2.11.4.1 Disconne Disconnect ct Switches Switches (Motor (Motor Ope Operate rated) d) Scan the motorized mechanism electrical components for signs of overheated terminal strips, connections, relays, contactors and defective heaters. Compare results with other  similar mechanisms. 2.11.4 2.11.4.2 .2 Circ Circuit uit Brea Breaker kerss Scan the operating mechanism/control cabinet’s electrical components for signs of  overheated terminal strips, connections, relays, contactors and defective heaters. Compare results with other similar breaker mechanisms. Scan the tanks and interrupter interrupter poles of circuit circuit breakers and check for hot spots or variances when compared to other similarly loaded circuit breakers. 2.11.4.3 2.11.4.3 Transfor Transforme mers rs and Tap Changer Changerss Scan the operating mechanism/control cabinet’s electrical components for signs of  overheated terminal strips, connections, relays, contactors and defective heaters. Compare results with other similar transformer mechanisms. Scan the radiator looking for restrictions in the oil flow that may cause variances when compared to other parts of the cooling system or similar transformers. Scan the tap changer compartment looking for variances when compared to other similarly tap changers. Compare the tap changer temperature to the main tank. The tap changer is normally normally a few degrees cooler than the main tank. 2.11.4.4 2.11.4.4 Instrum Instrument ent Transform Transformers ers Scan the tanks of instrument transformers looking for variances when compared to similar  instrument transformers. 2.11.4.5 2.11.4.5 Surge Surge Arresto Arrestors rs (Lightnin (Lightning g Arresto Arrestors) rs) Scan the porcelains of surge arrestors and check for variances when compared to similar  surge arrestors. Page 6 3. EQUI EQ UIP PME MEN NT IN INSP SPEC ECTI TION ON/M /MIN INOR OR MA MAIN INTE TENA NANC NCE E 3.1 INTRODUCTION 3.1.1 Minor maintenance is performed to assess the overall equipment condition, the correct functioning of the equipment and to determine requirements for major maintenance. 3.1.2 Maintenance Maintenance of equipment should be carried carried out by trained maintenance maintenance personnel and in accordance with this procedure and specific manufacturer’s instructions. 3.1.3 All appropriate appropriate forms should be filled filled out and a file maintained maintained on the equipment. 3.1.4 All personnel involved shall be briefed on all aspects of the work prior to the start of any maintenance or testing activity. Particular emphasis should be placed on personnel hazards and the safety precautions associated with these hazards. Proper working clearances must  be maintained at all times. time s. 3.1.5 In planning the work, refer to: - Manufacture Manufacturer’s r’s instruction instruction books, technical technical drawings, drawings, etc. etc. - Trai Traini ning ng lesso lessons ns - Substat Substation ion Inspe Inspecti ction on Reports Reports - Previo Previous us overhau overhaull and and trouble trouble report reportss - Copy of of any special special GRENLEC GRENLEC orders orders or manufacturer manufacturerss technical technical bulletins bulletins 3.1.6 Make your yourself self awar awaree of clos close-b e-by y live appa apparat ratus us whil whilee cond conducti ucting ng the insp inspect ection. ion. 3.2 3. 2 125V 12 5VDC DC BA BATT TTER ERY Y & CH CHAR ARG GER IN INSP SPEC ECTI TION ON 3.2.1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S 3.2. 3. 2.2 2 Hydrom Hydromete eter, r, Voltme Voltmeter ter and Ammete Ammeter  r  Dist Distil ille led d Wa Wate ter  r  Face ace Shi Shield eld Apron Gloves Gloves (chemi (chemical cal resist resistant) ant) SPEC SP ECIA IAL L SA SAF FET ETY Y HA HAZ ZAR ARD DS Batteries Batteries contain sulfuric sulfuric acid. Do not allow battery fluid to come in contact with eyes or  skin. If contact occurs, flush the affected area immediately with water. Batteries generate hydrogen gas, which is flammable and explosive. To reduce the possibility of explosion, never expose the battery to open flame or sparks. Do not smoke near the battery. Tools should be insulated to avoid the chance of sparks. sparks. Batteries contain contain stored energy and may explode if inadvertently shorted. Page 7 3.2.3 INSPECTION 3.2.3.1 temperature is between 20 and 25°C. Check to ensure that the battery room temperature 3.2.3.2 Record DC voltage reading on the charger voltmeter and note any variation from normal range of values. 3.2.3.3 Record the charger ammeter reading. reading. The normal current drain on the battery should be marked on the meter. Note if the reading is outside the normal range. 3.2.3.4 Check the battery terminals for corrosion or discoloration. 3.2.3.5 Check for  leaks. There should be no visible signs of electrolyte on the battery jars, the jar  covers or in the trays. 3.2.3.6 Measure and record the corrected specific gravity (S.G.) of the electrolyte in the pilot cell and determine if an equalize charge is required. The pilot cell is one which is used as a convenient means to indicate the condition and state of charge of the whole battery. The  pilot cell is the one of poorest quality, lowest specific gravity gravit y reading and lowest voltage. 3.2.3.7 Measure and record the voltage of the pilot cell and determine if an equalize charge is required. The pilot cell is the one used to estimate the condition and state of charge of the whole battery. 3.2.3.8 electrolyte level . Add distilled water if the level is below the lower limit. Check the electrolyte 3.2.3.9 Equalize Battery (periodic application of a controlled overvoltage cycle to battery) 3.3 CIRCUIT BREAKER IN INSP SPE ECTION 3.3. 3. 3.1 1 SPECIA SPEC IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S Multi Meter   Clip on Ammeter   Foam Spray Recommended lubricants 3.3. 3. 3.2 2 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL  Isolate the equipment  Carry out a visual check to ensure the equipment is isolated  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is inspected.  Mark off the work area with signs and easily visible tape. Page 8  3.3 .3.3 .3 The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before working on any mechanism. SAFETY HAZARDS Some points in the control cabinet may be live. If work is required on a live circuit arrange for isolation isolation at the source end of the circuit. circuit. This circuit circuit breaker is composed composed of many mechanical devices, devices, which may be under spring loading regardless of the operating position. Ensure that all spring operating systems for   both closing and opening are fully discharged if work wo rk is required in the mechanism. Safety Note: Be aware of near-by live parts before commencing work on the circuit breaker. 3.3.4 INSPECTION 3.3.4.1 Verify the operation of the breaker operation counter. Record the counter reading before and after the inspection. 3.3.4.2 Check the bushing for chips, cracks, flashover burns, copper splash, copper wash, correct cementing cementing and fasteners. fasteners. Clean the bushings bushings if they are contaminated contaminated with dirt, dust or  other pollutants. 3.3.4.3 Check circuit breaker housing, structures, covers, fittings etc. for any sign of rusting, corrosion or damage to painted surface. 3.3.4.4 Check control and operator mechanism compartments: a. Look for loose, loose, broken, corroded corroded wire/ terminals terminals,, loose contactor contactor parts, parts, burnt coils and contacts. Check fuses, connections, contactors. Check for any sign of contact burning and deterioration in insulation of control wire or coils.  b. Check for sign of corrosion, moisture, external contamination or damage. Check all cable entrances are properly sealed against rodent. Inspect seals for any sign of external contamination or aging. c. Check the the operation operation of anti-condens anti-condensation ation heaters heaters.. 3.3.4.5 Inspect Inspect the contacts of the auxiliary auxiliary switches. switches. Check for loose connections connections and erosion, erosion,  burning or chattering of o f contacts. c ontacts. Check Ch eck also the auxiliary switch linkage alignment for  wear & lubrication. Clean or adjust, if required. 3.3.4.6 Check the condition of the contacts on all the relays. 3.3.4.7 Check the condition of the following items: Mechanism bearings, Linkages, springs and shafts. Check springs for defects, cracks and tightness of fittings. Page 9 3.3.4. 3.3.4.8 8 Oper Op erati ating ng mech mechani anism sm Inspect operating mechanism. Check lubrication. Check for smooth operation during manual operation. Clean and lubricate the operating mechanism/ linkage as per  manufacturer’s instructions. Note the condition of the parts. Use recommended lubricant only. 3.3.4.9 Verify the operation of position indicator (open/close) to ensure it is indicating correctly. 3.3.4.10 Check the charging spring indicator indicator in both the charged charged and discharged discharged position. 3.3.4.11 Record Contact wear  3.4 3. 4 POW OWER ER TR TRAN ANSF SFOR ORME MER R IN INSP SPEC ECTI TION ON Minor overhaul on the transformer shall be conducted with the transformer  energized and in service. 3.4. 3. 4.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S This procedure should be used with the attached inspection report form. Ensure all forms are completely filled out. A copy of the completed inspection form should be sent to the Distribution Department. Tools and Materials - Volt Volt / Ohm Ohm Mete Meter  r  - Foam oam Spr Spray - Recomm Recommend ended ed Lubric Lubricant antss Oil Sample & Test - Approv Approved, ed, Clea Clean, n, Oil Oil Sampl Samplee Jars Jars and and Syrin Syringes ges - Labels, Labels, GRENLEC GRENLEC and Laborat Laboratory ory Forms Forms and Shipping Information Information - Clean Clean PVC Hoses, Hoses, Fittin Fittings gs and Wipers Wipers - Bucket Bucket and Waste Waste Oil Contain Container  er  3.4. 3. 4.2 2 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL The maintenance of transformers should be carried out by trained maintenance personnel and in accordance with this procedure and specific manufacturer’s instructions. Some points in the control cabinet may be live even with all the control switches open. If  work is required on a live circuit arrange for isolation at the source end of the circuit. Safety Note: Make yourself aware of close-by live apparatus before starting to work  on the transformer. Page 10 3.4.3 3.4 .3 TRAN TR ANSF SFOR ORMER MER INS INSPE PECT CTION ION (I (INN-SER SERVIC VICE) E) 3.4.3.1 Listen Listen for any abnormal sounds that may indicate indicate loose windings, windings, blocking or other  mechanical problems. 3.4.3.2 Check the oil level in the main tank on transformer transformerss equipped with conservator tanks. tanks. The gauge should show a normal level, adjusted for temperature. 3.4.3.3 Check the pressure gauge reading on sealed (no conservator) type transformers. The gauge should indicate a positive pressure. 3.4.3.4 Check the bushing condition. condition. Look for broken, chipped or cracked bushings, bushings, flashover   burns, copper splash, copper wash, correct cementing and fasteners. Clean the bushings if  they are contaminated with dirt, dust or other pollutants. 3.4.3.5 Check pressure relief vent for signs of damage or oil leakage. Check for signs of relief vent diaphragm operation, cracked diaphragm and visible evidence of oil around relief area. 3.4.3.6 For transformers equipped with a silica gel breather check the color of the silica gel. Check  to ensure the breather breather vent is not plugged plugged with debris or insects. 3.4.3.7 Check valves, gaskets and fittings fittings for any sign of oil leakage or damage. 3.4.3.8 Check panels, structures, covers, valves, fittings for signs corrosion or damage. 3.4.3.9 Check the control cabinet for broken or corroded wire/terminals, loose contactor parts,  burnt coils and contacts. Check fuses, connections. conn ections. Check conductors and coils for  deterioration in insulation. 3.4.3.10 Inspect the control cabinet for signs of corrosion, moisture, external damage or  contaminati contamination. on. Ensure cable entrances entrances are properly sealed sealed against rodents. rodents. Inspect Inspect seals for signs signs of external contamination contamination or aging. Check the door. 3.4.3.11 Check the operation of anti-condensation heaters. 3.4.3.12 Check and record the maximum and existing oil and winding winding temperatures. temperatures. Check the temperature gauges for correct functioning - upper drag hand limit is not excessive, drag hands indicate reasonable temperature range. Reset. 3.4.3.13 Operate Operate the fans. fans. Check that all fans are operating properly and turning in the correct direction, direction, there is no audible indication indication of bearing trouble, fan guards guards are fixed in place and there is no damage to blades and wiring is in good condition. 3.4.3.14 Check the radiators. radiators. Remove any bird nests, bird excrement, or other foreign debris debris that will restrict the flow of air or cause corrosion or damage to the units. 3.4.3.15 Take an oil sample from the tank. Perform a dielectric test. Results of the Dielectric test should be used to assess the transformer condition. Record and compare the results with  previous tests and ANSI recommended values. 3.4.3.16 Check Buchholz Relay for flammable gas. 3.4.3.17 Check pressure relief device for normal condition. Page 11 3.4.4 3.4 .4 ON-L ON -LOA OAD D TA TAP P CH CHAN ANGE GER R ININ-SER SERVI VICE CE INS INSPE PECT CTION ION 3.4.4.1 3.4.4.1 Operate Ope rate the Tap changer changer (raise/l (raise/lowe ower) r) a) Check the tap changer operation counter is operating properly.  b) Check C heck the tap position indicator is operating correctly c) Check for irregular operation, noises, etc. d) Record final reading 3.4.4.2 Check the gear lubricant levels and refill if necessary, using manufacturer’s recommended lubricant. 3.4.4.3 Check linkages for correct operation. Lubricate drive gears according to manufacturer  recommendations 3.4.4.4 Check the mechanical and electrical limits limits by operating operating the tap changer through its complete range of taps and attempt to overdrive (mechanically and electrically) at both ends of the tap range. NOTE: The limits limits must be checked manually first. first. 3.4.4.5 Test the Buchholz relays. Check for flammable gases. 3.4.4.6 Take an oil sample from the tap changer. Perform a dielectric dielectric test. Results Results of the Dielectric Dielectric test should be used to assess the tap changer condition. condition. Record and compare the results with  previous tests, and ANSI recommended values. 3.4.5.7 Check pressure relief device for normal condition. 3.5 11KV SW SWIT ITC CHGEAR IN INS SPECTIO ION N 3.5. 3. 5.1 1 SPECIA SPEC IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S Multi Meter   Clip on Ammeter   Foam Spray Recommended lubricants Vacuum Cleaner   3.5. 3. 5.2 2 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL   De-energize the equipment Carry out a visual check to ensure the equipment is isolated; where visual check is not  possible carry out checks with an approved voltage indicator to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is inspected. Page 12  The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before performing an inspection or maintenance. maintenance.  De-energize control power to the circuit breaker by removal of the fuse holder or by opening the molded case circuit breaker.  Perform the spring discharge test before removing or inserting the circuit breaker. See Instruction Manual for procedure.  3.5 .5.3 .3 Ensure circuit breaker door is closed before racking. See Instruction Manual for racking  procedures. SAFETY HAZARDS Some points in the control cabinet may be live. If work is required on a live circuit arrange for isolation isolation at the source end of the circuit. circuit. This circuit circuit breaker is composed composed of many mechanical devices, devices, which may be under spring loading regardless of the operating position. Ensure that all spring operating systems for   both closing and opening are fully discharged if work wo rk is required in the mechanism. Safety Note: Be aware of near-by live parts before commencing work on the circuit breaker. 3.5.4 INSPECTION 3.5.4.1 A general visual inspection inspection of the switchgear switchgear and a check on accessories accessories shall be conducted conducted every year. A more detailed detailed inspection shall be carried carried out every five (5) years. years. 3.5.4.2 Inspect general condition of the switchgear installation. Check housing, structures, covers, fittings etc. for any sign of rusting, corrosion or damage to painted surface. 3.5.4.3 Check the bushing for chips, cracks, flashover burns, copper splash, copper wash, correct cementing cementing and fasteners. fasteners. Clean the bushings bushings if they are contaminated contaminated with dirt, dust or  other pollutants. 3.5.4.4 Verify the operation of the breaker operation counter. Record the counter reading before and after the inspection. 3.5.4.5 Inspect switchgear interior for accumulation of dust, dirt or foreign matter. 3.5.4.6 Clean panels and check connections connections 3.5.4.7 Check control and circuit breaker compartments: a. Look for loose, loose, broken, corroded corroded wire/ terminals terminals,, loose contactor contactor parts, parts, burnt coils, contacts and terminal blocks. Check fuses, connections, contactors. Check for any sign of contact burning and deterioration in insulation of control wire or coils.  b. Check for sign of corrosion, moisture, external contamination or damage. Check all cable entrances are properly sealed against rodent. Inspect seals for any sign of external contamination or aging. c. Check the the operation operation of anti-condens anti-condensation ation heaters heaters.. d. Examine indicating indicating lamps and and replace replace as require required d Page 13 3.5.4.8 Inspect Inspect the contacts of the auxiliary auxiliary switches. switches. Check for loose connections connections and erosion, erosion,  burning or chattering of o f contacts. c ontacts. Check Ch eck also the auxiliary switch linkage alignment for  wear & lubrication. Clean or adjust, if required. 