THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
Page 1 of 11
i ii iii
OFF-LINE MAINTENANCE AND ACCEPTANCE TESTING PROCEDURE FOR AC METAL-
ENCLOSED
AND STATION CLASS SWITCHGEAR > 1 kV TO 36KV

Equipment Group: E112 = Switchgear and MDPs

iv E112B = > 1kV Metal-Enclosed

Equipment Type:
E112C = Station Class Switchgear

v
Scope This procedure defines the requirements and methods for Acceptance
Testing (ACCTST) and off-line Predictive/ Preventive Maintenance
(OVHAUL) for >1kV to 36kV Metal-Enclosed and Station Class
Switchgear. The intent is to maximize the reliability of this equipment at
minimum cost through the combination of testing equipment upon
installation and employment of a regularly scheduled off-line maintenance
with the ultimate objective of eliminating all unexpected failures.

Maintenance of AC Metal Enclosed Switchgear below 1kV is described in

G7M-1130-00. Maintenance procedures for breakers associated with
>1kV – 36kV and above switchgear is G7M-1151-00.

Definition METAL ENCLOSED SWITCHGEAR: A switchgear assembly completely

enclosed on all sides and top with sheet metal (except for ventilation
openings and inspection windows) containing primary power switching or
interrupting devices or both, with buses and connections and may include
control and auxiliary devices. This includes metal clad and low voltage
power circuit breaker switchgear.

INFRARED INSTRUMENT (INFRED): An instrument designed to detect

emitted heat radiation and to convert it to a visible signal.

INSULATION TEST (MEGGER): This test provides an assessment of the

insulation condition of a piece of equipment by imposing a DC voltage
generally to one of the leads and ground.

MANDATORY TEST/INSPECTIONS ( ) – These test are considered

mandatory for both acceptance testing and routine off-line PPM. An MOC
approved by the Switchgear TRL is required if these tests are not
completed.

SUPPLEMENTAL TEST/INSPECTIONS ( ) – In general, all tests are

used for initial acceptance testing. Routine off-line PPM tests are not as
stringent and items marked as supplemental are only to be performed
when there is a suspected problem with the equipment. For example: If
switchgear breaker trips without a protective relay flag indication, then a
MEGGER inspection may be used to troubleshoot the problem. For this
example case, an MOC is not required for performing the supplemental
tests. However, performing additional tests just for the sake of testing or
just because the tests have been traditionally done at a particular site is
not supported by the Electrical Discipline or Global Maintenance
Leadership. An approved MOC from the Switchgear TRL is required
before such supplemental testing is initiated.

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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Safety Safety is an integral part of all jobs. As such, all applicable Electrical Safe
Work Standards and Isolation of Energy Sources (IOES) criteria shall be
rigidly applied in the execution of the work described in this PPM
specification.

It is the responsibility of the lead person administering the PPM activities

to assure that all safety related procedures are identified and followed by
individuals involved with the PPM activities. This responsibility however
does not relieve the individual workers from understanding and following
the criteria defined by the Electrical Safe Work Standards and all sub
practices.

Note: It is common for Switchgear, Motor Control Centers (MCCs), Main

Distribution Panels (MDPs) and High Voltage Panels (HVPs) to have
multiple control power sources within the same cubical/assembly. Control
power sources may be from adjacent equipment cells (usually interlocks),
space heater panels, and control system alarms, etc. As such, these sub
control power systems often remain energized within the equipment
compartment even if the main control power source for the compartment
was de-energized. Caution must therefore be taken when performing
PPM work on or around these systems and the ”Test Before Touch”
criteria defined by EWP-30 and 32 is mandated.

Equipment Needed The following table list the test equipment and other equipment needed to
perform this procedure.

Test Equipment Other Equipment

Approved Voltage tester per EWP-32 Manufacturer’s Instruction Manuals

1000V Megger Cleaning Materials

AC/DC Hipot (depending on mfg. Hand tools

requirements).

Ductor (Micro ohm meter) Personal protective equipment such as

Nomex clothing, high voltage rubber
gloves, and flash equipment when
necessary.

Torque Wrench, Screwdriver, AC/DC control schematic for the systems

Flashlight that are included in the PPM activities.

