SMP-030 - Copia2

SMP-030 PREVENTATIVE MAINTENANCE MAJOR ELECTRICAL EQUIPMENT
1. Purpose and Contents
The purpose of this Standard Maintenance Procedure is to provide maintenance practices for
electrical equipment at Praxair facilities. These activities should be followed to minimize the expected
outages of electrical equipment. By setting in place these procedures, employed in a structured
maintenance program, unexpected equipment problems and outages will be reduced.
1. Purpose and Contents ....................................................................................................... 1

2. Introduction...................................................................................................................... 2
3. High Voltage Distribution Systems....................................................................................... 3
3.1 Circuit Breakers and Switches ...................................................................................... 3
3.1.1 Oil and SF6 Circuit Breakers .................................................................................. 3
3.1.2 Isolating Switches ................................................................................................ 4
3.1.3 Motorized Isolating Switches ................................................................................. 5
3.1.4 Manual Grounding Switches ................................................................................. 6
3.2 Aerial / Yard Bus ........................................................................................................ 7
3.3 Ground Grid............................................................................................................... 7
4. Medium Voltage Distribution Systems .................................................................................. 8
4.1 Circuit Breakers and Switches ...................................................................................... 8
4.1.1 Oil Circuit Breakers and Switches .......................................................................... 8
4.1.2 Vacuum Circuit Breakers and Switches (See SMP-133)............................................ 8
4.1.3 Air Magnetic Circuit Breakers and Switches (See SMP-133) ...................................... 9
4.2 Medium Voltage Starters (See SMP-134) ...................................................................... 9
4.3 Medium Voltage Bus Duct (See SMP-132)..................................................................... 9
4.4 Medium Voltage Power Feeders................................................................................... 9
4.5 Medium Voltage Cable Pits and Wireways..................................................................... 9
4.6 Power Factor Correction Capacitors............................................................................ 10
5. Low Voltage Distribution Systems ..................................................................................... 11
5.1 Motor Control Centers ............................................................................................... 11
5.2 Transfer Switches ..................................................................................................... 11
5.3 Low Voltage Bus Duct (See SMP-132) ........................................................................ 12
5.4 Power Cable............................................................................................................ 12
5.5 Uninterruptible Power Supplies ................................................................................... 13
5.6 Buildings and Grounds .............................................................................................. 13
5.6.1 Lighting ............................................................................................................ 13
5.6.2 Air Conditioning................................................................................................. 13
5.7 Plant Emergency Trip Stations ................................................................................... 13
5.8 Protection and Control............................................................................................... 14
5.8.1 Batteries........................................................................................................... 14
5.8.2 Metering........................................................................................................... 15
5.8.3 Relays ............................................................................................................. 15
5.8.4 Wiring .............................................................................................................. 16
5.9 Variable Speed Drives............................................................................................... 16
5.10 Electrical Process Heaters ......................................................................................... 17
6. Transformers .................................................................................................................. 17
6.1 Oil Immersed Power Transformers.............................................................................. 17
6.1.1 Substation Type (See SMP-132).......................................................................... 17
6.1.2 Pole Mounted Transformers ................................................................................ 17
6.1.3 Tap Changers (See SMP-132) ............................................................................ 18
6.2 Dry Type Power Transformers (See SMP-132)............................................................. 18
6.3 Potential and Current Transformers............................................................................. 18
6.4 Neutral Grounding Resistors (See SMP-132) ............................................................... 18
7. Drives ............................................................................................................................ 19
7.1 Form Wound Motors (operating above 600V) ............................................................... 19
7.1.1 Induction (See SMP-131).................................................................................... 19
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7.1.2 Synchronous (See SMP-131).............................................................................. 19
7.2 Random Wound Motors (Operating at or below 600V)................................................... 19
7.2.1 NEMA Frame.................................................................................................... 19
7.2.2 Above NEMA Frame Size................................................................................... 20
7.3 Generators .............................................................................................................. 20
7.3.1 Cogeneration Type ............................................................................................ 20
7.3.2 Standby Generators ........................................................................................... 20
8. References .................................................................................................................... 22
Appendix A: Earth Resistance Testing ...................................................................................... 23
2. Introduction
This document serves as a tool to aid in the standardization of preventive maintenance