3.5.4.9 Check the condition of the contacts on all the relays. 3.5.4.10 Check the condition of the following items: Mechanism bearings, Linkages, springs and shafts. Check springs for defects, cracks and tightness of fittings. 3.5.4.11 3.5.4.11 Operati Ope rating ng mechani mechanism sm Inspect operating mechanism. Check lubrication. Check for smooth operation during manual operation. Clean and lubricate the operating mechanism/ linkage as per  manufacturer’s instructions. Note the condition of the parts. Use recommended lubricant only. 3.5.4.12 Verify the operation of position indicator (open/close) to ensure it is indicating correctly. 3.5.4.13 Check the charging spring indicator indicator in both the charged charged and discharged discharged position. 3.5.4.14 Record Contact-wear while checking spring 3.5.4.15 Check for proper condition of instrument transformers. Replace burned out fuses. Check   primary and secondary connections. 3.5.4.16 Insert the draw-out section into the panel 3.5.4.17 Check out all the necessary functions and interlocking 3.5.4.18 Replace reassemble, re-insulate, return all items to proper operating conditions and remove grounds prior to energizing. 3.6 33KV SW SWIT ITC CHGEAR IN INS SPECTIO ION N 3.6. 3. 6.1 1 SPECIA SPEC IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S Multi Meter   Clip on Ammeter   Foam Spray Recommended lubricants Vacuum Cleaner   3.6. 3. 6.2 2 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL   De-energize the equipment Carry out a visual check to ensure the equipment is isolated; where visual check is not  possible carry out checks with an approved voltage indicator to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is inspected. Page 14  The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before performing an inspection or maintenance.  De-energize control power to the circuit breaker by removal of the fuse holder or by opening the molded case circuit breaker.  Perform the spring discharge test before removing or inserting the circuit breaker. See Instruction Manual for procedure.  3.6 .6.3 .3 Ensure circuit breaker door is closed before racking. See Instruction Manual for racking  procedures. SAFETY HAZARDS Some points in the control cabinet may be live. If work is required on a live circuit arrange for isolation isolation at the source end of the circuit. circuit. This circuit circuit breaker is composed composed of many mechanical devices, devices, which may be under spring loading regardless of the operating position. Ensure that all spring operating systems for   both closing and opening are fully discharged if work wo rk is required in the mechanism. Safety Note: Be aware of near-by live parts before commencing work on the circuit breaker. 3.6.4 INSPECTION 3.6.4.1 A general visual inspection inspection of the switchgear switchgear and a check on accessories accessories shall be conducted conducted every year. A more detailed detailed inspection shall be carried carried out every five (5) years. years. 3.6.4.2 Inspect general condition of the switchgear installation. Check housing, structures, covers, fittings etc. for any sign of rusting, corrosion or damage to painted surface. 3.6.4.3 Check the bushing for chips, cracks, flashover burns, copper splash, copper wash, correct cementing cementing and fasteners. fasteners. Clean the bushings bushings if they are contaminated contaminated with dirt, dust or  other pollutants. 3.6.4.4 Verify the operation of the breaker operation counter. Record the counter reading before and after the inspection. 3.6.4.5 Inspect switchgear interior for accumulation of dust, dirt or foreign matter. 3.6.4.6 Clean panels and check connections connections 3.6.4.7 Check control and circuit breaker compartments: a. Look for loose, loose, broken, corroded corroded wire/ terminals terminals,, loose contactor contactor parts, parts, burnt coils, contacts and terminal blocks. Check fuses, connections, contactors. Check for any sign of contact burning and deterioration in insulation of control wire or coils.  b. Check for sign of corrosion, moisture, external contamination or damage. Check all cable entrances are properly sealed against rodent. Inspect seals for any sign of external contamination or aging. c. Check the the operation operation of anti-condens anti-condensation ation heaters heaters.. d. Examine indicating indicating lamps and and replace replace as require required d Page 15 3.6.4.8 Inspect Inspect the contacts of the auxiliary auxiliary switches. switches. Check for loose connections connections and erosion, erosion,  burning or chattering of o f contacts. c ontacts. Check Ch eck also the auxiliary switch linkage alignment for  wear & lubrication. Clean or adjust, if required. 3.6.4.9 Check the condition of the contacts on all the relays. 3.6.4.10 Check the condition of the following items: Mechanism bearings, Linkages, springs and shafts. Check springs for defects, cracks and tightness of fittings. 3.6.4.11 3.6.4.11 Operati Ope rating ng mechani mechanism sm Inspect operating mechanism. Check lubrication. Check for smooth operation during manual operation. Clean and lubricate the operating mechanism/ linkage as per  manufacturer’s instructions. Note the condition of the parts. Use recommended lubricant only. 3.6.4.12 Verify the operation of position indicator (open/close) to ensure it is indicating correctly. 3.6.4.13 Check the charging spring indicator indicator in both the charged charged and discharged discharged position. 3.6.4.14 Record Contact-wear while checking spring 3.6.4.15 Check for proper condition of instrument transformers. Replace burned out fuses. Check   primary and secondary connections. 3.6.4.16 Insert the draw-out section into the panel 3.6.4.17 Check out all the necessary functions and interlocking 3.6.4.18 Replace reassemble, re-insulate, return all items to proper operating conditions and remove grounds prior to energizing. Page 16 4. EQUIPMENT TESTING 4.1 INTRODUCTION 4.1.1 Equipment testing is performed to assess the overall equipment condition and to determine requirements for major maintenance. 4.1.2 Testing Testing of equipment equipment should be carried carried out by trained maintenance maintenance personnel and in accordance with this procedure and specific manufacturer’s instructions. 4.1.3 All appropriate appropriate forms should be filled filled out and a file maintained maintained on the equipment. 4.1.4 All personnel involved shall be briefed on all aspects of the work prior to the start of any testing activity. Particular emphasis should be placed on personnel hazards and the safety  precautions associated with these hazards. haz ards. Proper P roper working clearances must be maintained at all times. 4.1.5 In planning the work, refer to: - Manufacture Manufacturer’s r’s instruction instruction books, technical technical drawings, drawings, etc. etc. - Trai Traini ning ng lesso lessons ns - Releva Relevant nt IEEE IEEE Standar Standards ds - Copy of of any special special GRENLEC GRENLEC orders orders or manufacturer manufacturerss technical technical bulletins bulletins 4.2 SAFETY OF PERSONNEL Prior to performing any test of power apparatus, there should be a meeting of all people who will be involved or affected by the test. The test procedure should be discussed so there is a clear understanding of all aspects of the work to be performed. Consideration of  safety in electrical testing applies not only to personnel but also to the test equipment and equipment equipment under test. Particular Particular emphasis emphasis should be placed on personnel personnel hazards and the safety precautions associated with these hazards. 4.3 SAFETY HAZARDS Insulation tests in the field present a hazard to personnel unless suitable precautions are taken.  Equipment Equipment to be tested shall be disconnecte disconnected d from the power system. A visual check of  the disconnection disconnection should be carried carried out. When this is not possible, possible, check with a voltage voltage indicator.  Grounds are then applied. Personnel shall be instructed to treat all ungrounded apparatus as energized. Ground Connection Use of working grounds should comply with established company guidelines. Warning Signs and Barriers The test area may be marked off with signs and easily visible tape. Page 17 4.4 TRANSFORMER TESTING 4.4. 4. 4.1 1 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL 4.4 .4.2 .2  Isolate the equipment  Carry out a visual check to ensure the equipment is isolated  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the transformer and its controls are disconnected from all power, both high voltage and control voltage before it is inspected.  Mark off the work area with signs and easily visible tape. SAFETY HAZARDS Some points in the control cabinet may be live. If work is required on a live circuit arrange for isolation isolation at the source end of the circuit. circuit. Be aware of near-by live parts before commencing work on the transformer. Under no conditions shall tests be performed on a transformer under vacuum because under these conditions the dielectric strength of the system is significantly reduced. 4.4. 4. 4.3 3 TEMP TE MPER ERAT ATUR URE E IN INDI DICA CATO TOR R TE TEST ST Test the alarm points, cooling operation and correct indication of the temperature indicators  by removing the temperature sensor bulb from the transformer and putting it in a oil heater  and slowly raise and lower the temperature. 4.4.4 MEGGER TEST Perform a MEGGER test on the windings and core. Test HV to LV, HV and LV to ground and the core to ground (if core is accessible). If a core ground resistor is installed check its value. Record the results 4.4. 4. 4.5 5 WIND WI NDIN ING G RE RESI SIST STAN ANC CE TE TEST ST Objective Objective - Check for abnormalities, due to loose connections, broken strands and high contact resistance in tap changers. Interpretation of results is usually based on a comparison of measurements made separately on each phase in the case of a wye-connected winding or between pairs of terminals on a delta-connect delta-connected ed winding. Comparison may also be made with original original data measured measured in the factory. factory. Variations Variations of up to 5 % for any of the above comparisons comparisons is satisfactory satisfactory.. Resistance measurements are converted to values corresponding to the reference temperature in the transformer test report by the following formula: R S = R M * TS + T K  TM +TK  Page 18 Where: RS = Resistance at desired temperature Ts RM = Measured resistance resistance TS = Desired reference temperature (C) TM = Temperature Temperature at which resistan resistance ce was measured measured (C) TK  = 234.5 C (copper)) (copper)) = 225 C (Aluminum) (Aluminum)))  Note: The Th e value of Tk may be as high h igh as 230 2 30 for Alloyed Aluminum. 4.4 .4.6 .6 POWER FACTOR TEST This test is carried out to determine deterioration of, contamination of, or physical damage to the insulation Test voltages for typical field test sets range from below 100v to as high as 12 kV. Temperature correction should be made during the measurements. Interpretation Pow Power Fac Factor Ins Insulat lation ion conditio ition n Less than 0.5% 0.5%-1.0% Above 1.0% Good Acceptable Questionable One of the most useful methods of evaluating test results is by comparison to previous test results on the same equipment. 4.4.7 4.4 .7 TRAN TR ANSF SFOR ORMER MER TU TURNS RNS RA RATI TIO O TES TEST T (T (TTR TR)) The turns’ ratios should be determined for all taps. The turns’ ratio tolerance should be within 0.5 % of the nameplate specifications for all windings. For three-phase Y connected windings this tolerance applies to the phase-to-neutral voltage. Out-of-tolerance ratio measurements may be symptomatic of shorted turns, especially if  there is an associated high excitation current. Open turns in the excited winding will be indicated by low exciting current and no output voltage. voltage. Open turns in the output winding will be indicated by normal normal levels of exciting exciting current, current, but no or very low levels of unstable output voltage. voltage. The turn ratio test may also detect high-resistance connection in the lead circuitry or high contact resistance in tap changer by higher excitation current. Page 19 4.5 4. 5 OIL OI L SA SAMP MPLE LE COL OLLE LECT CTIO ION N AN AND D TE TEST ST 4.5. 4. 5.1 1 SAF SA FET ETY Y PRE RECA CAU UTI TION ON The oil sampling of electrical equipment should be carried out by trained maintenance  personnel and in accordance with this procedure If the transformer is suspected to be developing internal problems avoid area of transformer explosion vent discharge when sampling the equipment. Personnel sensitive to Transformer Oil should wear latex gloves to avoid skin contact. 4.5.2 GATHER SAMPLES Setup Connect sample hose to bottom sampling valve.  Note: Special S pecial tests may ma y call for top oil samples. Flush Flush oil through the valve, fittings and hose to clean and dry them and to ensure the sample is representative of the oil in the equipment, not just in the valve and piping. Using a clear jar check the oil being flushed for water and debris. When satisfied satisfied that sampling sampling can begin reduce oil flow and maintain the same rate throughout throughout sample collection as opening and closing the sample valve may release unwanted debris. Fill Sample Jars and Syringes Jars: rinse Jar 3 times, put PVC hose to bottom of Jar (to avoid aeration) and fill almost completely completely with final sample. Label Jar and place in container container to protect it from breakage and sunlight. Syringes: Syringes: hold Syringe vertical with its valve at top and rinse Syringe 3 times and manipulate to expel air bubbles. Fill slightly above full mark with final sample. Tilt Syringe and inspect for air bubbles. bubbles. If any bubbles are detected repeat final fill and inspect again. Repeat if necessary until a bubble free sample is obtained. Note that if a bubble appears later this is a result of the sample cooling and evolving gas: this bubble must not be expelled. Record syringe serial number and store it in its protective container away from sunlight. Complete Sample Information Fill in all information requested on the sample forms completely and accurately equipment data, sampling point, oil temperature(s), ambient temperature, humidity, purpose of sample, date, crew name(s), etc. Local Dielectric Testing Ensure Ensure that the Oil Tester is set up to perform tests according according to the proper ANSI Standard.  Note - Compare Comp are results to previous test results to establish if there is a ‘Trend’ Page 20 4.6 CIRCUIT BREAKER TEST STIN ING G 4.6. 4. 6.1 1 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL      4.6 .6.2 .2 Isolate Isolate the equipment equipment and carry out a visual check to ensure ensure the equipment equipment is isolated isolated Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated. Ground the equipment Ensure the breaker and its controls are disconnected from all power, both high voltage and control voltage before it is inspected. Mark off the work area with signs and easily visible tape. SAFETY HAZARDS Some points in the control cabinet may be live. If work is required on a live circuit arrange for isolation isolation at the source end of the circuit. circuit. Safety Note: Be aware of near-by live parts before commencing work. 4.6 .6.3 .3 MICRO-OHM TE TES ST Measure Measure and record record the micro-ohm micro-ohm readings readings of each phase with the breaker closed. Test leads should be placed between the power leads on the bushing terminals. Be sure that both the power leads and test leads are making a good connection with the bushing terminal. terminal. Sources of high micro-ohm readings could be poor connection of test leads, bushing caps,  bushing adapter & interrupter and contact block. 4.6 .6.4 .4 TIM IME E/ TRAVEL TEST Perform a circuit breaker timing test using an approved circuit breaker timer and compare the results with the recommended values provided in the manufacturer’s instruction manual. The results for the following tests should be recorded. 1. 2. 3. 4. 5. 6. Opening Opening time time Open spread (differe (difference nce between poles) Closing Closing time time Close spread spread (difference (difference between between poles) Close/trip Close/trip time time Slow operating operating speed could be an indication of weak opening or closing closing springs or   binding in the mechanism. 7. Investigate Investigate any readings, which exceed the maximum values given by the manufacturer. manufacturer. 4.6.5 DC HI-POT TEST The high pot test should be carried carried with the following values: values: 11kV 11kV Brea Breake kerrs - 33kV 33kV Brea Breake kerrs - Circuit Breaker Open: Connect high-voltage high-voltage lead to pole 1 and ground all other poles. Repeat all other poles. Circuit Breaker Closed: Connect high-voltage lead to Pole 1 with either pole of phase 2 and 3 grounded. Page 21 4.6 .6.6 .6 VACUUM BO BOT TTLE TEST With the circuit breaker open conduct test on each phase. For each phase connect highvoltage lead to pole 1 with other pole grounded. 4.6 .6.7 .7 LOW DC VOLTAGE TE TES ST Perform Perform low voltage voltage close and trip test at 80% of the rated control control voltage. 4.6. 4. 6.8 8 SPRI SP RING NG CH CHAR ARGI GING NG SY SYST STEM EM CH CHEC ECK  K  After normal close operation, measure and record the spring recharging time. Measure and record the charging motor current. 