CT Test Set

Amp Bucket or Equal

3∅ Variable Test Source

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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P/PM Schedule The required frequency for P/PM inspections for >1kV to 36kV Metal-
Enclosed and Station Class Switchgear is established via the Condition
Based Electrical PPM web site.

Data Form For execution of the above-mentioned Acceptance Testing and

Predictive/Preventive Maintenance tasks, a combined Data Form G7M-
1150-01 is available. This Data Form refers to the actions described on the
following pages and shall be used as a checklist and record for final data
entry into the GEMTS system. GEMTS should capture only the Service,
Reason, and Cause codes, and only test data by exception using the text
comments for the work order. Additional results or information, like
replacement of electrical or mechanical parts, modifications and notification
of critical conditions, which should enter the history or could effect the P/PM
schedule should also be recorded in the text comments of the work order.

Preparation Follow the steps below before starting the tests and inspections on the
equipment.

OVHAUL
Step Service Action P/PM ACCTST
offline

Plan and schedule the inspection as

1 PREP established via the Condition Based
Electrical PPM web site.

Review the AC/DC control schematic of

the disconnect switch assembly. Look
for possible control power sources from
2 PREP
interlocks, alarms, remote controls,
space heaters, etc. that may be present
within the equipment compartment.

If control wire modifications are included

in the scope of the PPM process,
complete the requirements of G7M-
1000-00 and G7M-1000-A (Risk
3 PREP
Management Methodology for
Instrument, Electrical, Analyzer, and
Process Control Equipment) prior to
initiating work.

Complete all electrical clearing of

equipment per the criteria defined in the
4 PREP
Electrical Safe Work Standards and
Isolation of Energy Sources (IOES).

Review all technical specifications,

5 PREP operating manuals and previous
inspection data if appropriate.

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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OVHAUL
Step Service Action P/PM ACCTST
offline

After de-energizing, appropriate

lockout/tagout, and grounding if
6 PREP
required by EWP-33, open all breaker
/disconnect doors.

Pull all fuses on the primary and

7 PREP secondary side of potential transformers
to prevent backfeed.

Perform the “test before touch” per

EWP-30 and 32. Be aware and take
necessary precautions against contact
with energized systems (wires, relays,
8 PREP terminal blocks, etc. If power is found
on a system that should not be
energized (per review of control
schematics - Step 2 above), STOP THE
JOB and investigate.

Visual and Follow the steps below to perform a visual and mechanical inspection of the equipment.
Mechanical
Inspection

Step Service Action OVHAUL ACCTST

P/PM
offline

Compare equipment nameplate

1 VISIN1 information data with actual operating
conditions, drawings and specifications.

Inspect the physical condition of all

electrical and mechanical bus and
auxiliary components (PTs, VTs,
metering, etc.) for deterioration and
2 VISIN1 missing, broken, or loose parts, etc.
This includes the inspection of
insulators, insulation materials, signs of
overheating or electric sparks and door
fastener functionality.

Visually inspect for proper grounding of

each switchgear cell and check for two
3 VISIN1
ground connections to the ground grid
system.

Verify switchgear control wiring is

4 VISIN1
bundled properly and clear of live parts.

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

Tighten main current carrying part (bus

system, runbacks, switch, etc.) to the
manufacturers torque specifications. If
TORQUE/ such information is not available, tighten
5
DUCTOR in accordance with Engineering Practice
G7M-0020-26. Ductor test may also be
used to confirm proper connection after
initial torque test has been completed.

Tighten control, VT, CT, and metering

6 TORQUE wires on all devices and terminal

blocks.

Clean the enclosure, breaker cells, bus,

7 CLN and disconnects using approved
methods and materials.

Clean circuit breaker runbacks and all

vi
8 CLN electrical contacts with a burnishing tool
including finger clusters contact points.

Lubricate contact surfaces and moving

assemblies (including breaker runback
vii
9 LUBAF contact fingers) using approved
methods and materials in accordance
with manufacturer’s instruction manual.

Visually inspect all bar type current

transformers. Look for evidence of
corona damage on the insulation
surfaces near the high current carrying
viii conductor. If evidence of corona is
10 VISN1
found, the current transformer may
need to be repaired or replaced.
Contact a member of the Switchgear
TRN as required for assistance in
evaluating any corona issues.