practices on major electrical equipment associated with Praxair electrical systems. This is one step in
the continuous process to enhance the safety and reliability of our facilities, while holding costs to a
minimum.
The Electrical Specialist shall determine the applicability and interval of preventative
maintenance activities based on operating conditions, historical records, personal experience, and
equipment criticality. Operating and environmental conditions to consider may include but are not
limited to, equipment age, duty-cycle, load factor, temperature, cleanliness, humidity, and
corrosiveness. .
The Electrical Specialist may elect to add or omit steps of a preventative maintenance activity
based on its applicability, favorable (or unfavorable) conditions found in other similar inspections , and
operating factors of the equipment. Such modifications must be made with input from the Expert
Network and Operations Management unless parameters have been previously defined to delegate
authority to the Electrical Specialist. If a procedure step is omitted or added, notation in the Work Order
record shall indicate these details.
All electrical work described within, will be performed by qualified personnel, as determined by
plant management under the guidance of the Praxair Technology Center and region Reliability Centers.
A number of factors will be used in determining qualification: affiliation with recognized testing/service
organizations; experience; safety record; quality control programs; and training to list a few.
Prior to performing any of the activities described herein, a thorough review of all relevant
safety aspects must take place. All Praxair safety policies must be strictly adhered to. For this SMP,
Policy 2.05, “Electrical Safety” W
( orldwide S&ES Manual), or regional safety manuals should be
particularly observed. The completion of some of the activities listed in this SMP requires the use of a
Hazardous Work Permit (HWP). The pre-job discussion is essential and must be held with all involved
parties prior to starting work.
The plants and regional Reliability Centers share the responsibility for program
implementation. Record keeping is an integral part of this process. Each Reliability Center will use the
computerized maintenance management system (CMMS) program to record data and manage
maintenance work orders. Corrective work orders, originated from equipment inspections will also
employ the CMMS program. This will ensure communication between regions and Tonawanda.
If there are any questions about this document, or general electrical questions, please call the
Global Expert Network at the Praxair Technology Center.
This SMP is to be used in conjunction with the manufacturer's documentation. Due to the
varied manufacturers, types, vintages, and options, this SMP serves to point out significant areas of
maintenance. For specific procedures and additional requirements, manufacturer's literature should be
consulted.
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3. High Voltage Distribution Systems
3.1 Circuit Breakers and Switches
3.1.1 Oil and SF6 Circuit Breakers
Oil and SF6 (sulfur hexaflouride) circuit breakers are used in primary
substations and transmission lines where high-speed opening and closing operations are required.
The breakers use the oil or the SF 6 gas as the arc suppression medium.
MAINTENANCE PROCEDURE
In general, these devices require minimal maintenance under normal

operating conditions. If the plant has experienced fault conditions that the main incoming system
breaker was called on to interrupt the fault current, the breaker inspection and maintenance intervals
should be reduced.
PERIODIC MAINTENANCE ITEMS
1. For oil circuit breakers (O. C. B.s) only, conduct a comprehensive oil
analysis, including dissolved gases (reference SMP-132 Appendix B
for recommended oil quality levels).
2. For O. C. B.s, visually inspect for oil leaks around bushings.
3. Perform a thermographic scan of all exposed current carrying

components and control cabinet components and not e any
abnormalities. (SMP-073)
4. Visually inspect the external surfaces for rust and corrosion. Look
for oil leaks, and pressures on the SF6 gas and the air operator on
the O.C.B. Verify the area is clean and clear of operating
obstructions. Also, visually check the control box for corroded wiring
terminations and jumpers.
5. For oil circuit breakers, observe and document tank and bushing oil
levels. Generate a PM-R work order if any deficiency is found
6. For SF6 circuit breakers, verify and document the amount of SF6 gas
remaining in the cylinder. Replace cylinder with full one if required.
7. If applicable (only on pneumatically controlled breakers), bleed

condensate from air tank
8. On pneumatically controlled breakers, verify & document pressure

on air operator
9. Operate the breaker if possible. Do this only if the facility is down.