4.6.9 FUNCTION TESTS Perform the breaker function tests: seal-in, anti-slam and anti-pump. 5. MAJOR MAINTENANCE 5.1 INTRODUCTION Major overhauls overhauls are an internal or more in depth analysis analysis of the equipment to determine if  replacement replacement or overhaul of parts is required and if required required carry out the necessary part replacement or refurbishment. Equipment maintenance in the field presents a hazard to personnel unless suitable  precautions are a re taken. tak en. Equipment to be maintained shall be disconnected from the power system. A visual check  of the disconnectio disconnection n should be carried out. When this is not possible, possible, check with a voltage voltage indicator. Grounds are then applied. Personnel shall be instructed to treat all ungrounded apparatuss as energiz apparatu energized. ed. 5.2 5. 2 MAJO MA JOR R OV OVER ERHA HAUL UL ON 33 33KV KV VA VACU CUUM UM CI CIRC RCUI UIT T BR BREA EAKE KERS RS 5.2. 5. 2.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S - Micr Microo-oh ohm m Test Tester  er  - Circui Circuitt Breake Breakerr Timing Timing Tester  Tester  - Volt Volt / Ohm Ohm Mete Meter  r  - Clip Clip on Amme Ammete ter  r  - Minimu Minimum m Voltag Voltagee Tester  Tester  - Hi-P Hi-Pot ot Test Tester  er  - Foam oam Spr Spray - Recomm Recommend ended ed lubrica lubricants nts Page 22 5.2. 5. 2.2 2 SAF SA FET ETY Y OF PER ERSO SONN NNEL EL The maintenance of vacuum circuit breakers should be carried out by trained maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions.  Isolate Isolate the equipment equipment and carry out a visual check to ensure ensure the equipment equipment is isolated isolated  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is overhauled.  Mark off the work area with signs and easily visible tape.  The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before working on any mechanism.  Follow the manufacturer’s recommendation to protect against radiation hazard while carrying out HI POT tests. 5.2 .2.3 .3 CIRC CI RCUI UIT T BR BREA EAKE KER R MA MAIN INTE TENA NANC NCE E 5.2.3.1 Check the breaker operation counter is operating. Record the counter reading before and after the overhaul. 5.2.3.2 Check the bushing condition. condition. Look for broken, chipped chipped or cracked bushings, flashover burns, copper splash, copper wash, correct cementing and fasteners. Clean the bushings if they are contaminated with dirt, dust or other pollutants. 5.2.3.3 Check operating operating mechanism/con mechanism/control trol cabinets, cabinets, structures, structures, covers, fittings fittings etc. for  any sign of rusting, corrosion or damage. 5.2.3.4 Check the general condition condition of the operating operating mechanism/control mechanism/control panel. panel. Look for  loose, broken, corroded wire/ terminals, loose contactor parts, burnt coils and contacts. Check fuses, connections, contactors for signs of contact burning, and control wire and coils for sign of deterioration deterioration in insulation. insulation. 5.2.3.5 Inspect the operating operating mechanism/co mechanism/control ntrol panel for any sign of corrosion, corrosion, moisture, external contamination or damage. Check all cable entrances are properly sealed against rodents rodents and check for signs of external contaminati contamination on or aging. Check the door fits properly. properly. 5.2.3.6 Check the operation operation of anti-condensati anti-condensation on heaters. heaters. 5.2.3.7 Inspect auxiliary switch contact - check for loose connections and erosion, burning or chattering of contacts. Check also the auxiliary switch linkage alignment for wear  & lubrication. Clean or adjust as required. 5.2.3.8 Check the condition of the contacts on all the relays. Page 23 5.2.3.9 Check the condition condition of the following items: Mechanism bearings, Rollers, Linkages, springs and shafts for defects, cracks and tightness of fittings. 5.2.3.10 Clean and lubricate lubricate the operating operating mechanism mechanism as per manufacturer’s manufacturer’s instructions. Note the condition of the parts. Use only the recommended lubricant. 5.2.3.11 Check the operation of open/close position indicator/ linkage to ensure it is indicating correctly. 5.2.3.12 Check the charging spring indicator in both the charged and discharged position to ensure it is indicating indicating correctly. correctly. 5.2.3.13 Check the mechanism mechanism measurement specifications specifications as per the manufacturer’ manufacturer’s s instruction manual. 5.2.3.14 Check and record the measurements of the contact wear indicator as per the manufacturer instruction manual. 5.3 5. 3 125V 12 5VDC DC LE LEAD AD AC ACID ID BA BATT TTER ERIE IES S AN AND D CH CHAR ARGE GER  R  5.3. 5. 3.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S - 5.3. 5. 3.2 2 Hydr Hydrom omet eter  er  Volt Voltme mete terr Amme Ammete ter  r  Dist Distil ille led d Wa Wate ter  r  Impe Impedan dance ce Test Tester  er  Cleani Cleaning ng Solutio Solution n (baking (baking soda) soda) Dura Durabl blee Wipe Wipers rs Face ace Shi Shield eld Apron Gloves Gloves (chemi (chemical cal resist resistant) ant) SPEC SP ECIA IAL L SA SAF FET ETY Y HA HAZ ZAR ARD DS Batteries Batteries contain sulfuric sulfuric acid. Do not allow the battery fluid fluid to contact eyes or skin. If  contact occurs, flush the affected area immediately with water. Batteries generate hydrogen gas, which is flammable and explosive. To reduce the possibility of explosion, never expose the battery to open flame or sparks. Do not smoke near the battery. Tools should be insulated insulated to avoid the chance of sparks. Batteries Batteries contain a large amount of stored stored energy and may explode if inadvertently inadvertently shorted during the overhaul. overhaul. Page 24 5.3. 5. 3.3 3 CHA CH ARG RGER ER IN INSP SPEC ECTI TION ON 5.3.3.1 Calibrate the charger voltmeter for correct float and equalize voltages. The calibration should be done using an accurate accurate portable voltmeter. voltmeter. 5.3.3.2 Calibrate Calibrate the charger charger ammeter ammeter reading. reading. The calibration should be done using an accurate accurate  portable ammeter. 5.3.3.3 Remove dust and contamination from all the components and surfaces in and on the charger. 5.3.3.4 Check the contacts on timing devices, devices, relays, and switches switches for signs of burning, burning, heating heating or  deterioration. 5.3.3.5 Check the calibration of the under-voltage and over-voltage alarms as per manufacturer  instructions. .3.4 .4 5.3 BATT BA TTER ERY Y IN INSP SPEC ECTI TION ON 5.3.4.1 Check to ensure that the battery room temperature is between 20 to 25 Deg. C. 5.3.4.2 Battery cells: a) Check for signs signs of deterioration deterioration.. Check plates for buckling, buckling, sulfating sulfating or plate plate growth. Check inter-plate spacers for signs of charring; check bottom of cell for excessive sedimentation, or active material fallen from plates.  b) Check outside of the batteries for cracked cells or acid attack on inter-cell connections c) Check for corrosio corrosion n or discoloration discoloration on battery battery cell terminals terminals on connections connections d) Check for leaks. leaks. There should should be no visible signs of electroly electrolyte te on the battery jars, jars, the  jar covers cove rs or in the trays e) Clean the outside outside of the cells to remove remove any conductive salt salt deposits or dust dust deposits. deposits. Use a baking soda solution to neutralize the acid. Do not allow any cleaning solution to enter the cells. f) Replace defective cell as per instructions outlined in Section 4.3.5. 5.3.4.3 Measure and record the corrected relative density (specific gravity) of the electrolyte in the  pilot cell. 5.3.4.4 Measure Measure and record record the voltage voltage of o f the pilot cell. 5.3.4.5 Measure and record the corrected relative density (specific gravity) of the electrolyte in all the cells. Measure and record the voltage of all the cells. Choose the new pilot cell (lowest reading). The pilot cell is one, which is used as a convenient means to indicate the condition and state of charge of the whole battery. The pilot cell is generally the poorest cell, determined determined by the specific gravity reading reading and the cell with the lowest voltage. voltage. Page 25 5.3.4.6 Shut off the battery charger and test the ability of the battery to supply typical peak load, e.g., breaker closing current. 5.3.4.7 With the charger shut off for 90 minutes; test the capacity of the battery to supply a steady load while maintaining the voltage. Record the results 5.3.4.8 Perform an Impedance test on all the battery cells. Compare with previous test results. Check the percent change of each cell and percent deviation from the average cell. 5.3.4.9 Check the electrolyte level. Add distilled water if required 5.3.4.10 Place batteries on equalize. 5.3. 5. 3.5 5 BATT BA TTER ERY Y CE CELL LL CHAN ANG GE OU OUT T 5.3.5. 5.3.5.1 1 Specia Spe ciall Tools Tools and and Mater Material ialss - 5.3.5. 5.3.5.2 2 Standby battery battery of same voltage voltage and enough enough capacity capacity for short short term use Suitably Suitably sized temporary temporary cables cables and connector connectorss for battery connections connections Micro-ohmm Micro-ohmmeter, eter, insula insulated ted tools, tools, cleaning cleaning materials materials and suitabl suitablee connection connection corrosion corrosion inhibitor for inter-cell/block connectors Specia Spe ciall Safet Safety y Haza Hazards rds The change out of defective batteries batteries should be carried carried out by trained maintenance maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions. Batteries contain sulfuric acid. Do not allow the battery fluid to contact eyes or skin. Personal protective equipment must be worn. If contact occurs, flush the affected area immediately with water. Batteri Batte rie es gene nerate ratehy hyd drog roge en gas as,, which is fl flam ammab ablle and ande exp xpllos osive ive. To re red duce ucethe the pos oss sibil ibility ityof of exp xplos losion, ion, never exp xpos ose e th the e bat atte tery to toop ope en fl flam ame or sparks arks.. Do no nott smok oke e near the heb battery ry.. Too Tools ls sho hould uld be ins insulat ulate ed to avoid the hec cha hanc nce e of sparks or sho horts rts.. Perso Pe rsonne nnel sho hould uld to touc uch h a ground rounde ed surfac urface e pri rior or to toto touc uching hing th the e bat atte tery to tod drain an any y stat st atiic charg charge e. Batteries Batteries contain large amounts of stored energy and can cause high energy DC arcs and cell explosion explosion if shorts shorts are created. created. Extreme care and thorough job planning must be employed employed to avoid these hazards. Rubber gloves and flash goggles should be used while making and breaking the parallel connections. 5.3.5. 5.3.5.3 3 Batte Battery ry Chang Changee-out out Proce Procedur duree 5.3.5.3.1 Ensure that the replacement battery is of the same voltage as the one to be replaced, is in a similar state of charge and has adequate capacity to meet the minimal needs of the DC  Network during the time of the Works. Check that the battery area a rea is well ventilated in order to prevent build up of explosive gasses. Page 26 5.3.5.3.2 If required, ground or insulate the replacement battery rack/carrier as required to match the setup of the battery to be replaced. replaced. Check to ensure that the replacement replacement batteries batteries intercell/block connections are secure. 5.3.5.3.3 Securely connect the negative of the replacement battery to the negative of the battery to be replaced using adequately sized cable. Use two-hole terminal lugs at the load bus better  facilitates replacement battery connections without disturbing the normal connections. 5.3.5.3.4 Connect the positive side cable to the positive of the replacement battery. Check with a DC voltmeter voltmeter to ensure ensure minimal voltage between the positive positive cable and the positive of the  battery to be replaced. A 100W light bulb in a ‘pigtail lamp holder’ can be temporarily connected connected across the two positives positives to allow the two batteries batteries to equalize equalize their charges charges and  prevent any an y appreciable spark when the final connection conn ection is made-up. 5.3.5.3.5 When it is safe to do so, connect the positive cable to the positive of the battery to be replaced. This now puts the two batteries in parallel. Disconnect the replaced battery at both negative negative and positive positive side so as to fully isolate it. 5.3.5.3.6 Proceed with repairs as required on the replaced battery. Note that inter-cell/block  connections connections can be checked with a Micro-ohmm Micro-ohmmeter eter to determine determine resistance resistance and any need to dismantle for cleaning and re-greasing. 5.3.5.3.7 The above procedure may be used to replace a few cells if the work allows this but great care must be exercised with polarities, number of cells replaced/paralleled, minimal voltage difference and connection security before the parallel is completed. It is usually safer to replace the whole battery. 5.3.5.3.8 When the work is completed, the original battery can be returned to service and the temporary battery can be removed, using the same step-by-step procedure outlined above. 5.4 5. 4 MAJO MA JOR R OV OVER ERHA HAUL ULS S ON PO POWE WER R TR TRAN ANSF SFOR ORME MERS RS 5.4. 5. 4.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S 5.4. 5. 4.2 2 Volt Volt / Ohm Ohm Mete Meter  r  Transf Transform ormer er Test Test Equipmen Equipmentt Oil Oil Sampl Samplee Equip Equipme ment nt Proces Processed sed transf transform ormer er oil for top up Temper Temperatu ature re Contro Controll Oil Heater  Heater  Ther Thermo mome mete ter  r  Foam oam Spr Spray Recomm Recommend ended ed lubrica lubricants nts SAF SA FET ETY Y OF PER ERSO SONN NNEL EL  Isolate the equipment  Carry out a visual check to ensure the equipment is isolated Page 27 5.4 .4.3 .3  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the transformer and its controls are disconnected from all power, both high voltage and control voltage before it is inspected.  Mark off the work area with signs and easily visible tape. SAFETY HAZARDS Some points in the control cabinet may be alive even with all the control switches open. If  work is required on a live circuit, then it may be necessary to arrange for isolation at the source source end of the circuit. circuit. Safety Note: Be aware of near-by live parts before commencing work. 5.4. 5. 4.4 4 TRAN TR ANSF SFOR ORME MER R IN INSP SPEC ECTI TION ON 5.4.4.1 Prior to isolating the transformer listen for any abnormal sounds that may indicate loose windings, blocking or other mechanical problems. 5.4.4.2 Check the oil level in the main tank on transformer transformerss equipped with conservator tanks. tanks. The gauge should show a normal level, adjusted for temperature. 5.4.4.3 For transformers equipped with a conservator tank drain the conservator tank to remove condensation. 5.4.4.4 Check the pressure gauge reading on sealed (no conservator) type transformers. The gauge should indicate a positive pressure. 5.4.4.5 Check the bushing / porcelain porcelain condition. condition. Look for broken, chipped chipped or cracked bushings/ bushings/  porcelain, flashover burns, copper splash, copper copp er wash, correct cementing c ementing and fasteners. Clean the bushings if they are contaminated with dirt, dust or other pollutants. 5.4.4.6 Check the relief vent and/or the self-resetting pressure relief vent for signs of damage or oil leakage. Check for signs of past relief vent diaphragm operation; cracked/broken diaphragm, self resetting pressure relief vent indicator operated, visible evidence of oil around relief area. 5.4.4.7 If the transformer is equipped with a silica gel breather check the colour of the silica gel. Blue indicates dry and pink indicates wet. Check to ensure the breather vent is not plugged with debris or insects. 5.4.4.8 Check valves, gaskets, gaskets, packing, and fittings fittings for any sign of oil leakage or damage. 5.4.4.9 Check control cabinet, structures, covers, valves, fittings piping etc. for any sign of rusting, corrosion or damage. Page 28 5.4.4.10 Check the general condition condition of the control cabinet. cabinet. Look for loose, broken, corroded corroded wire/ terminals, loose contactor parts, burnt coils and contacts. Check fuses, connections, contactors contactors,, any sign of contact burning, burning, any sign of deteriorati deterioration on in insulation of control control wire or coils. 5.4.4.11 Inspect the control cabinet for any sign of corrosion, moisture, external contamination or  damage. damage. Check all cable entrances entrances are properly properly sealed against against rodents. rodents. Inspect Inspect weather/ weather/ rodent seals seals for any sign of external contamination contamination or aging. Check the door fits properly properly and hardware keeps the door secure. secure. 5.4.4.12 Check the operation of anti-condensation heaters. 5.4.4.13 Check and record the maximum and existing oil temperature and winding temperature. Check that the temperature gauge is functioning properly; upper drag hand limit is not excessive, upper and lower drag hands indicate a reasonable temperature range and reset  properly. In addition ad dition record the maximum current. 5.4.4.14 Operate Operate the fans. fans. Check that all fans are operating properly and turning in the correct direction. No audible indication of mounting/bearing trouble, fan guards are fixed in place and there is no damage to blades. Wiring is in good condition. 5.4.4.15 Operate Operate the pumps. Check that all pumps are operating properly properly with no audible indication of trouble and that the flow indicators indicators are working. working. Wiring Wiring is in good condition. condition. 5.4.4.16 Check the radiators/coolers. Remove any bird nests, bird excrement, or other foreign debris that will restrict the flow of air or cause corrosion or damage to the units. 