THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-1045-00
GLOBAL 11-AUG-2003
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OFF-LINE MAINTENANCE AND ACCEPTANCE TESTING PROCEDURES
FOR ELECTRICAL METERING AND METERING LOOPS

Equipment Group: E103 = Metering and Metering Loops

E1031 = Metering: Ampere

Equipment Type:
E1032 = Metering: Volt
E1033 = Metering: Watt
E1034 = Metering: KWH
E1035 = Metering: KVAR
E1036 = Hours
E1037 = Amp Hours
E1038 = Power Factor
E1039 = Revenue Metering

Scope This procedure defines the requirements and methods for Acceptance Testing
(ACCTST and off-line Predictive/ Preventive Maintenance (OVHAUL) for
electrical metering systems. 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.

Definitions TRANSDUCER – This is typically considered a step-down device. Voltage and

current at reduced levels is converted to even lower voltage and current levels
and the output is used to display, measure or record the primary device
parameters. For example: A voltage transducer is connected to the secondary
side of a potential transformer and the transducer will convert the voltage to a
level such that it will drive a digital or analog display meter, digital input to a
control system, or other device. The meter or other device will display the
primary voltage level of the potential transformer primary.

INDICATOR – An instrument in which only the present value of the measured

quantity is visually displayed. This is often refereed to as a meter.

RECORDER – A device that makes a permanent record, often graphic, of

varying signals.

APPROVED METHODS OR MATERIALS – Acceptable to the authority having

jurisdiction.

MANDATORY TEST/INSPECTIONS ( ) – These test are considered mandatory

for both acceptance testing and routine off-line PPM. A MOC approved by the
Protective Relay 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 preformed when there is a
suspected problem with the equipment. For example: If meter displays a false
reading while in service, supplemental tests may be necessary to identify the
specific problem. Such tests may include bench testing of transducers, re-
calibration of the loop, etc. 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

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ELECTRICAL G7M-1045-00
GLOBAL 11-AUG-2003
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Leadership. An approved MOC from the appropriate TRL is required before
such supplemental testing is initiated.

Safety Safety is an integral part of any and all jobs. As such, all applicable Corporate
and site-specific safety and loss prevention practices and procedures shall be
rigidly applied in the execution of the work described in this Practice. It is the
responsibility of the lead person administering this Practice to assure that such
safety related Practices/procedures are identified and followed by all involved.

All electrical equipment to be tested off line should be in a de-energized state (in
as much as possible). Because of inherent dangers in any high voltage work,
special care must be taken to safeguard personnel during testing and inspection
of equipment. Use of personal protective equipment is mandatory when
performing these job tasks.

Special Safety and Review relaying, metering, and control prints prior to performing the
Operational maintenance. It is important to know the peculiarities of the control circuit
Information Related associated with the metering system being maintained as metering loop systems
to Metering sometimes control load shed systems, GT runbacks or an actual chemical
process.

Specific care should be taken when removing transducers and analog meters
from service. Voltages up to 240V are often found on transducers. Care must
also be taken when working with current transformer circuits as opening a
current transformer secondary under loaded conditions will result in very high AC
secondary voltages that are dangerous to personnel and can damage the
current transformer and relay(s).

Additionally:


Make certain meter identification and existing records are in agreement. If a

discrepancy is found, investigate.


Exclude unnecessary and unauthorized personnel from the test area and
equipment being tested. Test currents and voltages can be deadly. Relays
checked in-service can contain hazardous voltage which can cause personal
injury and damage to property.


Before making any electrical tests on metering systems, make certain the
devices are not damaged or inoperative. Do a thorough visual inspection
prior to making any electrical tests.


If the test technician makes a mistake and trips a circuit, they should
acknowledge it immediately.

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

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GLOBAL 11-AUG-2003
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Field Test Equipment Other Equipment

Multi-meter, RMS responding Manufacturer’s Instruction Manuals

Relay Test/Calibration Set Screwdrivers

Insulation Resistance Test Set Wrenches

Milli-Amp Meter Cleaning materials

Portable Computer (for some Personal protective equipment such as

microprocessor based metering Nomex clothing, high voltage rubber
systems) gloves, mono-goggles, and flash
equipment, when necessary.

Miscellaneous leads Hand tools

P/PM Schedule The required frequency for P/PM inspections for the various metering systems is
established via the Condition Based Electrical PPM web site. PPM on non-
revenue metering systems is usually minimal. OFF-LINE PPM testing of metering
circuits generally involves calibration (CALCHK) when necessary and cleaning
(CLN).