DO NOT TAKE A FACILITY OUTAGE TO CONDUCT THIS TEST.
MAJOR MAINTENANCE ITEMS
1. For pneumatically controlled breakers only:
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A. Inspect air compressor, change oil and replace belts.
B. Check pilot valve for proper operation and replace if

necessary.
2. Check control mechanism (breaker should be operated several

times with no load).
3. Exercise trip and control loops.
4. Check calibration of pressure switches against the value stamped on

the breaker nameplate.
5. Measure average breaker trip & close velocities
6. Check the breaker opening and closing timing
7. Check the contact resistance using a high current digital low

resistance ohmeter (DLRO) tester.
8. Confirm operation of circuit breaker control cabinet space heater
9. Verify circuit breaker trip-free operation
10. Power factor tests are to be performed across each pole with the
breaker open and each phase-to-ground with the breaker closed. If
the breaker is a single tank (i.e., all three poles in one tank), then
with the contacts closed, the breaker shall be power factor tested
phase-to-phase in addition to the above tests. Power factor tests are
also to be performed on circuit breaker bushings. All measurements
are to recorded for future reference.
3.1.2 Isolating Switches
High voltage isolating switches are typically used in substation applications to

provide physical and electrical isolation from the incoming power supply for maintenance of the main
circuit breakers, transformers and wavetraps. These switches are mounted in the substation aerial
structure and operated with a hand crank through a gear operator. Under no circumstances are these
switches to be operated under load.
These devices require minimal maintenance. The primary concern is the

operator mechanical linkage and the seating of the contacts in the holder. Prior to performing any
major maintenance (relating to the switch itself) both the line and load side of the switch must have
visual ground jumpers installed and verified.
1. While under load, check the contacts for heat with a thermographic
monitor camera. (SMP-073)
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1. Operate the switch and inspect the blade make and break
synchronization. Adjust if necessary
2. Operate the switch and inspect the contact position and contact
pattern. Adjust if necessary
3. Visually inspect all contact areas for signs of arcing. Repair / replace
as necessary
4. Lubricate and verify operation of all key interlocks and sequencing of

schemes
5. Clean and grease all operator components
6. Visually inspect the insulators
7. Coat the contact and holder very lightly with Mobil 28 (red grease) or
Carnuba wax product
3.1.3 Motorized Isolating Switches
High voltage motorized isolating switches are typically used n i substation

applications to provide physical and electrical isolation from the incoming power supply for
maintenance of the main circuit breakers, transformers and wavetraps. These switches are mounted in
the substation aerial structure and operated with a motor operator through a gearbox. The motorized
switches are typically mechanically larger than the hand operated isolating switches. With the
exception of the motor operator, these devices are functionally identical to the hand operated isolating
switch. Under no circumstances are these switches to be operated under load.
These devices require minimal maintenance. The primary concern is the

operator mechanical linkage and the seating of the contacts in the holder. Prior to performing any
major maintenance (relating to the switch itself) both the line and load side of the switch must have
visual ground jumpers installed and verified.
1. While under load, check the contacts for heat with a thermographic
monitor camera. (SMP-073)
1. Inspect all electrical connections to the drive motor
as necessary
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schemes
Carnuba wax product
3.1.4 Manual Grounding Switches
Manual grounding switches provide a positive means to ground a section of a

high voltage distribution system for maintenance purposes. The switches are similar in construction to
manual isolating switches and are placed at the highest point of the incoming tower structure. The
primary maintenance concerns are the mechanical operator and the condition of the contact surfaces.
Unlike isolating switches, grounding switches do not carry current in normal operation. These
switches are positively interlocked with the incoming isolating switches to the affected section
of the distribution system. Under no circumstances defeat any safety or interlock system.
These devices require minimal maintenance. The primary concerns being