5.4.4.17 Take an oil sample from the tank. Perform a dielectric test. Results of the Dielectric test should be used to assess the transformer condition. Record and compare the results with  previous tests, GRENLEC specifications and the manufacturer’s specifications. An oil sample should also be taken from the tap changer if it is not scheduled for maintenance 5.5 5. 5 MAJO MA JOR R OV OVER ERHA HAUL UL ON ON ON-L -LOA OAD D TA TAP P CH CHAN ANGE GERS RS 5.5. 5. 5.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S - Volt Volt / Ohm Ohm Mete Meter  r  Rati Ratiom omet eter  er  Windin Winding g Resist Resistanc ancee Tester  Tester  Oil Oil Sampl Samplee Equip Equipme ment nt Diel Dielec ectr tric ic Test Test Set Oil Filter Filter/Ha /Handl ndling ing Equipm Equipment ent New New Filt Filter ered ed Oil Oil Oil Pails Durabl Durablee Wipers Wipers/Cl /Cloth othss (Lint (Lint Free) Free) Filter Filtered ed transf transform ormer er oil Manufa Manufactu cturer rer Recommen Recommended ded Tools Tools Page 29 - 5.5. 5. 5.2 2 Lift Lifting ing Rig Rig (Cra (Crane) ne) Lifting Lifting Equipment Equipment (slings (slings & rope-blocks) rope-blocks) Foam oam Spr Spray Recomm Recommend ended ed lubrica lubricants nts SPEC SP ECIA IAL L SA SAF FET ETY Y HA HAZ ZAR ARD DS The maintenance maintenance of under load tap changers changers should be carried carried out by trained maintenance maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions. Some points in the control cabinet may be alive even with all the control switches open. If  work is required on a live circuit, then it may be necessary to have the Protection Department arrange for isolation at the source end of the circuit. The ULTC consists of mechanical components, components, which will be set in motion to observe observe their   performance during du ring the th e overhaul. Safety Note: Make yourself aware of close-by live apparatus before starting to work on the tap changer. 5.5. 5. 5.3 3 TAP TA P CH CHA ANG NGER ER OV OVER ERH HAU AUL L Prior to opening the tap changer ensure all tools and foreign material from workers pockets etc. are prevented from falling into the tap changer compartment. 5.5.3.1 Check the tap changer operation counter is operating. Record the counter reading before and after the overhaul. 5.5.3.2 Operate the tap changer manually one tap position in both directions (raise and lower). Check the operation of mechanism and linkages for any undue mechanical restriction,  binding, irregular operation, noises, etc. 5.5.3.3 Operate Operate the tap changer by raising raising and lowering lowering it one tap position. position. Check for irregular  irregular  operation, operation, noises, noises, etc. Check the winding resistance resistance on each of these three positions. positions. Operate the ULTC through the neutral position, stop at the next tap and again check the winding resistance. This process will check the diverter and reversing switches prior to the overhaul.  NOTE: Refer to the manufacturer manual to ensure the tap changer is on the recommended tap position before beginning the overhaul. Do not change the diverter switch position after  it has been disengaged disengaged from the drive linkage. 5.5.3.4 Ensure Ensure the oil handling equipment is clean, dry and there is a supply of approved insulating insulating oil. Connect the oil handling handling equipment and slowly remove the oil from the tap changer. Open the bleeder valve in the tap changer cover. 5.5.3.5 After the oil is removed, open the cover as per manufacturer manufacturer recommendation. recommendation. Flush (using (using the tube flush device) the insert with filtered oil, inserting the flushing nozzle down into the openings openings in the top casting casting to flush down the arcing arcing chamber. Disconnect Disconnect and remove the insert from the transformer following the manufacturer recommendations. Continue to flush Page 30 as it is being lifted, paying particular particular attention to the center, center, interphase drive tube both inside inside and out. When the flushing flushing is complete, drain the remaining remaining oil from the tap changer. changer. 5.5.3.6 Remove any remaining carbon from the insert and the housing using clean durable lint free wipers. 5.5.3.7 Check the support cylinder and internal insulating components. Inspect all insulation for  signs of deterioration including tracking, overheating and cracking. 5.5.3.8 Check the mechanical condition condition of the shafts, gearboxes gearboxes and pivot points for signs of wear  or misalignment. 5.5.3.9 Measure Measure the contact contact thickness of the moving and stationery stationery contacts contacts as per the manufacturer recommendations. Compare the readings with the recommended measurements. 5.5.3.10 Inspect the flexible shunts, contacts and joints for signs of fraying, heating or deterioration. 5.5.3.11 Measure the diverter resistors resistance values as per the manufacturer recommendation. Compare the results with the recommended values. 5.5.3.12 Re-install the tap changer insert into the transformer following the manufacturer  instructions. 5.5.3.13 Fill the tap changer compartment with new filtered oil and perform recommended bleeding  procedures. 5.5.3.14 Operate the tap changer manually one tap position in both directions (raise and lower). Check the operation of mechanism and linkages for any undue mechanical restriction,  binding, irregular operation, noises, etc. 5.5.3.15 Perform Perform any other checks recommended recommended by the manufacturer manufacturer to ensure the tap changer has  been assembled and installed correctly. co rrectly. 5.5.3.16 Check the gear lubricant levels and refill if necessary, using manufacturer’s recommended lubricant. 5.5.3.17 Check the mechanism / linkages for correct operation. Lubricate drive gears according to manufacturer recommendations 5.5.3.18 Check that the tap position indicator/linkage operates correctly. 5.5.3.19 Check the mechanical and electrical limits limits by operating operating the tap changer through its complete range of taps and attempt to overdrive (mechanically and electrically) at both ends of the tap range. limits must be checked manually first. first. NOTE: The limits 5.5.3.20 Test the RS 1000/2000 Bucholtz protective device. Page 31 5.5.3.21 Take an oil sample from the tap changer after it has been refilled. Perform a dielectric test to ensure the installed installed oil is of acceptable quality. quality. Compare Compare the results results with the manufacturer’s and GRENLEC’s recommended specifications. 5.5.3.22 Perform a ratio test on 5 tap positions - top, bottom, neutral, and both sides of neutral  positions. Record R ecord the results. 5.6 MAJO MA JOR R OV OVER ERHA HAULS ULS ON DI DISCO SCONN NNEC ECTS TS & AS ASSOC SOCIA IATE TED D EQ EQUI UIPM PMEN ENT T 5.6. 5. 6.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S 5.6. 5. 6.2 2 Micr Microo-oh ohm m Test Tester  er  Volt Volt / Ohm Ohm Mete Meter  r  Clip Clip on Amme Ammete ter  r  Recomm Recommend ended ed lubrica lubricants nts SPEC SP ECIA IAL L SA SAF FET ETY Y HA HAZ ZAR ARD DS Some points in the control cabinet of motor operated disconnect may be live even with all control switches open. If work is required on a live circuit, it may be necessary to arrange for isolation isolation at the source end of the circuit. circuit. 5.6. 5. 6.3 3 DISC DI SCON ONNE NECT CT SW SWIT ITCH CH IN INSP SPEC ECTI TION ON 5.6.3.1 Manually operate the switch and check: contact alignment, toggles, stops, linkage, undue insulator movement and general ease of operation 5.6.3.2 Check porcelain for chips or cracks, flashover burns, copper splash, copper wash, correct cementing cementing and fasteners. fasteners. Clean the porcelains porcelains if they are contaminated. contaminated. 5.6.3.3 Check contact pressure. Check jaw for correct compression. Observe jaw spread as blade closes into jaw. 5.6.3.4 Check contacts for burning, erosion or deterioration. 5.6.3.5 Check the wiping contacts for burning, erosion or deterioration. 5.6.3.6 Clean and lubricate the contacts with recommended lubricants. 5.6.3.7 Clean and lubricate the linkages with recommended lubricants. 5.6.3.8 Remove gearbox covers and inspect the gears, linkages, bearings, shafts and pins. Lubricate if necessary with approved lubricant. 5.6.3.9 Check that all the connections to the switch are tight with no signs of burning, damage, or  discoloration indicating heating. 5.6.3.10 Check that there is no undue stress stress on the insulator insulator stacks 5.6.3.11 Check the switch grounding connections are tight and undamaged. 5.6.3.12 Clean and paint corroded spots on linkages, mechanism or gearbox. 5.6.3.13 Operate the switch manually and electrically where so equipped. Page 32 5.6.3.14 Perform a micro-ohm test on switches that are in highly contaminated or corrosive environments. The readings on all three phases should be comparable. Measure Measure and record record the micro-ohm micro-ohm readings readings of each phase with the switch closed. Test leads should be placed between between the power leads on the connection connection terminals. terminals. Be sure that  both the power leads and test leads are making m aking a good connection with the connection terminal. 5.6. 5. 6.4 4 MOTO MO TOR R ME MECH CHAN ANIS ISM M IN INSP SPEC ECTI TION ON 5.6.4.1 Check the general condition condition of the operating operating mechanism. Look for loose, broken, corroded corroded wire/ terminals, loose contactor parts, burnt coils and contacts. Check fuses, connections, contactors (for signs of contact burning), insulation of control wire or (coils for signs of  deterioration). 5.6.4.2 Inspect the operating mechanism box for signs of corrosion, moisture, or damage. Check  cable entrances are properly sealed. Inspect seals for signs of contamination or aging. Check the door fits properly properly and the door secure. secure. 5.6.4.3 Check the operation of anti-condensation heaters. 5.6.4.4 Inspect Inspect the contacts of the auxiliary auxiliary switches. switches. Check for loose connections connections and erosion, erosion,  burning or chattering of o f contacts. c ontacts. Check Ch eck also the auxiliary switch linkage alignment for  wear & lubrication. Clean or adjust, if required. 5.6.4.5 Clean and lubricate the operating mechanism as per manufacturer’s instruction. Oil the  bearings in the operating mechanism. Use recommended recomm ended lubricant. 5.6.4.6 Inspect motor commutator and brushes for wear. 5.6.4.7 Check interlock switches and locking devices for proper operation. 5.6.4.8 Measure Measure and record record motor current current during open and close operation. 5.6. 5. 6.5 5 STA ST ATI TION ON BU BUS S IN INSP SPEC ECTI TION ON 5.6.5.1 Check the porcelain porcelain condition. Look for broken, chipped or cracked porcelain, porcelain, flashover  flashover   burns, copper splash, copper wash, correct cementing and fasteners. Clean the porcelains if  they are contaminated with dirt, dust or other pollutants. 5.6.5.2 Check that all the connections to the bus are tight with no signs of burning, damage, or  discoloration indicating heating. Ensure all locking washers are secure and not damaged. Check welded connections for cracks. 5.6.5.3 Check expansion connections for fraying, binding or damage to shunts. 5.6.5.4 Check that there is no undue stress on insulator stacks. 5.6.6 SURG SU RGE E AR ARRE REST STOR ORS S (L (LIG IGHT HTNI NING NG AR ARRE RESTO STORS RS)) 5.6.6.1 Check Check the porcela porcelain in for chips or cracks cracks,, flashov flashover er burns, burns, copper copper splash splash,, copper copper wash, wash, correct cementing and fasteners. Clean porcelains if contaminated. 5.6.6.2 Check that all the line and ground connections to the arrestor are tight with no signs of   burning, damage, d amage, or discoloration. disco loration. Page 33 5.7 5. 7 MAJO MA JOR R OV OVER ERHA HAUL ULS S ON IN INST STRU RUME MENT NT TR TRAN ANSF SFRM RMER ERS S 5.7. 5. 7.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S - 5.7. 5. 7.2 2 Oil Oil Sampl Samplee Equip Equipme ment nt Diel Dielec ectr tric ic Test Test Set Durabl Durablee Wipers Wipers/Cl /Cloth othss SPEC SP ECIA IAL L SA SAF FET ETY Y HA HAZ ZAR ARD DS The maintenance of Instrument Transformers should be carried out by trained maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions. Some points in the junction/conne junction/connection ction box may be live even with all the control switches open. If work is required on a live circuit arrange for isolation at the source end of the circuit. Safety Note: Make yourself aware of close-by live apparatus before starting to work  on the instrument transformers. transformers. 5.7.3 5.7 .3 INSTR IN STRUM UMEN ENT T TR TRAN ANSF SFOR ORMER MERS S IN INSP SPEC ECTIO TION N 5.7.3.1 Check the bushing / porcelain porcelain condition. condition. Look for broken, chipped chipped or cracked bushings/ bushings/  porcelain, flashover burns, copper splash, copper copp er wash, correct cementing c ementing and fasteners. Clean the bushings if they are contaminated. 5.7.3.2 Check valves, gaskets, gaskets, packing, and fittings fittings for any sign of oil leakage. leakage. 5.7.3.3 Check the oil level of the tank, adjusted adjusted to the temperature. temperature. 5.7.3.4 Check main tank, fittings, etc. for any sign of rusting, corrosion or damage. 5.7.3.5 Check the general condition condition of the junction/connec junction/connection tion box. Look for loose, broken, corroded wire/ terminals. Check fuses and connections for any sign of burning and insulation of control wire for signs deterioration. 5.7.3.6 Inspect the junction/connection box for any sign of corrosion, moisture, external contamination or damage. Check all cable entrances are properly sealed against rodents. Inspect Inspect weather/ rodent seals seals for any sign of external contamination contamination or aging. Check the cover fits properly and hardware keeps the cover secure. secure. Page 34 5.8 5. 8 MAJO MA JOR R OV OVER ERHA HAUL UL ON 33 33KV KV SW SWIT ITCH CHGE GEAR  AR  5.8. 5. 8.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S 5.8. 5. 8.2 2 - Micr Microo-oh ohm m Test Tester  er  - Circui Circuitt Breake Breakerr Timing Timing Tester  Tester  - Volt Volt / Ohm Ohm Mete Meter  r  - Clip Clip on Amme Ammete ter  r  - Minimu Minimum m Voltag Voltagee Tester  Tester  - Hi-P Hi-Pot ot Test Tester  er  - Foam oam Spr Spray - Recomm Recommend ended ed lubrica lubricants nts SAF SA FET ETY Y OF PER ERSO SONN NNEL EL The maintenance of vacuum circuit breakers should be carried out by trained maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions.  Isolate Isolate the equipment equipment and carry out a visual check to ensure ensure the equipment equipment is isolated isolated  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is overhauled.  Mark off the work area with signs and easily visible tape.  The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before working on any mechanism.  Follow the manufacturer’s recommendation to protect against radiation hazard while carrying out HI POT tests. 5.8 .8.3 .3 33KV 33 KV SW SWIT ITCH CHGE GEAR AR MA MAIN INTE TENA NANC NCE E 5.8.3.1 Record Record the counter reading before and after the overhaul. 5.8.3.2 Check the bushing condition. Clean the bushings if they are contaminated contaminated with dirt, dust or  other pollutants. 5.8.3.3 Inspect auxiliary switch contact - tighten loose connections. Check the auxiliary switch linkage alignment for wear & lubrication. Clean, lubricate or adjust as required. 5.8.3.4 Clean and lubricate the operating mechanism as per manufacturer’s instructions. Note the condition of the parts. Use only the recommended lubricant. 5.8.3.5 Check the operation of open/close position indicator/ linkage to ensure it is indicating correctly. Page 35 5.8.3.6 Check the charging spring indicator indicator in both the charged charged and discharged discharged position to ensure it is indicating correctly. 5.8.3.7 Check the mechanism measurement specifications as per the manufacturer’s instruction manual. 5.8.3.8 Check and record the measurements of the contact wear indicator as per the manufacturer  instruction manual. 5.9 5. 9 MAJO MA JOR R OV OVER ERHA HAUL UL ON 11 11KV KV SW SWIT ITCH CHGE GEAR  AR  5.9. 5. 9.1 1 SPEC SP ECIA IAL L TO TOOL OLS S AN AND D MA MATE TERI RIAL ALS S 5.9. 5. 9.2 2 - Micr Microo-oh ohm m Test Tester  er  - Circui Circuitt Breake Breakerr Timing Timing Tester  Tester  - Volt Volt / Ohm Ohm Mete Meter  r  - Clip Clip on Amme Ammete ter  r  - Minimu Minimum m Voltag Voltagee Tester  Tester  - Hi-P Hi-Pot ot Test Tester  er  - Foam oam Spr Spray - Recomm Recommend ended ed lubrica lubricants nts SAF SA FET ETY Y OF PER ERSO SONN NNEL EL The maintenance of vacuum circuit breakers should be carried out by trained maintenance  personnel and in accordance with this procedure and specific manufacturer’s instructions.  Isolate Isolate the equipment equipment and carry out a visual check to ensure ensure the equipment equipment is isolated isolated  Where visual check is not possible possible carry out checks with an approved approved voltage indicator  to ensure the equipment is fully isolated.  Ground the equipment  Ensure the circuit breaker and its mechanisms are disconnected from all power, both high voltage and control voltage before it is overhauled.  Mark off the work area with signs and easily visible tape.  The circuit breaker is composed of many mechanical devices, devices, which may be under  spring loading regardless of the operating position. Ensure all spring operating systems are fully discharged before working on any mechanism.  Follow the manufacturer’s recommendation to protect against radiation hazard while carrying out HI POT tests. Page 36 5.9 .9.3 .3 11KV 11 KV SW SWIT ITCH CHGE GEAR AR MA MAIN INTE TENA NANC NCE E 5.9.3.1 Record Record the counter reading before and after the overhaul. 5.9.3.2 Check the bushing condition. Clean the bushings if they are contaminated contaminated with dirt, dust or  other pollutants. 