Verify a tight connection on all

accessible control wire lug/terminal strip
connections on relays, terminal blocks,
ix switches, etc. For non-IP21
10 TORQUE
connections, mark all accessible screw

heads with paint pencil, marker or other See Note 1

similar means to indicate that tightness
check has been performed

Note 1:
• Tightness Verification Related to Acceptance Testing – Intent is to make a ‘one-time’
control wire tightness verification on new switchgear. Tightness inspection should be
completed prior to initial energization of the switchgear.

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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• Tightness Verification Related to OVHAUL/PPM – On existing systems, a single
tightness check cycle is allowed (but not required) to validate appropriate connections. If
this validation is completed, terminal screws should be marked as noted above such that
future tightness verifications are not required. Control wire lug tightness inspections
should not repeated as part of normal OVHAUL/PPM on existing switchgear assemblies
unless one or both of the following are true:
o Connections are subjected to high vibrations from adjacent equipment or
systems
o Connections have been identified as being loose during troubleshooting.

Electrical Tests Follow the steps below to perform electrical tests on the equipment.

Step Service Action OVHAUL ACCTST

P/PM
offline
Using a 500V megger, measure the
insulation resistance of each control
circuit with respect to ground with the
1 MEGGER
primary fuses of the PT removed. The

minimum Megohm value should be per

G7M-0020-08.

Perform an overpotential test of one (1)

minute on each bus, phase to phase
and phase to ground. Test voltages in
accordance with G7M-0020-09.

2 HIPOT Note: This test is performed with bus

de-energized and isolated from the
main disconnect, and any other bus
attachments such as metering, ground
detectors, etc. The minimum megohm
value should be per G7M-0020-08.

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GLOBAL 11-APR-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

Using a micro ohmmeter (ductor),

perform resistance test across each
phase with breaker main
contacts/disconnect switches closed
and in series with all current carrying
components of the breaker. For
accurate off-line Ductor results, the
breakers cluster fingers and/or
disconnect switches must be in a
connected position on the bus and
overall doctor measurements are taken
x
3 DUCTOR between the main and load bus. The

deviation from adjacent closed contacts

and similar breakers by more than 20%
shall be investigated. Note: It
may not be practical to
ductor the main bus through
the racked-in and closed
breaker to the load bus
during OVHAUL. Do this test
if the main bus is accessible
during OVHAUL but always
during ACCTST.

Perform maintenance on all circuit

breakers per the requirements in G7M-
4 PPM 1151-00 and per the inspection as
established via the Condition Based
Electrical PPM web site.

Perform off-line maintenance and

xi acceptance tests on all current and
5 FUNTES
potential transformers according to
G7M-1041-00.
Perform off-line maintenance and
xii acceptance tests on all protective relays
6 FUNTES
and metering according to G7M-1011-
00.
Manually operate circuit breakers,
7 FUNTES relays, etc. to determine satisfactory
operating condition.
On draw-out designs, rack the breaker
in and out several times and check the
8 FUNTES clearances on arc chutes and other

close proximity equipment for proper

clearance.

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ELECTRICAL G7M-1150-00
GLOBAL 11-APR-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

Verify breakers have proper

engagement of contacts/stabs with
mating receptacles on the contact
9 FUNTES surfaces using grease or dye and that
breakers cannot be disengaged from
the main bus while in closed position
without it automatically trips.
xiii
Calibrate and function test all
10 CALCHK protective relays according to practice
G7M-1011-00.

Functional Tests Follow the steps below to perform functional tests on the equipment.

Step Service Action OVHAUL ACCTST

P/PM
offline
Perform operational test of all controls
and interlocks with control circuits
properly energized but without main bus
1 FUNTES
being energized. Confirm proper

operation per the engineering design

criteria.

Operate circuit breakers from each

control point. Trip by manually and
electrically operating every control trip
2 FUNTES device. Check space heaters, control
circuits, automatic trip/transfer
operations, interlocks, indicating lights,
etc.
Check annunciators, alarms, targets
3 ALMTST and remote indications shall be
confirmed to operate properly.

Verify that closed breaker mechanism

springs discharge when the breaker is
inserted into or removed from the
4 FUNTES cubicle and that breakers are correctly

labeled with proper warning signs and

operating instructions are in place or
posted.

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ELECTRICAL G7M-1150-00
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Step Service Action OVHAUL ACCTST
P/PM
offline

Calibrate all meters and metering loops

according to G7M-1045-00. Verify
5 CALCHK Multipliers. Verify proper primary and

secondary fuse rating for circuit

breakers as indicated.