the operator mechanical linkage and the seating of the contacts in the holder.
1. none
as necessary

schemes
Carnuba wax product
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3.2 Aerial / Yard Bus
The aerial/yard bus consists of the structure and buswork in the main substation.
These systems usually consist of an incoming tower, structural steel, and a network of uninsulated bus.
Voltages may vary from 23,000V to 345,000V.
The maintenance on this equipment consists of continual good housekeeping

practices. The area should be kept clear and free of tripping hazards and vegetation. Structures
should be free of rust.
1. Visually inspect for damage, corrosion and abnormalities.
2. Thermographically inspect all electrical connections while the system is in

service under full load. (SMP-073)
3. Verify the condition of all structural grounding straps. This is to include circuit
breakers, towers, supports, fencing, and static poles.
4. Visually inspect lightning arrestor insulator for any cracking or other damage.
Assure that any vent ports are clear and free of discharge. If surge counter
exists, record value. Verify that arrestor grounding is intact.
1. Repair all structural defects
2. Inspect insulators for any defects (arcing, tracking, or pitting)

®
3. Clean and Collinite wax all insulators
4. Thoroughly inspect lightning arrestors for any defects or other abnormalities.

If applicable, test surge counter operation through current injection. Assure
that all hardware is properly torqued and free from corrosion.
3.3 Ground Grid

The ground grid consists of a system of interconnected bare conductors buried in the
earth in the form of a grid. Substation grids are generally constructed of bare copper welded at each
junction. The ground grid provides a common, uniform, zero-potential reference point.
The ground grid is an integral part of the electrical distribution system that is often
neglected. Over 90% of the system lies buried under the operating equipment. Failure to maintain the
system can lead to unnecessary equipment damage and personal injury.
1. Visually inspect all above ground mechanical connections.
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1. Check ground grid resistance with ground resistance fall-of-potential method
outlined in Appendix A.
4. Medium Voltage Distribution Systems
4.1 Circuit Breakers and Switches

4.1.1 Oil Circuit Breakers and Switches
Medium voltage oil circuit breakers and switches are devices which interrupt
a current flow utilizing oil to extinguish the resulting arc. Each time an arc is extinguished there is some
burning that occurs in the oil. It is imperative that the quality of the oil is regularly monitored to insure
that it maintains close to its original insulating characteristics. Typically, oil circuit breakers and
switches are used in systems that require fast interrupting times. This is necessary when the device
must interrupt full load or fault conditions.
The use of oil circuit breakers in Praxair Facilities in medium voltage

distribution systems is very uncommon. The technology was popular in the early 1900's, but became
more scarce with the advent of the air circuit breaker. The maintenance procedure on these breakers
consists of two basic parts. The testing and continual monitoring of the oil, and the general
maintenance of the mechanical operator. Remember that these devices operate at extremely high
speeds with a great deal of stored energy. Always take special precautions to stay clear of all
moving components of the operator.
1. Oil samples should be taken annually. Each sample should be

tested for total dielectric, color, power factor, interfacial tension, and
dissolved gases (for specific values see Appendix B in SMP-132).
1. Interrupters and switches are to be checked for proper contact

resistance, breaker travel, and velocity (timing).
2. The breaker power stabs are to be checked for evidence of

overheating, looseness, etc. Their alignment and contact with the
stationary stubs should also be checked.
3. Power factor tests are to be performed across each pole with the
breaker open and each phase-to-ground with the breaker closed. If
the breaker is a single tank (i.e., all three poles in one tank), then
with the contacts closed, the breaker shall be power factor tested
phase-to-phase in addition to the above tests.
4.1.2 Vacuum Circuit Breakers and Switches (See SMP-133)
This section has been moved to SMP-133 “Preventative Maintenance for