5.9.3.3 Inspect auxiliary switch contact - tighten loose connections. Check the auxiliary switch linkage alignment for wear & lubrication. Clean, lubricate or adjust as required. 5.9.3.4 Clean and lubricate the operating mechanism as per manufacturer’s instructions. Note the condition of the parts. Use only the recommended lubricant. 5.9.3.5 Check the operation of open/close position indicator/ linkage to ensure it is indicating correctly. 5.9.3.6 Check the charging spring indicator indicator in both the charged charged and discharged discharged position to ensure it is indicating correctly. 5.9.3.7 Check the mechanism measurement specifications as per the manufacturer’s instruction manual. 5.9.3.8 Check and record the measurements of the contact wear indicator as per the manufacturer  instruction manual. 5.10 5. 10 STAT ST ATIO ION N GR GROU OUND ND MA MAIN INTE TENA NANC NCE E This procedure should be used with the attached inspection report form plus copies of the Station Ground Network Drawing. Complete the report form and mark drawings to reflect the connections, test points used, the test results. 5.10.1 5.1 0.1 SPEC SP ECIAL IAL TO TOOL OLS S AN AND D MA MATE TERIA RIALS LS 5.10 5. 10.2 .2 Ground Ground/Ea /Earth rth Resist Resistance ance Tester  Tester  Micr Microo-oh ohmm mmet eter  er  Bonding Bonding Jumper Jumperss and Portab Portable le Ground Groundss SPEC SP ECIA IAL L SA SAFE FETY TY HA HAZA ZARD RDS S The maintenance inspection of Station Ground Networks should be carried out by trained maintenance personnel and in accordance with this procedure. A system fault may occur during a test. The use of Rubber Gloves is recommended. Proper  work clearances must be maintained at all times. Jumper ground connections requiring repairs to prevent electrocution if system conditions create a current flow while the connection is insecure. Page 37 5.10.3 5.1 0.3 GROU GR OUND ND NE NETW TWOR ORK K IN INSP SPEC ECTI TION ON 5.10.3.1 5.10.3.1 Visual Visual Inspec Inspection tion (above (above ground) ground) Inspect all station ground connections, cable and cable securing clips on equipment and structures structures.. Spot check bolted bolted connectors connectors for tightness. tightness. Note the location location of any problems problems on drawing. 5.10.3.2 5.10.3.2 Visual Visual Inspec Inspection tion (below (below ground) ground) Dig down and expose 10% of the buried cable cable and ground rod connections. connections. Use care not to separate separate any connections connections during the digging as lethal voltages voltages could develop. Inspect Inspect and note note on the drawin drawing g which which connec connectio tions ns were exposed exposed and any suspect suspected ed faults faults.. Refer Refer to this record before future future inspections inspections to ensure ensure that different different connections connections are exposed during each each inspect inspection ion.. Where Where numerous numerous defects defects are found more section sectionss must be dug up for  further inspection. 5.10 5.10.3 .3.3 .3 Repa Repair irss Repairs in an energized station are hazardous and must be carried out during periods of  good weather with no equipment switching switching.. Suitably Suitably sized bonds/ jumpers with with clean, tight connections connections must be used to bypass any connection to be opened. Bolted Bolted connections must must  be cleaned, greased and properly tightened and Cadweld joints re-welded. Repair activities must be noted in the report. 5.10 5. 10.4 .4 GROU GR OUND ND NE NETW TWOR ORK K TE TEST STS S Refer to the original commissioning test and subsequent maintenance test results to plan and execute a repetitive repetitive test scenario. scenario. Use the same test equipment equipment and test method as on  previous jobs. Compare current results to previous ones. Note recent weather patterns,  particularly rainfall, as this th is can affect the test result. resul t. Page 38 APPENDIX 6.1 INSPECTION SHEETS Page 39 SUBSTATION IN SERVICE INSPECTION SHEET Substation/Location: Inspection Date: Item No. Descriptions (Inspection/Checks) 1 1.1 1.2 1.3 Disc Disconn onnec ectt Switc Switch h Inspe Inspect ction ion Switch Switch (prop (properly erly closed/op closed/opened ened & in req. op. position) position) Porcelain Porcelain Condition Condition (dirt, chips, chips, flashover) flashover) Linkages Linkages,Oper ,Operating ating Handles, Handles, (damage (damage & correct correct positioning) Motor Mechanis Mechanism m (damage, (damage, corrosion corrosion)) Anti Condens Condensation ation Heaters Heaters (working (working)) Station Station Bus & Surge Surge Arres Arrester ter Inspect Inspection ion Porcelain Porcelain Condition Condition (Chip, (Chip, flashover, flashover, burns, burns, dirt) Bus Connectio Connections ns (Discolor (Discoloration ation,, damage, damage, heating/burning, ti ghtness) ghtness) Vacu Vacuum um Circ Circuit uit Brea Breake ker  r  Operating Operating Mechanis Mechanism/Con m/Control trol Cabinet, Cabinet, Tank (damage/corrosion/deterioration) Anti Condens Condensation ation Heaters Heaters (working (working)) Transfo Transforme rmerr & Tap Changer Changer Inspec Inspection tion Main Main tank/ta tank/tap-c p-chan hanger ger oil levels levels Pressure Pressure gauges gauges on sealed sealed tanks (+ve pressur pressure) e) Silica Silica gel gel - Main Main Tank Tank/Ta /Tap p Chan Changer ger (Dry/Wet (Dry/Wet)) Valves, welds, welds, gaskets gaskets (damage/lea (damage/leakage kage)) Control Control Cabinet/Tan Cabinet/Tank/Tap k/Tap Changer Changer operating operating mechanism mechanism (deterioration, corrosion, damage) Fan operation operation (correct (correct rotation, rotation, radiators radiators free of debri) debri) Anti Anti Conden Condensa sation tion Unit Unit (work (working ing)) Oil & Winding Temperatures (Normal Readings) Instrument Transformers Tank (deterioration, corrosion, damage, leakage) Marshalling Boxes (Corrosion, damage) Structure Inspection Foundation (Cracks, shifting, deterioration) Structures (deterioration, corrosion) 1.4 1.5 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 4.3 4.4. 4.5 4.6 4.7 4.8 5 5.1 5.2 6 6.1 6.2 Observations/Readings Corrections Carried out Date Description Engineer: TRANSFORMER TRANSFORMER IN SERVICE INSPECTION SHEET Substation/Location: Inspection Date: Transformer S.N.: MVA Rating Manufacturer: Year of Manufacture Voltage Rating HV/LV: Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Descriptions (Inspection/Checks) Pain Painte ted d Surfa Surface ce Bushin Bushing g Condi Conditio tion n Fans (Check (Check operation/ operation/curre current) nt) Motors (Check (Check operation/ operation/curre current) nt) Transformer Transformer tank, tank, fittings fittings - genera generall conditio condition n Radiator/Co Radiator/Cooler oler Condition Condition Press Pressure ure Relief Relief Devic Device e - Tank Tank Pressure Pressure Relief Relief Device Device - Diverter Diverter Sw. Winding Temperature Temperature Deg. C. (Cur./Max) (Cur./Max) Oil Temperatu Temperature re Deg. Deg. C (Cur./ (Cur./ Max.) Oil Level Level - Tap Tap Chan Changer  ger  Oil Level Level - Main Main Tank Tank Pressure Pressure (gauge) (gauge) reading reading Valves, Gaskets Gaskets (Leaks (Leaks - gas or oil) Silica Silica gel gel - Tap Tap Chan Changer  ger  Test Dielectric Str. kV* Hydran, ppm T.C. Sensing Volts  Auxiliary Volts  Ambient Temp. Deg. C Humidity Test Test Equi Equipm pmen entt Observation/Readings Date Resu Result lt Corrections Carried out Description TRANSFORMER TRANSFORMER IN SERVICE INSPECTION SHEET Test Dielectric Str. kV* Hydran, ppm T.C. Sensing Volts  Auxiliary Volts  Ambient Temp. Deg. C Humidity Substation/Location: Inspection Date: Transformer S.N.: MVA Rating Manufacturer: Year of Manufacture Voltage Rating HV/LV: Item No. Descriptions (Inspection/Checks) Test Test Equi Equipm pmen entt Observation/Readings Date Resu Result lt Corrections Carried out Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Pain Painte ted d Surfa Surface ce Bushin Bushing g Condi Conditio tion n Fans (Check (Check operation/ operation/curre current) nt) Motors (Check (Check operation/ operation/curre current) nt) Transformer Transformer tank, tank, fittings fittings - genera generall conditio condition n Radiator/Co Radiator/Cooler oler Condition Condition Press Pressure ure Relief Relief Devic Device e - Tank Tank Pressure Pressure Relief Relief Device Device - Diverter Diverter Sw. Winding Temperature Temperature Deg. C. (Cur./Max) (Cur./Max) Oil Temperatu Temperature re Deg. Deg. C (Cur./ (Cur./ Max.) Oil Level Level - Tap Tap Chan Changer  ger  Oil Level Level - Main Main Tank Tank Pressure Pressure (gauge) (gauge) reading reading Valves, Gaskets Gaskets (Leaks (Leaks - gas or oil) Silica Silica gel gel - Tap Tap Chan Changer  ger  Silica Silica gel gel - Main Main Tank Tank No. of Tap Tap Changer Changer Operations Operations (Found/Left) (Found/Left) Tap Chang Changer er Position Position Min/Presen Min/Present/Max t/Max Electrical Electrical Conne Connections ctions - Infrared Infrared 20 Noise/Vibration 21 Buchholz Ralay & Gas Catcher Divice 22 Temperature Indication Test (Cooling/Alarm/Trip) 23 Control Cabinet: 23.1 Moisture, seals, contamination, Cable entrances 23.2 Anti Condensation Heaters 23.3 Wiring, contactors, coils, connections, insulation Engineer: 12/17/2012 Appendix 6.1 Inspection Sheets TAP CHANGER INSPECTION SHEET Substation: Date: Transformer Serial # Tap Changer Manufacturer  Tap Changer Serial # # of Tap Changer Op Found # of Tap Changer Op Left Item No. 1 1.1 1.2 1.3 1.3 1.4 1.4 1.5 1.6 1.7 1.8 2 3 4 Descriptions (Inspections/Checks) Contacts Pitting Burning All Allignm ignmen entt Free Freedo dom m of move moveme ment nt Spring Pressure  Arc resistance m aterial Heating in current carrying parts Support Cylinder and Insulating Components (Check for tracking, cracking, wear and misalignment) Flexible Shunts, connections and Joints - Check for  fraying, heating and deterioration Fasteners Operating Mechanism Measurements  Ambient Temperature Deg C Humidity Oil Temperature Reading Deg. C Winding temperature Reading Deg C Oil Dielectric Test, kV Contact Thickness, mm Contact Resistance Values, Ohms Observations/Readings Remarks Compare with Manufacturer  Values Corrective Actions Carried Out Date Description TAP CHANGER INSPECTION SHEET Substation: Measurements  Ambient Temperature Deg C Humidity Oil Temperature Reading Deg. C Winding temperature Reading Deg C Oil Dielectric Test, kV Contact Thickness, mm Contact Resistance Values, Ohms Date: Transformer Serial # Tap Changer Manufacturer  Tap Changer Serial # # of Tap Changer Op Found # of Tap Changer Op Left Item No. 1 1.1 1.2 1.3 1.3 1.4 1.4 1.5 1.6 1.7 1.8 2 3 4 4.1 4.2 4.3 4.4 4.5 5 6 7 8 9 10 Descriptions (Inspections/Checks) Observations/Readings Remarks Compare with Manufacturer  Values Corrective Actions Carried Out Date Description Contacts Pitting Burning All Allignm ignmen entt Free Freedo dom m of move moveme ment nt Spring Pressure  Arc resistance m aterial Heating in current carrying parts Support Cylinder and Insulating Components (Check for tracking, cracking, wear and misalignment) Flexible Shunts, connections and Joints - Check for  fraying, heating and deterioration Fasteners Operating Mechanism Do manual operation and check for binding, mechanical restriction, noise and irregular operation Mechanical & Electrical Limits Mechanical linkages operation & lubrication Belt Gear Box Lubricant Level Tap Position Indicator  Liquid level indicator operation Buchholz Relay Pressure relief valve - exhaust screen Control wire connections tightness Voltage relay time delay Setting (0.5-1s req.) Engineer: BUSWORK & INSULATOR INSPECTION SHEET (QUEENS PARK) Bus Insulators, Surge Arresters, Instrument Transformers, Substation/Location: Queens Park Inspection Date: Item No. 1 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.6 1.7 1.8 2 2.1 2.1 2.2 2.2 2.3 2.3 2.4 2.4 2.5 2.6 2.7 3 Decsription Observation/Readings (Inspections/Checks) Identify equipment: Bus Insulator Insulator Porcelain Porcelain Condition Condition Line Line 1 Line Line 2 Line Line 3 Line Line 4 Transf Transform ormer er T1 Transf Transform ormer er T2 Transf Transform ormer er T3 Transf Transform ormer er T4 Surge Arresters & Potential Transformers, Disconnect Switch, Porcelain Condition Line Line 1 Line Line 2 Line Line 3 Line Line 4 Transf Transform ormer er T1 Transf Transform ormer er T2 Transformer T3 Transf Transform ormer er T4 Conductors & Connectors, Transformer, PTS, RATING Test Equipment Binoculars Infrared Camera Manufacturer  Corrections Carried out Date Description BUSWORK & INSULATOR INSPECTION SHEET (QUEENS PARK) Bus Insulators, Surge Arresters, Instrument Transformers, Substation/Location: Queens Park Inspection Date: Item No. 1 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.6 1.7 1.8 2 2.1 2.1 2.2 2.2 2.3 2.3 2.4 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Test Equipment Binoculars Infrared Camera Decsription Observation/Readings (Inspections/Checks) Identify equipment: Bus Insulator Insulator Porcelain Porcelain Condition Condition Line Line 1 Line Line 2 Line Line 3 Line Line 4 Transf Transform ormer er T1 Transf Transform ormer er T2 Transf Transform ormer er T3 Transf Transform ormer er T4 Surge Arresters & Potential Transformers, Disconnect Switch, Porcelain Condition Line Line 1 Line Line 2 Line Line 3 Line Line 4 Transf Transform ormer er T1 Transf Transform ormer er T2 Transformer T3 Transf Transform ormer er T4 Conductors & Connectors, Transformer, PTS, RATING A B C Disconnector (Thermovision). Line 1 Line 2 Line 3 Line 4 Transformer T1 Transformer T2 Transformer T3 Transformer T4 Manufacturer  Corrections Carried out Date Description D Engineer: BUSWORK & INSULATOR INSPECTION SHEET (GRAND (GRAND ANSE) Bus Insulators, Surge Arresters, Instrument Transformers, Substation/Location: Grand Anse Inspection Date: Item No. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Description (Inspection/Checks) Identify equipment with Defects: Bus Insulator Insulator Porcelain Porcelain Condition Condition 33kV 33kV Bay 1 33kV 33kV Bay 2 33kV 33kV Bay 3 33kV 33kV Bay 4 33kV 33kV Bay 5 Transformer Transformer T1 & 11kV Bay Transformer Transformer T2 & 11kV Bay Surge Arreste Arresters rs & Potential Potential Transforme Transformers, rs, Disconnect Switch, Porcelain Condition 33kV 33kV Bay 1 33kV 33kV Bay 2 33kV 33kV Bay 3 33kV 33kV Bay 4 33kV 33kV Bay 5 Transformer Transformer T1 & 11kV Bay Transformer Transformer T2 & 11kV Bay Test Equipment Binoculars Infrared Camera Observat io ions/Readings Date Manufacturer  Corrections Carried out Description BUSWORK & INSULATOR INSPECTION SHEET (GRAND (GRAND ANSE) Bus Insulators, Surge Arresters, Instrument Transformers, Substation/Location: Grand Anse Inspection Date: Item No. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Test Equipment Binoculars Infrared Camera Description (Inspection/Checks) Identify equipment with Defects: Bus Insulator Insulator Porcelain Porcelain Condition Condition 33kV 33kV Bay 1 33kV 33kV Bay 2 33kV 33kV Bay 3 33kV 33kV Bay 4 33kV 33kV Bay 5 Transformer Transformer T1 & 11kV Bay Transformer Transformer T2 & 11kV Bay Observat io ions/Readings Date Manufacturer  Corrections Carried out Description Surge Arreste Arresters rs & Potential Potential Transforme Transformers, rs, Disconnect Switch, Porcelain Condition 33kV 33kV Bay 1 33kV 33kV Bay 2 33kV 33kV Bay 3 33kV 33kV Bay 4 33kV 33kV Bay 5 Transformer Transformer T1 & 11kV Bay Transformer Transformer T2 & 11kV Bay Conductors & Connectors, Transformer, PTS, Disconnector (Thermovision). 