Data Form For execution of the above-mentioned Acceptance Testing and Predictive/
Preventive Maintenance tasks, a combined Data Form G7M_1045_01
(FUTURE) 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
metering system

OVHAUL
P/PM off-
Step Service Action line ACCTST

Plan and schedule the inspection as

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

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OVHAUL
P/PM off-
Step Service Action line ACCTST

Perform all necessary electrical safe

work steps according to the Corporate
2 PREP Safety Guidelines and local
requirements. Follow current ‘Electrical
Clearing Procedures’ for all equipment.

Review all technical specifications,

3 PREP operating manuals other manufacturing
literature.

Review previous inspection data and

4 PREP
calibration “as-found” and “as-left” data.

Discuss the intended maintenance with

the Owner or his representative and
other personnel involved in the job.
Determine with the operating personnel
5 PREP what actions should be taken in case a
circuit is inadvertently tripped. It is the
responsibility of the operating personnel
to determine whether or not the circuit
should be re-energized.

Electrostatic discharge straps should be

6 PREP used when handling printed circuit
boards and static components.

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

OVHAUL
Step Service Action P/PM off- ACC TST
line

Compare equipment nameplate/

1 VISIN1 labeling with one-line diagram and
report discrepancies.

Check all connections associated with

2 VISIN1
the metering system for tightness.

Verify proper connection of metering

3 VISIN1
inputs and outputs with prints.

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OVHAUL
Step Service Action P/PM off- ACC TST
line

Complete a visual inspection of the

metering system as follows. Look for:


Visible corrosion on terminals,


wires, circuit boards, etc.
Normal / excessive ambient
temperature in metering area. Note:
Elevated temperatures are detrimental
to electrolytic capacitors that are used
in transducers and modern electronic

meters.
Normal / excessive ambient
humidity in meter location.
4 VISIN1 

Normal / excessive dust / dirt in

metering room. Note: Elevated
humidity is detrimental to all metering

designs.
Normal / restricted access (trash &
storage around metering

equipment/panels).
Normal / inadequate metering

room/space lighting.
Proper enclosure/guarding of the

metering system.
Proper grounding of any signal
shield wires.
Remove dirt, corrosion, rust, metal
5 CLN filings, or other foreign material as
required.

Lubricate chart recorder moving parts

6 LUBAF
as required by the manufacturer

Check recorders for proper operation of

7 VISIN1 access door, pen movement, and paper
advance mechanisms.

Check all connections associated with

8 VISIN1
the metering system for tightness.

Verify proper connection of metering

9 VISIN1
inputs and outputs with prints.

Off-Line/On-Line Follow the steps below to perform off-line and on-line PPM on metering
PPM (OVHAUL) and systems. These tests are to be done with the metering disconnected from the
Acceptance Testing power and trip circuits. This document is not intended as a design
(ACCTST) specification or an instruction manual for personnel untrained in maintaining
metering systems. This document is not meant to replace the manufacturer’s
instruction manual, but should be used in conjunction with the manual.

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OVHAUL
Step Service Action P/PM off- ACC TST
line

Verify the accuracy of transducer and

metering loop using a current and
1 CALCHK voltage test standard across the entire


range. Confirm compliance with

manufacturer’s tolerances.

For loop-connected indicators and

recorders, use the output of the
transducer or another calibrated source
2 CALCHK
to drive the output loop. Check



accuracy throughout device’s range.

Confirm with manufacturer’s tolerances.

On recorders and indicators, check

3 FUNTES
movement for any sign of binding.
 

Verify operation of output and/or

4 CALCHK auxiliary contacts associated with


metering control.

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

OVHAUL
Step Service Action P/PM off- ACC TST
line

Verify that all test switches, covers, and

selector switches are returned to correct
1 PREP
state. Make certain that all metering
systems are operational.

2 PREP Inform operations of completion of work.

Make necessary revisions to prints.

3 PREP Make sure the design prints get
updated.

After all testing is completed, verify all

safety grounds have been removed, all
appropriate red tags removed, and any
4 PREP
other items compromised during the
test returned to their original operational
state before releasing to owner.

All test forms and data sheets are to be

5 REP submitted to the appropriate authority
for entry into GEMTS.

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OVHAUL
Step Service Action P/PM off- ACC TST
line

Issue additional work orders (REP) as

6 REP
necessary to make additional repairs.

11-AUG-2003, MOC2003.1000.105,By:Paul Gabba, Supercedes Issue Date 09-AUG-

2000, Complete rewrite and reformat for Condition Based PPM program.

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