Perform phase sequence test on

double-ended switchgear to ensure
proper bus phasing from each source.
6 FUNTES This test is done by applying 3θ voltage
sources to and from one end and
reading the other end with a volt and/or
phase angle meter.
Check alignment of breaker and cell
auxiliary switches and interconnecting
mechanisms. Confirm proper operation
and alignment of the auxiliary switch
xiv
7 VISIN1 assemblies. Auxiliary switch
alignment must be fully
representative of the breakers
position (not partially closed or
open).

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Return to Operation Follow the steps below to return the equipment to operation.

Step Service Action OVHAUL ACC TST

P/PM
offline
After testing is complete, visually
inspect for the following items:
1. All fuses replaced
2. All disconnected leads reconnected
3. All appropriate red tags removed
4. All DC control power to breakers
and protective relay systems have
been restored.
1 PREP
5. Resistance ground switches are
closed and in service.
6. All protective relay flags have been
reset.
7. All other items compromised during
testing have been returned to their
original state prior to releasing back
to owner.
All test forms and data sheets are to be
2 PREP submitted to the appropriate authority
for entry into GEMTS.

When energizing switchgear, follow the

3 PREP criteria established in EWP-21 (PPE for
Arc Flash Hazards).

For automatic transfer assemblies, have

operations return the switchgear
4 PREP
controls to “automatic” position after the
main breakers are put in service.

i
19-MAR-2007; MOC 2007_04416; By: Paul Gabba; Supersedes Issue Date 05-JUN-
2006; Reviewed. Updates throughout as a result of the Plaquemine Poly A Arc
Flash Incident.
ii
18-AUG-2003, MOC2003.1100.110, By:Paul Gabba, Supercedes Issue Date 07-MAR-
2001, Complete rewrite for the Condition Based PPM program.

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iii
05-JUN-2006; MOC 2006_03847; By: Brian Kinler, Supercedes Issue Date 24-
FEB-2006; Added AND ACCEPTANCE TESTING’ to the title.
iv
08-DEC-2004, MOC 2004_02277, By: Paul Gabba, Supercedes Issue Date 20-FEB-
2004, Corrected the Equipment Types
v
08-DEC-2004, MOC 2004_02277, By: Paul Gabba, Supercedes Issue Date 20-FEB-
2004, Corrected the Scope
vi
20-FEB-2004, MOC2004_01673, By:Paul Gabba, Supercedes Issue Date 18-AUG-
2003, Added Step 7 to ‘Visual and Mechanical Inspection’
vii
20-FEB-2004, MOC2004_01673, By:Paul Gabba, Supercedes Issue Date 18-AUG-
2003, Modified Step 8 of ‘Visual and Mechanical Inspection’
viii
24-FEB-2006; MOC 2006_03544, By: Paul Gabba; Supercedes Issue Date 08-DEC-
2004; Added item 9 under the Visual Inspection criteria section. New
requirement addresses corona inspection criteria for bar type current
transformers.
ix
19-MAR-2007; MOC 2007_04591; By: Paul Gabba; Supersedes Issue Date 05-JUN-
2006; Added STEP 10 and Note 1 at ‘Visual and Mechanical Inspection’.
x
20-FEB-2004, MOC2004_01673, By:Paul Gabba, Supercedes Issue Date 18-AUG-
2003, Modified Step 3 of ‘Electrical Test’
xi
05-JUN-2006; MOC 2006_03847; By: Brian Kinler, Supercedes Issue Date 24-
FEB-2006; At ELECTRICAL TESTS: Modified STEP 5.
xii
05-JUN-2006; MOC 2006_03847; By: Brian Kinler, Supercedes Issue Date 24-
FEB-2006; At ELECTRICAL TESTS: New STEP 6, ref to G7M-1011-00.
xiii
11-APR-2007; MOC 2007_04774; By: Brian Kinler; Supersedes Issue Date 19-
MAR-2007; At ELECTRICAL TEST Step 10, corrected the referenced practice
number and hyperlink.
xiv
08-DEC-2004, MOC 2004_02277, By: Paul Gabba, Supercedes Issue Date 20-FEB-
2004, Added STEP 7 at FUNCTIONAL TEST

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