33kV Bay 1 33kV Bay 2 33kV Bay 3 33kV Bay 4 33kV Bay 5 Transformer T1 & 11kV Bay Transformer T2 & 11kV Bay - RATING A B C D Engineer: STRUCTURE AND FOUNDATION INSPECTION SHEET Substation/Location: Inspection Date: Item No. 1 2 3 4 5 6 7 7.1 7.2 7.3 7.4 7.5 7.6 Test Thermovision Description (Inspections/Checks) Foundation (Cracking, shifting, deterioration) deterioration) Steel Support Structures (Peeling, corrosion) Circuit Breaker & Switchgear Structures (Corrosion) Structure Grounding Secure Equipment (Circuit Breakers, Switchgears, Switchgears, Marshalling Marshalling Kiosk, Disconnects) Grounding Secure Fencing (deterioration, ground connection) Junction Junction Boxes, Boxes, PT Marshalling Marshalling Boxes Boxes (Moisture (Moisture,, contaminations, seals, wiring, connections, insulation) PT Marshalling Boxes Marshalling Kiosk PT Junction Box Disconnect Switch Auxiliary Switch (proper functioning) Disconnect Switch Motor Box Disconnect Switch Interlocking device Observations/ Readings Test Equipment Date Corrections Carried out Description STRUCTURE AND FOUNDATION INSPECTION SHEET Substation/Location: Inspection Date: Item No. 1 2 3 4 5 Test Thermovision Description (Inspections/Checks) Observations/ Readings Test Equipment Date Corrections Carried out Description Foundation (Cracking, shifting, deterioration) deterioration) Steel Support Structures (Peeling, corrosion) Circuit Breaker & Switchgear Structures (Corrosion) Structure Grounding Secure Equipment (Circuit Breakers, Switchgears, Switchgears, Marshalling Marshalling Kiosk, Disconnects) Grounding Secure Fencing (deterioration, ground connection) 6 7 Junction Junction Boxes, Boxes, PT Marshalling Marshalling Boxes Boxes (Moisture (Moisture,, contaminations, seals, wiring, connections, insulation) 7.1 7.2 7.3 7.4 7.5 7.6 PT Marshalling Boxes Marshalling Kiosk PT Junction Box Disconnect Switch Auxiliary Switch (proper functioning) Disconnect Switch Motor Box Disconnect Switch Interlocking device Engineer: CIRCUIT BREAKER INSPECTION SHEET Substation/Location: Inspection Date: Circuit Breaker S.N.:  Ampere Rating Manufacturer: Year of Manufacture Voltage Rating: Item No. 1 2 3 3.1 3.2 3.3 4 5 6 7 8 Test/Measurement Conta ntact Wear Wear Phase hase A, mm Conta ntact Wear Wear Phase hase B, mm Contact Wear Phase C, mm  Auxiliary Volts, VAC/VDC  Ambient Temp. Deg. C Humidity Description (Inspection/Checks) Equipment Equipment structure structure & painted painted Surfac Surface e (conditi (condition) on) Bushing/Porcelain Bushing/Porcelain Condition (dirt, chips, burns, fastners) Control Control & Operat Operator or Mecha Mechanism nism Compartme Compartments: nts: Compartment General Condition (Moisture, contamination, rusting, corrosion or damage, weather, & rodent seals) Compartment Control Circuits (Wiring, contactors, contactors, coils, coils, connections, connections, insulation, insulation, fuses) Anti Condensation Condensation Heaters (operation) Motors Motors (Chec (Check k operati operation/me on/measure asure current) current) Operating mechanism (etc. bearings, linkages, lubrication, cleansliness, smooth manual operation); Clean & lubricate Position Position Indic Indicator ator (trip (trip & close close and and check check operati operation) on) Charging Charging Spring Spring (check (check indicati indication on in both both charge charged d and discharged pos., defects, tightness, cracks) Auxiliary Auxiliary switches switches (chec (check k contacts, contacts, check check alignmen alignmentt and Result Observation/Readings Date Test # of Opera perati tio on # of opera perati tio on left left Result Corrections Carried out Description CIRCUIT BREAKER INSPECTION SHEET Substation/Location: Inspection Date: Circuit Breaker S.N.:  Ampere Rating Manufacturer: Year of Manufacture Voltage Rating: Item No. 1 2 3 3.1 Test/Measurement Conta ntact Wear Wear Phase hase A, mm Conta ntact Wear Wear Phase hase B, mm Contact Wear Phase C, mm  Auxiliary Volts, VAC/VDC  Ambient Temp. Deg. C Humidity Description (Inspection/Checks) Result Observation/Readings Date Test # of Opera perati tio on # of opera perati tio on left left Result Corrections Carried out Description Equipment Equipment structure structure & painted painted Surfac Surface e (conditi (condition) on) Bushing/Porcelain Bushing/Porcelain Condition (dirt, chips, burns, fastners) Control Control & Operat Operator or Mecha Mechanism nism Compartme Compartments: nts: Compartment General Condition (Moisture, contamination, rusting, corrosion or damage, weather, & rodent seals) Compartment Control Circuits (Wiring, contactors, contactors, coils, coils, connections, connections, insulation, insulation, fuses) Anti Condensation Condensation Heaters (operation) Motors Motors (Chec (Check k operati operation/me on/measure asure current) current) Operating mechanism (etc. bearings, linkages, lubrication, cleansliness, smooth manual operation); Clean & lubricate Position Position Indic Indicator ator (trip (trip & close close and and check check operati operation) on) Charging Charging Spring Spring (check (check indicati indication on in both both charge charged d and discharged pos., defects, tightness, cracks) Auxiliary Auxiliary switches switches (chec (check k contacts, contacts, check check alignmen alignmentt and lubrication of linkages) Relay Relay Conditio Condition n (contacts (contacts)) Electrica Electricall Connect Connections ions (Infrared (Infrared test) test) Trip/Close Operation (Noise/Vibration, Counter) Vacuum Bottle (contact erosion, note wear) Counter Operation (operate/note counter reading) 3.2 3.3 4 5 6 7 8 9 10 11 12 13 Engineer: SWITCHGEAR INSPECTION SHEET Substation/Location: Inspection Date: Circuit Breaker S.N.:  Ampere Rating Manufacturer: Year of Manufacture Voltage Rating: Item No. 1 2 3 3.1 3.2 3.3 4 5 6 7 Test/Measurement Contac ntactt Wea Wear Phas Phase e A, mm Contac ntactt Wea Wear Phas Phase e B, mm Contact Wear Phase C, mm  Auxiliary Volts, VAC/VDC  Ambient Temp. Deg. C Humidity Description (Inspection/Checks) Equipment Equipment structure structure & painted painted Surface Surface (condit (condition) ion) Bushing Bushing Condi Condition tion (dirt, (dirt, chips, chips, burns, burns, fastners) fastners) Control Control & Operato Operatorr Mechan Mechanism ism Compartmen Compartments: ts: Compartment General Condition (Moisture, contamination, contamination, rusting, corrosion or damage, weather, & rodent seals) Compartment Control Circuits (Wiring, contactors, contactors, coils, coils, connections, insulation, fuses) Anti Condensation Condensation Heaters (operation) Motors Motors (Check (Check opera operation tion/meas /measure ure current) current) Operating mechanism (etc. bearings, linkages, lubrication, lubrication, cleansliness, smooth manual operation); Clean & lubricate Position Position Indic Indicator ator (trip (trip & close close and and check check operatio operation) n) Charging Charging Spring Spring (check (check indicat indication ion in in both charged charged and discharged pos., defects, tightness, cracks) Result Observat io ion/Readings Date Test # of Oper Opera ation tion fou found # of oper opera ation tion left Result Corrections Carried out Description SWITCHGEAR INSPECTION SHEET Substation/Location: Inspection Date: Circuit Breaker S.N.:  Ampere Rating Manufacturer: Year of Manufacture Voltage Rating: Item No. 1 2 3 3.1 3.2 3.3 4 5 6 7 8 9 10 11 12 Test/Measurement Contac ntactt Wea Wear Phas Phase e A, mm Contac ntactt Wea Wear Phas Phase e B, mm Contact Wear Phase C, mm  Auxiliary Volts, VAC/VDC  Ambient Temp. Deg. C Humidity Description (Inspection/Checks) Result Observat io ion/Readings Date Test # of Oper Opera ation tion fou found # of oper opera ation tion left Result Corrections Carried out Description Equipment Equipment structure structure & painted painted Surface Surface (condit (condition) ion) Bushing Bushing Condi Condition tion (dirt, (dirt, chips, chips, burns, burns, fastners) fastners) Control Control & Operato Operatorr Mechan Mechanism ism Compartmen Compartments: ts: Compartment General Condition (Moisture, contamination, contamination, rusting, corrosion or damage, weather, & rodent seals) Compartment Control Circuits (Wiring, contactors, contactors, coils, coils, connections, insulation, fuses) Anti Condensation Condensation Heaters (operation) Motors Motors (Check (Check opera operation tion/meas /measure ure current) current) Operating mechanism (etc. bearings, linkages, lubrication, lubrication, cleansliness, smooth manual operation); Clean & lubricate Position Position Indic Indicator ator (trip (trip & close close and and check check operatio operation) n) Charging Charging Spring Spring (check (check indicat indication ion in in both charged charged and discharged pos., defects, tightness, cracks) Auxiliar Auxiliary y switche switches s (check (check contacts, contacts, check check alignmen alignmentt and lubrication of linkages) Relay Relay Conditio Condition n (contacts) (contacts) Electrica Electricall Connecti Connections ons (Infrare (Infrared d test) test) Trip/Close Operation (Noise/Vibration, Counter) Vacuum Bottle (contact erosion, note wear) Engineer: DISCONNECT SWITCH INSPECTION SHEET Substation/Location: Inspection Date: Disconnect Switch S.N. Type/Model: Manufacturer/Year: Operating Position Voltage/Current Rating: Mechanism Type: Item No. 1 Description (Inspections/Checks) Manual Manual Operati Operation on (align (alignment ment,, togg toggles les,, linkages) 2 Porcel Porcelain ain Condit Condition ion (chips (chips,, dirt, dirt, burn burns) s) 3 Cont ontact 3.1 (Pressure/Compre (Pressure/Compression ssion)) Test/Measurements Equipment Result Contact Resistance Thermovision Reading  Auxiliary Volts (Motor   Ambient Temp. Deg. C Obse Observ rvat atio ions ns/R /Rea eadi ding ngs s Corr Correc ecti tion ons s Carr Carrie ied d Out Out Date Description DISCONNECT SWITCH INSPECTION SHEET Substation/Location: Inspection Date: Disconnect Switch S.N. Type/Model: Manufacturer/Year: Operating Position Voltage/Current Rating: Mechanism Type: Item No. 1 2 3 3.1 3.2 3.3 4 5 6 7 8 9 10 11 12 12.1 12.2 12.3 13 14 15 16 17 18 19 20 21 Description (Inspections/Checks) Manual Manual Operati Operation on (align (alignment ment,, togg toggles les,, linkages) Porcel Porcelain ain Condit Condition ion (chips (chips,, dirt, dirt, burn burns) s) Cont ontact (Pressure/Compre (Pressure/Compression ssion)) (Burning, (Burning, erosion, erosion, deterioratio deterioration) n) Lubrica Lubricate te Contac Contacts ts Hinge Hinge End Shunt Shunt (Burnin (Burning, g, erosio erosion, n, deterioration) Lubr Lubric icat ate e linka linkage ges s Gear Gear Box Box (gear (gears, s, linkag linkages, es, bearin bearings gs and pins) lubricate if necessary. Connec Connectio tions ns (tightn (tightness ess,, burning burning,, damage, discoloration) Insulat Insulator or Stacks Stacks (Undue (Undue stress) stress) Groundi Grounding ng Connec Connectio tions ns (tightn (tightness ess)) Clean and paint corroded corroded linkages linkages and mechanisms Test operate operate discon disconnec nectt switch switch Contact Contact Resista Resistance nce Conection Conection to Connect Connection ion Phase Phase A, A, μΩ Conection Conection to Connect Connection ion Phase Phase B, B, μΩ Conection Conection to Connect Connection ion Phase Phase C, C, μΩ Motor Motor Mech Mechani anism sm Insp Inspect ection ion Mechan Mechanism ism Cabine Cabinett (Wiring, Contactors, Contactors, coils, connection connections, s, insulation (Corrosion, moisture, contamination, cable entrances, seals) Anti Condensation Heaters (operation) Auxiliary switches (contacts, alignment and linkages Lubricate operateing mechanism Motor comutator brushes Interlock switches & locking devices Engineer: Test/Measurements Equipment Result Contact Resistance Thermovision Reading  Auxiliary Volts (Motor   Ambient Temp. Deg. C Obse Observ rvat atio ions ns/R /Rea eadi ding ngs s Corr Correc ecti tion ons s Carr Carrie ied d Out Out Date Description SUBSTATION GROUND GRID INSPECTION SHEET Substation/Location: Inspection Date: Grounding Layout Drawing #  Area of Ground Grid, m Item No. 1 2 3 Test/Measurement Recent Weather Conditions 2 Description (Inspection/Checks) Observation/Readings Date Correction Carried out Description Joi Joints nts Structure Structure Connecti Connections ons Conne Connecti ction on Proble Problem m Engineer: 125 VDC BATTERY CELL CHANGE OUT SHEET Measurements: Ambient Temperature: Battery Room Temp: Humidity: Substation/Location: Inspection Date: Date Battery Installed: Manufacturer: Year of Manufacture Rated Ampere Hour: Voltage Rating VDC: Battery Type: Battery Battery Cell Changed Changed (#) Reason for Change Comments 125 VDC BATTERY CELL CHANGE OUT SHEET Measurements: Ambient Temperature: Battery Room Temp: Humidity: Substation/Location: Inspection Date: Date Battery Installed: Manufacturer: Year of Manufacture Rated Ampere Hour: Voltage Rating VDC: Battery Type: Battery Battery Cell Changed Changed (#) Engineer/Supervisor: Reason for Change Comments BATTERY AND CHARGER INSPECTION SHEET Substation/Location: Inspection Date: Date Battery & Charger Installed: Battery: Battery Manufacturer/Year: Rated Ampere Hour: Voltage Rating VDC: Battery Type: Item No. 1.0 1.1 Description/ (Inspection/Checks) 1.2 1.3 1.4 2.0 2.1 2.2 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 Battery Battery Cell (Inspectio (Inspection) n) Deterioration (Buckling, charring, sedimentation plate growth) Deteriora Deterioration tion (Cracked (Cracked cells cells,, acid acid attack attack)) Connections/terminals Connections/terminals (corrosion, discoloration) discoloration) Battery Battery jar & covers covers (leaks) (leaks) Pilot cell (Measureme (Measurements) nts) Relative density/specific density/specific gravity (if charge charge is is required) required) Pilot Pilot Cell Voltage, Voltage, Volts Volts Batter Battery y Tests Tests Peak Load Load Test Test (abilit (ability y to supply supply peak peak load) load) Steady Steady Load Load Test (capac (capacity ity to to supply supply steady steady load) load) Impeda Impedance nce Test Test Electr Electroly olyte te Level Level Equaliz Equalize e Batteries Batteries Charge Chargerr Inspec Inspectio tion n Calibrate Calibrate Voltmeter  Voltmeter  Calibr Calibrate ate Ammeter  Ammeter  Clean Clean Charg Charger er (dust, (dust, conta contaminat mination) ion) Contacts, timers, relays (burning, heating, deterioration) 4.5 5.0 5.1 5.2 6.0 6.1 Calibration (under-voltage/over-voltag (under-voltage/over-voltage e alarms) Meter Meter Readin Readings gs DC Voltag Voltage, e, VDC VDC (deviat (deviation ion from normal normal range) range) Amp Readi Readings, ngs, A (deviat (deviation ion from from normal normal range range)) Enviro Environme nment: nt: Battery Battery Room Room Temper Temperature ature (20 - 25Deg 25Deg C) C) Charger: Charger Manufacturer/Year: Charger Type: Ambient Temperature, Deg. C Observations/ Readings Engineer/Supervisor: APPENDIX 6.2 TEST SHEETS Date Corrections Carried Out Descriptions APPENDIX 6.2 TEST SHEETS TURNS RATIO TEST (TTR) Substation: Date: Transformer S.N.: Manufacturer: Year of Manufacturer: Voltage Rating HV/LV: Humidity  Ambient Temperature I te tem No. Tap Changer Manufacturer  Year of manufacture Serial No. Type No. of Operations kV Co nn nn ec ectio ns ns Ratio Tap Positions Positions 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 17 Voltage Design Ratio 1 1.1 1.2 1.3 Star Star - Delta Delta (Ynd-1 (Ynd-1)) Phase A (H1-Ho:X1-X2) Phase B (H2-Ho:X2-X3) Phase C (H 3-Ho:X3-X1) 1.4 1.5 2 2.1 2.2 2.3 Maximum Maximum Variati Variation on (%) Max Curre Current nt mA Delt Delta a - Star Star (Dyn (Dyn1) 1) Phase A (H1-H3:X1-Xo) Phase B (H2-H1:X2-Xo) Phase C(H3-H2:X3-Xo) 2.4 2.5 Maximum Maximum Variati Variation on (%) Max Curre Current nt mA Max allowed = 0.5% Notes 1. Perform Null & Unity Ratio checks 2. Check winding polarity 3. Do not change connection connection until the test set is deenergised deenergised Engineer/Supervisor  Date: Page 1 12/17/2012 Appendix 6.2 Test Sheets INSULATION RESISTANCE (IR) TEST SHEET Substation/Location: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV, kV: Test Equipment Manufacturer  Model Winding Temp, Deg. C  Ambient Temperature: Deg C Temperature Correction Humidity: Item No. Test Oil Temp, Deg. C Test Volts 1 1.1 1.1 1.2 1.2 1.3 Megger - Insulation HV to LV and and Grou Ground nd LV to HV and and Grou Ground nd HV to LV 5 KV 2 2.1 Core Insulat io ion Res. Core Core ground ground strap strap - 500V 15 15s 30s 1m 2m 3m Resistance Readings - M Ohms 4m 5m 6m 7m 8m 9m 10m A.I. P.I. INSULATION RESISTANCE (IR) TEST SHEET Substation/Location: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV, kV: Test Equipment Manufacturer  Model Winding Temp, Deg. C  Ambient Temperature: Deg C Temperature Correction Humidity: Item No. Test Oil Temp, Deg. C Test Volts 15 15s 30s 1 1.1 1.1 1.2 1.2 1.3 Megger - Insulation HV to LV and and Grou Ground nd LV to HV and and Grou Ground nd HV to LV 5 KV 2 2.1 Core Insulat io ion Res. Core Core ground ground strap strap tank ground 500V P.I. P.I. A.I. A.I. Polari Polarizat zation ion Index Index Absor Absorpti ption on Index Index 10m reading/1m Reading 1m reading/30s Reading Tested by: Date:  Approved: Date: 1m 2m 3m Resistance Readings - M Ohms 4m 5m 6m 7m 8m 9m A.I. 10m P.I. WINDING RESISTANCE TEST SHEET Substation: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV: Connection Item No. 1 Tester (Manufacturer/Model Ambient Temp Winding Temp Deg. C Deg. C Readings Description Tap Position Dial Position I % Ohms Amps 2 2.1 ye with Neutral RAY (R AN) (H1-H0/X1-X0) 2.2 RBY (RBN) (H2-H0/X2-X0) 2.3 RCY (RCN) (H3-H0/X3-X0) 2.4 RT =R AN + R BN + R CN 2.5 RTC = R T * (T S +TK)/(TM + T K) 3 3.1 Delta RAD (R AB)(H1-H2/X1-X2) 3.2 RBD (RBC)(H2-H3/X2-X3) inding Unit Dial Position I % Res. Ohms Amps inding Unit Dial Position I % Res. Ohms Amps inding Unit Res. WINDING RESISTANCE TEST SHEET Substation: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV: Connection Item No. 1 Tester (Manufacturer/Model Ambient Temp Winding Temp Deg. C Deg. C Readings Description Tap Position Dial Position I % Ohms Amps 2 2.1 ye with Neutral RAY (R AN) (H1-H0/X1-X0) 2.2 RBY (RBN) (H2-H0/X2-X0) 2.3 RCY (RCN) (H3-H0/X3-X0) 2.4 RT =R AN + R BN + R CN 2.5 RTC = R T * (T S +TK)/(TM + T K) 3 3.1 Delta RAD (R AB)(H1-H2/X1-X2) 3.2 RBD (RBC)(H2-H3/X2-X3) 3.3 RCD (RCA)(H3-H1/X3-X1) 3.4 RT = /2*(R AB + R BC + R CA) 3.5 RTC = R T * (T S +TK)/(TM + T K) TM Measured temperature TS Reference temperature (Temp rise + 30 deg. C.) TK 234.5 (for Cu) inding Unit Dial Position I % Res. Ohms Amps Tested by: Date:  Approved Date: inding Unit Dial Position I % Res. Ohms Amps EXCITATION CURRENT TEST SHEET Substation: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV: Tester:  Ambient Temperature: Temperature Correction Factor: Humidity: Item No. Test Readings Volts 1 1.1 1.1. 1.1.1 1 1.1. 1.1.2 2 1.1. 1.1.3 3 Exci Excita tati tion on Curr Curren entt Test Test Method I Phas Phase eA Phas Phase eB Phas Phase eC Deviation (%) Amps Remarks inding Unit Res. EXCITATION CURRENT TEST SHEET Substation: Date: Transformer S.N.: MVA Rating Manufacturer: Voltage Rating HV/LV: Tester:  Ambient Temperature: Temperature Correction Factor: Humidity: Item No. Test Readings 1 1.1 1.1. 1.1.1 1 1.1. 1.1.2 2 1.1. 1.1.3 3 Deviation (%) Remarks Amps Volts Exci Excita tati tion on Curr Curren entt Test Test Method I Phas Phase eA Phas Phase eB Phas Phase eC Excitation Current Test Method I Test Voltage = 10% phase voltage (lower voltages may be used). Engineer: 125 VDC BATTERY TEST SHEET Substation/Location: Inspection Date: Date Battery Installed: Manufacturer: Year of Manufacture Rated Ampere Hour: Voltage Rating VDC: Battery Type: Cell # 1 2 3 4 Prio Priorr to load load test test      l     s     y      l     v e     t      i      i     e     t      t      l     s     a      C    o      l     n      V     e     e      R      d Measurements: Ambient Temperature: Battery Room Temp: Humidity: Vol Voltag tage rea reading dings s load load test test     n      i     m      0      3     n      i     m      0      6 Cell # Befo Before re Load Load Test Test Voltage readings load test     y     v e     t      i      i      t     s     a      l     n     e     e      R      d     n      i     m      0      9 31 32 33 34      l      l      t     s     e     l      C    o      V     n      i     m      0      3     n      i     m      0      6     n      i     m      0      9 125 VDC BATTERY TEST SHEET Substation/Location: Inspection Date: Date Battery Installed: Manufacturer: Year of Manufacture Rated Ampere Hour: Voltage Rating VDC: Battery Type: Cell # Prio Priorr to load load test test 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Engineer:      l     s     y      l     v e     t      i      i     e     t      t      l     s     a      C    o      l     n      V     e     e      R      d Measurements: Ambient Temperature: Battery Room Temp: Humidity: Vol Voltag tage rea reading dings s load load test test     n      i     m      0      3     n      i     m      0      6 Cell # Befo Before re Load Load Test Test Voltage readings load test     y     v e     t      i      i      t     s     a      l     n     e     e      R      d     n      i     m      0      9 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59      l      l      t     s     e     l      C    o      V     n      i     m      0      3     n      i     m      0      6     n      i     m      0      9 VACUUM VACUUM BREAKER TEST SHEET Test Equip (Manufacturer/Model) Ohm Meter   Dielectric Test Set Substation: Date: Circuit Breaker S.N. Voltage/Current Rating, kV/kA Manufacturer: BIL, KV Description Micro-ohm Testing Bushing to Bushing Phase A, μΩ Bushing to Bushing Phase B, μΩ Bushing to Bushing Phase C, μΩ Time/Travel Test Opening Time, ms Opening Spread, ms Closing Time, ms Closing Spread, ms Close/Trip Time, ms Dielectric Test: Phase A - Phase B, μA Phase A - Phase C, μA Phase B - Phase C, μA Phases (A, B, C) to Ground, μA Vacuum Integrity Charging Spring: Spring Charging Time, s Charging Motor Current, Amps Function Tests Seal-In  Anti-Slam  Anti-Pump Ambient Temperature, Deg C Humidity, % Test Results Comments Tested By: Date:  Approved By: Date: APPENDIX 6.3 HIGH VOLTAGE ELECTRICITY SYSTEM SAFETY RULES APPENDIX 6.3 HIGH VOLTAGE ELECTRICITY SYSTEM SAFETY RULES HIGH VOLTAGE ELECTRICITY SYSTEM SAFETY RULES 1. INTR INTROD ODUC UCTI TION ON These Safety Rules shall be read in conjunction with the Occupational Health and Safety Administration Manual. These Safety Rules state the basic safety requirements for work on the Cement Company 24kV and 3.3kV Distribution System. These rules are designed to:  Ensure the works are carried out to recognized industry standards  Provide maximum protection to persons working on plant or equipment.  Provide a guide to safe working on or within the vicinity of high voltage electrical systems.  Provide Controls and responsibilities for individuals operating on or working in the vicinity vicinity of high voltage plant and equipment. It is the responsibility of individuals to be familiar with respect to these rules before operating on the distribution system. The Person-in-Charg Person-in-Chargee of the works shall be a Competent Person. 2. BASI BASIC C REQU REQUIR IREM EMEN ENTS TS  No person shall: 3.  Enter a substation without a Permit-to-Work .  Inter Interfe fere re with with any item item of elec electr trica icall equi equipm pment ent with without out firs firstt havi having ng been been give given n instructions to do so by the Authorized Engineer .  Commence Commence work until they fully understand understand their instruction instructionss and are conversant conversant with the nature and extent of the work to be carried out. Instructions shall not be exceeded.  Ente Enterr a conf confin ined ed spac spacee unti untill inst instru ruct cted ed to do so by the the Authorized Authorized Engineer Engineer following a job specific Risk Assessment, after all necessary safety precautions have  been taken. GENER ENERAL AL PROVI ROVISI SION ONS S These rules apply to the Cement Company 24/3.3kV:  All High Voltage substation, plant and equipment.  All High Voltage distribution cables.  All Low Voltage equipment under the control of Estates Services. 4. INFOR INFORMA MATIO TION, N, INSTR INSTRUC UCTIO TION N AND AND TRAIN TRAININ ING G Arrangements shall be made by the CCC to ensure that all persons with access to the above equipment are adequately informed of: - 5.  Risks to their Health and Safety  Preventive and protective measures to be taken  Procedure Procedure in the event of serious serious or imminent imminent danger   The risks arising from other activities in the workplace  Those with access to operate equipment are aware of the consequences of operations carried out.  Othe Otherr peop people le who who may be expos exposed ed to dange dangerr by the the opera operati tion onss or works works rece receive ive adequate information and where necessary instruction.  The capabilities of persons are taken into account in allocating tasks.  Persons are provided with adequate Health and Safety training and re-training. ISSU ISSUE E OF SAF SAFET ETY Y RULE RULES S A copy of these rules shall be issued as determined by the Document Owner . Each copy issued will carry the signature of the holder. The recipient shall be responsible for keeping them to hand for reference as necessary when work is being carried out under these rules. 6. VAR VARIATI IATION ON OF SAFE SAFETY TY RULE RULES S In special circumstances these safety rules may be varied to such an extent as is necessary and approved by the Document Owner . Approval may be given only if safety requirements are satisf satisfied ied in anothe anotherr way. way. These These variat variation ionss must must be documen documented ted and held as a perman permanent ent record. 7. OBJE OB JECT CTIO IONS NS ON SAFE SAFETY TY GROU GROUND NDS S When any person has concerns regarding the operation of or work upon the system, they shall refer them to the person issuing instructions or to a higher authority. The matter shall be investigated, and reviewed before proceeding. 8. TREA TREATM TMEN ENT T FOR FOR EL ELEC ECTR TRIC IC SH SHOC OCK  K  All persons who may be in charge of or control of any operation or work on the system shall  be trained and an d conversant with the treatment for electric shock. 9. DEFINITIONS 9.1 A CAUTION NOTICE is a notice conveying a warning against interference. 9.2 CIRCUIT MAIN EARTH means the earthing equipment applied before the issue of, and at a position recorded in a Safety Document . 9.3 DANGER  means a risk to health or of bodily injury. Page 43 9.4 notice ce readi reading ng 'DANGER', warn warning ing of elect electri rica call or physi physica call DANGER DANGER NOTICE is a noti danger. 9.5 DEAD means an electrical potential at or about zero voltage and disconnected from any Live System. 9.6 DOCUMENT OWNER  is the person appointed to be responsible for the application of these safety rules. 9.7 EARTH means the conductive mass of the earth. 9.8 EARTHED means that the system or equipment being worked upon is connected to EARTH through switchgear or by adequately rated earth leads. 9.9 means discon disconnec nected ted from from associ associate ated d plant, plant, equipm equipment ent and conduc conductor torss by an ISOLATED means isolating device in the isolating position, or by adequate physical separation, or sufficient gap. 9.10 LIVE means electrically charged. 9 .1 1 A COMPETENT PERSON is a person person recognized recognized as having sufficient sufficient technical knowledge and/or experience to enable him/her to avoid danger and who may be nominated to receive and clear specified 9 .1 2 An AUTHORISED PERSON is a Competent Person , over the age of 18 years, who has Authorized Person is  been appointed in writing by the Senior Authorized Person . An Authorized authorized to carry out specified duties, which may include, subject to the permission of the Control Engineer , the issuing and cancelling of Safety Documents . 9 .1 3 A SENIOR AUTHORISED PERSON is an Authorized Authorized Person who has been appointed in writ writin ing g to carry carry out out spec specif ifie ied d dutie duties, s, incl includ udin ing g the the issu issuee and and cance cancell llat atio ion n of  Safety Documents . The Sen Senior ior Author Authorize ized d Pers Person on is also also resp respon onsi sibl blee for for the the dayday-to to-d -day ay management of Authorized Persons . 9 .1 4 A CONTROL CONTROL ENGINEER  ENGINEER  is an Authorized Authorized Person or a Senior Senior Authori Authorized zed Person Person Authorized Person or a Senior Authorized Person specifically nominated in writing by an Authorized to exercise the function of control control of the system. 9.15 LIMITATION-OF-ACCESS - Instructions which define the limitations and nature of work, which which may be carrie carried d out when verbal instru instructi ctions ons are not consid considere ered d suffic sufficien ientt for that  purpose, and where a Permit-to-Work  or  Permit-to-Test is not applicable. 9.16 PERMIT-TO-WORK  A permit to work specifies the high voltage equipment which has  been made safe to work on, the safety precautions applied to ensure continued safety and the work which is to be carried out. 9.17 specifies ies the high high voltage voltage equipme equipment nt which which has been been made safe for  PERMIT-TO-TEST specif testing to proceed and the conditions under which the testing is to be carried out. 9 .1 8 A SAFETY LOCK  is a lock that has a unique key, being different from all other standard locks used on the system. 9.19 IMMEDIATE IMMEDIATE SUPERVISION SUPERVISION means supervision by a person, having adequate technical knowledge or experience, who is continuously available at the location where work or testing is in progress. 9.20 PERSONAL PERSONAL SUPERVISION SUPERVISION means means superv supervisi ision on by a person person,, having having adequat adequatee technic technical al knowledge knowledge or experience, experience, who is at all times in the presence of the person person being supervised. supervised. Page 44 9.21 Switching ng is the operati operation on of circui circuitt breaker breakers, s, isolat isolators ors,, fuses fuses or other  other  SWITCHING - Switchi methods of making or breaking an electrical circuit and/or the application and removal of  Circuit Main Earths . 9.22 LOW VOLTAGE (LV) is a voltage not exceeding 1000 volts 9.23 HIGH VOLTAGE (HV) is a voltage exceeding 1000 volts 9.23 Electr tric ical al,, mech mechan anic ical al,, hydr hydrau auli lic, c, pneu pneuma mati tic, c, vacu vacuum um,, HAZA HAZARD RDOU OUS S ENER ENERGY GY: Elec Flywheels, Flywheels, springs, elevated parts that could fall, capacitors, capacitors, batteries, batteries, or other energy p resent resent in or capable capable of being emitted from circuit circuit or equipment. equipment. 9.24 SANCTION FOR TEST : A form of declaration signed and given by an Authorized Person to a compete competent nt person person in charge charge of functi functiona onall testin testing g or perfor performing ming test on distri distribut bution ion equi equipme pment nt or appa appara ratu tuss for for the the purp purpos osee of maki making ng known known to such such perso person n exact exactly ly what what equipment/apparatus is to be functional tested. 10. 10. GENE GE NERA RAL L PREC PRECAU AUTI TION ONS S 10.1 10.1 Gene Ge nera rall Safe Safety ty (a) In addition to the requirements requirements specified specified in these Safety Rules Rules the safety of all persons at work shall be achieved by maintaining general in the vicinity of the work place. (b) The Competent Person must ensure that arrangements are maintained to ensure that other  work areas are not adversely adversely affected by the activities activities for which he is responsible. responsible. 10.2 Access Access to and Work Work in Substati Substations ons (a) Only Competent Competent Persons, Authorized Authorized Person and Senior Authorized Persons have authority to access substations. (b) Persons not classified as above may gain access or work on the system provided they are under the supervision supervision of, at minimum, a Competent Person . (c) Access doors and gates shall normally be kept lock. Keys are to be issued only by an Authorized Person . 10.3 Access Access to to High High Volta Voltage ge Equip Equipme ment nt a and nd Condu Conducto ctors. rs. (a) Barriers, doors, or gates preventing access to live equipment shall be kept locked. (b) Keys shall be accessible only to Authorized Person s. 11. 11. HIGH HIGH VOLT VOLTAG AGE E SW SWIT ITCH CHIN ING G 11.1 High High voltag voltagee switch switching ing shal shalll be carri carried ed out out only only by an an Authorized Authorized Persons or a Competent Person under the personal supervision of an Authorized Authorized Person. Person. Switching shall be carried out only with the authority of the System Control Engineer . 11.2 It is forbidde forbidden n to undertake undertake switching switching operations operations by signal signal or prearranged prearranged understand understanding ing after  after  an agreed time interval. 11.3 11.3 Any Any conc concer erns ns over over swit switch chin ing, g, or wher wheree swit switch chge gear ar show showss sign signss of dist distre ress ss,, must must be communicated to the Control Engineer who will investigate before continuing. Page 45 12. 13. 13. RECORDS  Verbal instructions shall be recorded and repeated back to the sender, to ensure that it has been accurately received.  The Authorized Person actually carrying out switching shall ensure a record is made of  the time and particulars of any switching. USE OF VOLT VOLTAG AGE E TES TESTIN TING G DEVI DEVICE CES S Where voltage testing devices are used, they shall be tested immediately before and after use as a check on functionality. 14. SAFETY SAFETY PRECA PRECAUTI UTIONS ONS FOR WORK ON OR NEAR NEAR HIGH HIGH VOLT VOLTAGE AGE SYSTEMS SYSTEMS 14.1 14.1 Gener Ge neral al Requi Requirem rement entss Safe access to live conductors can only be achieved after the following steps have been completed. completed. The section section of the system to which access is required must be:(a) Dead (b) Isolated , and all practical steps taken to lock off from all points of supply, including voltage voltage transformer transformers, s, auxiliary auxiliary transforme transformers, rs, common neutral neutral earthing earthing equipment equipment and other sources of supply from which the section of the system can be made LIVE. (c) Caution Notices must be fixed at all points of isolation. (d) Earthed at all points of disconnection of HIGH VOLTAGE supply. (e) Screened where necessary to prevent DANGER  from other  LIVE parts of the system. (f) Danger Notices to be attached to adjacent live equipment. (g) Identified at the point of work. (i) Releas Released ed for work by issue issue of approp appropria riate te Safety Document which shall not be issued unless the recipient is fully conversant with the part of the system to be worked on and the nature and extent of the work to be done. (j) Where the design of equipment inhibits compliance with the above steps, the work will be carried out under instruction of the Senior Authorized Person after agreement with the Control Engineer . The instructions shall be documented in writing and signed by the Senior Authorized Person . Page 46 14.2. 14.2. Isolatio Isolation n of Equip Equipmen mentt and Cond Conducto uctors rs (a) Isolatio Isolation n and re-conn re-connect ection ion can only be complet completed ed with with the author authority ity of the Control Engineer . (b) Safety Locks shall be used to lock open all switchgear at points of isolation. Person. (c) Keys shall be kept in a key safe or in the possession of the Senior Authorized Person. (d) Fuses, links (and carriers) that control circuit to be worked on shall be removed and kept Document . in the custody of the person issuing the Safety Document (e) Caution Notices shall be fixed at all points of isolation. isolation. 14.3 14.3.. Eart Earthi hing ng (a) Where practical, practical, earthing shall be provided provided by b y use of a circuit circuit breaker or earthing earthing switch. (b) The trip feature shall normally be rendered inoperative before closing. This renders the switch inoperative whilst it remains a Circuit Main Earth . (c) After closing, the breaker or switch shall be locked in the EARTH position. (d) Circuit Main Earths can only be applied or removed with the authority of the Control Engineer who shall record the time of application and removal. (e) Circuit Main Earths shall be recorded on the Safety Documentation . 14.4 14.4 Perm Permitit-toto-Wor Work  k  14.4.1 Authority to issue (a) Before any work can commence on the high voltage systems a Permit-to-Work  must be issued. (b) A Permit-to-Work  can only be issued by a Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer . 14.4.2 Procedure Procedure for Issue Issue and Receipt Receipt (a) A Permit-to-Work  can only be received by a Competent Person who shall retain the  permit in their possession. (b) It will be explained by the issuer and the contents read back by the Competent Person who must confirm understanding of the permit, the nature and extent of the work to be done before signing its receipt. (c) Where there is more than one working party, each working party must have a separate  permit. The Permits-to-Work  should be cross-referenced. 14.4.3 Procedure Procedure for Clearance Clearance and Cancellation Cancellation (a) The recipient shall sign the permit to clear it and hand to a Senior Authorized Person, or  an Authorized Person with the permission of the Control Engineer . Indicating that the work is 'complete' or 'incomplete' and that all gear and tools 'have' or 'have not' been removed. Page 47 (b) The Senior Authorized Person , or an Authorized Authorized Person with the permission of the Control Engineer, shall cancel it and inform inform the Control Engineer . (c) Circuit Main Earths shall be removed only when all Permits-to-Work  associated with the earths have been cancelled. cancelled. 14.5 14.5 Perm Permitit-toto-Te Test st 14.5.1 Authority Authority to issue (a) Before any testing can commence on the high voltage system, a Permit-to-Test must be issued. (b) A Permit-to-Test can only be issued by a Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer . 14.5.2 Procedure Procedure for Issue Issue and Receipt Receipt (a) A Permit-to-Test can only be received by an Authorized Person who shall retain the Permit-to-Test in their possession at all times during testing. (b) It will be explained and the Authorized Person , who after reading the contents back to the issuer, must confirm understanding of the PERM1T-TO- TEST, the nature and extent of the testing testing to be carried out before before signing its receipt. receipt. 14.5.3 Procedure Procedure for Clearance Clearance and Cancellation Cancellation (a) The recipient shall sign the document to clear it and hand to a Senior Authorized Person, or an Authorized Person with the permission of the Control Engineer . Indicting that testing is 'complete' or 'incomplete', all equipment 'has' or 'has not' been removed and the operational state of the equipment. (b) The Senior Authorized Person , or an Authorized Authorized Person with the permission of the Control Engineer, shall cancel it and inform inform the Control Engineer . 14.6. 14.6. Limitat Limitationion-Of-A Of-Acce ccess ss 14.6.1 General General (a) A LIMITATION-OF-ACCESS shall be issued when it is considered necessary to have written instruction to avoid danger and other  Safety Documentation is not applicable. (b) Authority to issue - Only a Senior Authorized Person or an Authorized Person with specific authority to do so may issue a LIMITATION-OF-ACCESS. 14.6.2 Procedure Procedure for Issue Issue and Receipt Receipt (a) A LIMITATION-OF-ACCESS shall be explained and issued to the PERSON in direct charge of the work, who after reading the contents to the person issuing it and confirming that he understands it and is conversant with the nature and extent of the work to be done shall sign the receipt. (b) The recipient shall retain the limitation in their possession at all times when work is being carried out. Page 48 14.6.3 Procedure Procedure for Clearance Clearance and Cancellation Cancellation (a) The recipient shall sign the LIMITATION-OF-ACCESS to clear it and hand to a Senior Authorized Person , or  Authorized Person . Authorized Person, with specific authority to do so, (b) The Senior Authorized Person , or  Authorized shall cancel it. 15. 15. PROC PROCED EDUR URES ES FOR FOR WORK WORK ON PART PARTICU ICULA LAR R ITEMS ITEMS OF PLA PLANT NT,, EQUIP EQUIPME MENT NT AND CONDUCTORS 15.1 15.1 Gener Ge neral al Requi Requirem rement entss (a) All high voltage equipment within the zone of work are connected to Circuit Circuit Main Earths at the time when the specified equipment is released for work or testing by the Document . issue of a Safety Document (b) In these circumstances the recipient of the Safety Document may, in the course of work  or testing, disconnect from the Circuit Main Earths as required any equipment within the zone of work. Authorized Person with the permission of the (c) The Senior Authorized Person , or an Authorized Control Engineer, Engineer, shall, at the time of issue of the Safety Document Document, demonstrate to the recipient that the equipment and/or conductor are dead. (d) The equipment and conductors shall be re-connected to the Circuit Main Earths before the Safety Document is cleared. (e) Precau Precautio tions ns shall shall be taken taken to prevent prevent danger danger from from potent potential ial differ differenc ences es arisin arising g from from remote earth points by bonding and earthing at a point as near as possible to the point of  work. 15.2 Work on on Ring Ring Main Equ Equipm ipment ent when when an an LV system system back back feed is is available available (a) When work is to be carried out on HIGH VOLTAGE contacts or connections of Ring Main Equipment where there is a known or potential back feed to the substation, the Low Voltage switch or links shall be isolated, screened and a CAUTION NOTICE applied. (b) Where facilities facilities exist to lock open switches or secure secure LV control panels a safety lock shall  be applied. (c) The remote ends of all High Voltage in-feeds must be Isolated, Safety Locked, Caution Notices applied and Earthed . (d) A Permit-to-Work  must be issued for work on the Ring Main Equipment. 15.3. 15.3. With-Dr With-Drawab awable le Equipme Equipment nt (a) All spout shutters not required to be opened for immediate work or operation shall be locked shut, if not otherwise made inaccessible. (b) Withdrawn equipment shall be discharged to earth, but need not remain connected to earth. (c) Work on withdrawn equipment that remains within the immediate area shall be completed under a Limitation-of-Access . Page 49 15.4 Busbar Spouts, Busbars and Busbar connections connections of of Multi-panel Multi-panel Switchboards Switchboards When work is carried out on the above, isolation shall be carried out as follows (a) The section on which work is to be carried out shall be ISOLATED from all points from which it can be made LIVE. (b) Isolation arrangements shall be locked. (c) Where practicable, the shutters of LIVE spouts shall be locked shut. (d) Caution Notices shall be attached, at all points where the busbar can be made LIVE. (e) Danger Notices shall be attached attached on adjacent adjacent LIVE equipment. (f) EARTHING - Where practicable, the section of busbar will be verified as not LIVE by use of a testing device, typically on the panel where the Circuit Main Earth is to be applied. (g) The Circuit Main Earth is to be applied at a panel other than that at which work is to take place, on the ISOLATED section section of busbars. busbars. (h) The Senior Authorized Person , or an Authorized Authorized Person with the permission of the Control Engineer, shall satisfy himself that the recipient of the Permit-to-Work  is aware of the location of adjacent live circuits before issuing the permit. (i) Work on busbar spouts will be carried out under the PERSONAL SUPERVISION of the Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer . This will include:  Identifying Identifying spout to be worked on,  Provide access by removing shutter locks and  Proving Proving spout is not live using a voltage voltage testing device. (j) Work on busbars or busbar connections shall be completed as follows: (k) Access shall be identified by the Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer . (l) Access shall be made by the removal of appropriate cover plates under the PERSONAL SUPERVISION of the Senior Authorized Person , or an Authorized Person with the Engineer , where practicable each busbar or connection should  permission of the Control Engineer  be proved not LIVE by the use of a voltage testing device. (m) The Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer, Engineer, shal shalll rema remain in on site site until until he is sati satisf sfie ied d that that no furt furthe herr acce access ss is required to complete the work. 15.5 15.5 Feede Feederr Spout Spoutss and Connec Connectio tions, ns, Volta Voltage ge Tr Trans ansfor forme merr Spouts Spouts and Conne Connect ction ionss and and Single Panel Busbar Spouts and connections Isolation shall be carried out as follows: (b) The spouts or connections on which work is to be carried out shall be ISOLATED from all points from which it can be made LIVE. (c) Isolation arrangements shall be locked. Page 50 (d) The shutters of  LIVE spouts shall be locked shut. (e) Caution Notices shall be attached, at all points where the circuit can be made LIVE. (f) Danger Notices shall be attached where applicable on adjacent LIVE equipment. (g) Earthing - Where practicable, the spout contacts or connections shall be verified as not LIVE by use of a voltage testing device, typically on the panel where the Circuit Main Earth is to be applied. (h) The circuit shall be EARTHED at the point of work and, where reasonably practicable, at all points of isolation. Authorized Person Person with the permission of the (i) The Senior Authorized Person , or an Authorized Control Engineer, shall satisfy himself that the recipient of the Permit-to-Work  is aware of the location of adjacent live circuits before issuing the permit. (j) Work on the feeder, voltage transformer or busbar spouts on a single panel unit will be supervision of the Senior Authorized Person , or an carrie carried d out under the personal supervision Authorized Person with the permission of the Control Engineer . (k) This will include:  Identifying Identifying spout to be worked on,  Provide access by removing shutter locks, (l) Where necessary the Circuit Main Earth may be removed to provide access and (m) Prove each spout is NOT LIVE using a voltage-testing device. (n) No other work shall be carried carried out on the circuit circuit whilst earths are disconnected. disconnected. (o) Work on feeder or voltage voltage transforme transformerr connections and single single panel busbar or connections connections shall be completed as follows: (p) Access shall be identified by the Senior Authorized Person , or an Authorized Person with the permission of the Control Engineer . (q) Access shall be made by the removal of appropriate cover plates under the PERSONAL SUPERVISION of the Senior Authorized Person , or an Authorized Person with the  permission of the Control Engineer . Authorized Person with the permission of the (r) The Senior Authorized Person , or an Authorized shalll rema remain in on site site until until he is sati satisf sfie ied d that that no furt furthe herr acce access ss is Control Engineer, Engineer, shal required to complete the work. Authorized Person with the permission of the (s) The Senior Authorized Person , or an Authorized Control Engineer, shall take appropriate action to prove that each connection or busbar  in the work area is NOT LIVE by using a voltage voltage testing testing device 15.6. 15.6. Trans Tr ansfor forme mers rs (a) When work is to be carried out on the connections to, or the windings of, a transformer, the switchgear switchgear or fuse gear controlling controlling all windings shall be opened. (b) Additionally, Additionally, to prevent prevent the possibility possibility of the transformer transformer being made LIVE by back-feed, back-feed, all LOW VOLTAGE fuses or links on associated voltage or auxiliary transformers shall Page 51  be withdrawn and, where practicable, the voltage and auxiliary transformers shall be ISOLATED . (c) When work is to be carried out on a High Voltage or Low Voltage transformer and the Low Voltage windings of the transformer are controlled by a switch or isolator, the switch or isolator shall be secured open. In other cases, arrangements shall be made to ensure that the Low Voltage windings are ISOLATED from all sources of Low Voltage supply. (d) The transformer shall be ISOLATED from all common neutral earthing equipment from which it may become LIVE. (e) Caution Notices shall shall be atta attache ched d at all all point pointss of isol isolat atio ion, n, incl includ udin ing g thos thosee of Low Low Voltage. (f) The transformer shall be EARTHED at all points of isolation from High Voltage supply. Authorized Person with the permission of the (g) The Senior Authorized Person , or an Authorized Control Engineer, shall identify the transformer to be worked on at the point of work   before issuing Safety Documentation . 15.7. 15.7. High Voltage Voltage Cables Cables (a) Conductors must be Dead, Isolated and Earthed before the insulation can be interfered with. Authorized Person with the permission of the (b) The Senior Authorized Person , or an Authorized Control Engineer, shall identify and spike the cable at the point of work. Spiking may be omitted if the cable is visible along its entire length from the point of work back to an earthed switch. (c) The Control Engineer will be informed before and after any cable is spiked. (d) Precautions Precautions shall be taken to prevent Danger from induced or sheath voltage. 16. SAFETY SAFETY PRECA PRECAUTI UTIONS ONS FOR TEST TESTING ING OF HIGH HIGH VOLTA VOLTAGE GE EQUIPM EQUIPMENT ENT Testing under a Permit to Test Equipment cannot be connected to the System until it has passed the appropriate test. (a) Connection can only be made with the sanction of the Control Engineer . (b) The recipient of the Permit-to-Test shall:  Be responsible for coordinating the all testing,  Ensure Ensure that the equipmen equipment, t, test test leads leads and test test equipm equipment ent are suitably suitably protec protected ted to  prevent Danger,  Ensure Ensure that that 'Danger noticess are suitab suitably ly display displayed ed and 'Danger High High Voltage Voltage Testing Testing'' notice discharge all cables and capacitors before and after the application of test voltages. (c) The recipient recipient has the authority to:  Remove and replace earths to complete testing without the further reference to the Control Engineer .  Make LIVE from a testing supply. Page 52  Where practical, Circuit Main Earths shall be replaced before the Permit-to-Test is cancelled. 17. 17. RESP RESPON ONSIB SIBIL ILITI ITIES ES OF PERS PERSON ONS S 17.1 17.1.. Gene Ge nera rall All persons concerned with work on or in the vicinity of equipment or plant to which these safety rules apply have a duty to comply with these rules. 17.2. 17.2. Compet Competent ent Persons Persons - may: (a) Be nominated nominated to be responsible for a working working party. (b) Receive and retain a Permit-to-Work  or  Limitation-of-Access confirming they are fully conversant with the nature and extent of the work to be carried out. (c) Provide immediate or  Personal Supervision Supervision as required. (d) Implement all necessary measures to establish general safety. (e) Give authority for work under the safety document document they hold. (f) Clear  Safety Documentation Documentation , ensuring that all persons are aware that the safety document has been withdrawn and all tools and equipment removed. 17.3. 17.3. An Authori Authorized zed Person Person may in addition addition to the responsibiliti responsibilities es of a Competent Person : (a) Be authorized for  Switching on the System. (b) Be authorized to receive a Permit-to-Test . (c) Be authorized to issue and cancel a Limitation-of-Access . (d) Be authorized to issue and cancel a Permit-to-Work  with the permission of the Control Engineer . 17.4. 17.4. addition to the responsibilit responsibilities ies of an Authorized Person ; Senior Senior Authoriz Authorized ed Person Person may in addition (a) Issue and cancel a Permit-to-Work  or  Permit-to-Test . Ensuring that the recipient fully understands the nature and extent of the work or testing to be done. Personal Supervision Supervision on work specified as requiring a Senior (b) Provide immediate or  Personal Authorized Person , (c) Take on the responsibiliti responsibilities es of a Control Engineer for specified sections of a system. 17.5. Control Engineer has responsibil responsibility ity for and authority authority to: (a) Release Release equipment or plant from service. (b) Give authority authority for all High Voltage Switching. Switching. (c) Give authority authority for the issue of and acknowledge cancellati cancellation on of Safety Documentation Documentation . (d) Maintain Maintain a writte written n record record of all operatio operations ns and the issue issue and cancell cancellati ation on of  Safety Documents on the system. system. Page 53 18. 18. THE TH E KE KEY Y SAFE SAFETY TY RULE RULES S 18.1. 18.1. Switc Switchin hing g Employees/Contractors must always verify isolation/blocking points and test a circuit and/or  equipment to be sure if it is de-energized. Contractors must never perform an un-authorized operation of a circuit or a piece of equipment. 18.2. 18.2. Confined Confined Space Space Work  Work  Employ Employees ees/Co /Contr ntracto actors rs enteri entering ng confine confined d workspa workspaces ces are respons responsibl iblee for knowing knowing the  potential hazards associated with these spaces and for complying fully with the company’s safe work procedures for confined spaces. 18.3. 18.3. Fall Fall Protect Protection: ion: Employees must utilize fall protection in situations that require it. 18.4. 18.4. Groun Gr oundin ding: g: Employees/C Employees/Contrac ontractors tors must verify verify that any circuit requiring requiring grounding grounding is properly properly grounded grounded  before commencing work and work outside the minimum approach distance of an exposed energized circuit or parts of equipment unless properly protected. 18.5. 18.5. Persona Personall Protect Protective ive Equipme Equipment nt Employees/Contractors are responsible for knowing the potential hazards associated with the work they are performing, for selecting and using appropriate personal protective equipment (PPE) for this work, and for otherwise complying with the company’s procedures for the use and care of personal protective equipment. 18.6. 18.6. Shoring Shoring and and Tren Trench ch W Wall all Prote Protectio ctionn- Employees/C Employees/Contrac ontractors tors must exercise exercise care and take appropriate appropriate precautions precautions when entering entering trenches or excavated areas. They must also ensure that such areas have proper shoring and safe way out before entering. entering. Page 54 REFERENCES 1. Thes Thesee Safe Safety ty Rule Ruless are are base based d on the High High Volt Voltag agee Elec Electr tric icit ity y Syste System m Safe Safety ty Rule Ruless and and Associated Associated Safety Guidance Guidance for Loughborough Loughborough University University Estates Estates Services Services Health Health and Safety Policy 2. Nati Nation onal al Elec Electr tric ical al Code Code,, 1990 1990 3. Elec Electr tric ic Safe Safety ty Manu Manual al,, by John Cadick, Mary Capelli-Schellpfeffer, Dennis Neitzel 4. Occupa Occ upatio tional nal Saf Safety ety and Hea Health lth Adm Admini inistr strati ation on (OS (OSHA) HA) 5. JPS JP S Safety Manu nuaal APPENDIX Extractt From OSHA (Pages 386 -387) – Section (u) Substa Extrac Substations tions Page 55