Switchgear 4160V and Above”. [Add link when moved to database.]
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4.1.3 Air Magnetic Circuit Breakers and Switches (See SMP-133)

Switchgear 4160V and Above”. [Add link when moved to database.]
4.2 Medium Voltage Starters (See SMP-134)
This section has been moved to SMP-134 “Preventative Maintenance Medium

Voltage Fused Contactors”. [Add link when moved to database.]
4.3 Medium Voltage Bus Duct (See SMP-132)

Transformers”. [Add link when moved to database.]
4.4 Medium Voltage Power Feeders
Medium voltage power feeders are relatively maintenance free. 5 kV and 15 kV

cables have an expected life of approximately 20 years. The cables can be proof-tested but the tests
are generally considered to be destructive in nature. Before putting a cable in service the system can
be insulation resistance tested to insure that there will not be a fault on the initial voltage surge. The
driving level of an insulation resistance tester is generally not enough to make any determinations on
remaining life. The best test is the high potential test. This test drives the applied potential above the
rated voltage of the system. This test will fail a marginal cable and should be used if contingencies are
in place to replace failed cable.
Power feeders can be tested by insulation resistance tester. This will insure the cable
can be energized safely. On new installations cable should be high potential tested in accordance with
the Praxair Electrical Aboveground Electrical Specification AGE-6 [new installation levels]. Only high
potential test if preparations have been made to replace failed cable. If the cable fails, a pinhole
will be punched through the cable jacket.
1. None.
1. Inspect cable in cable trays for abrasions and deterioration.
2. Check tightness of bolted joints by calibrated torque wrench.
3. Perform insulation resistance test on each phase and compare to the

remaining phases. (Use the highest voltage available on the tester that is
under the rated voltage of the cable being tested)
4.5 Medium Voltage Cable Pits and Wireways
Medium voltage cable pits and wireways are relatively maintenance free. A common
misconception is that cable pits will remain free of water and contamination. Actually most pits and
wireways will eventually fill with water. Some are open to the atmosphere, while others may fill over
time due to humidity and condensation. The cable insulation is designed to handle water and most
contaminates. Do not attempt to remove water from a cable pit. Pits may contain low level methane
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concentrations that could be ignited by a very low level arc. Also cycling the cables to dry then back to
wet conditions, will tend to age the insulation more quickly than keeping the cable jackets either wet or
dry. A second common wireway is a cable tray system. The cable tray should be continuous,
connected mechanically and by ground bonding jumpers. In fault conditions the cable tray acts as a
return path for fault currents. Keeping the cable tray system in good mechanical condition insures that
the protective devices will interrupt fault conditions as designed.
Most of the necessary work required to maintain cable pits and wireways is
mechanical and housekeeping. Remember when inspecting wireways such as cable trays that they are
an integral part of the facilities grounding system. Any mechanical damage should be corrected as
soon as possible.
1. Visual inspection.
1. None.
4.6 Power Factor Correction Capacitors
A power factor correction capacitor (PFCC) is a device that is designed to increase

the reactive component in a power distribution system. This will cause the phase angle between the
voltage and current to decrease, reducing the inductive effects common in squirrel-cage induction
motors. PFCCs occur most often in small facilities without synchronous motors or facilities with larger
induction motors, when these facilities are financially penalized for running inductive loads.
The capacitive plates of most capacitors are usually immersed in an insulating oil.
They vary in size, but for most Praxair locations will be about the size of a standard car battery or a Ni-
cad substation battery. Since the units are sealed, physical inspection is limited. Most capacitors have
insulating posts on which the electrical connections are made. These posts are generally porcelain and
can crack if mechanically abused.
1. Visual inspection for:
- Broken or chipped porcelain insulators.

- Electrical tracking.
- Oil leaks in the main tank.
- Heating around the electrical connections.
2. The majority of these items are installed with fuses. The integrity of these
fuses should be verified during maintenance activities.
1. Perform insulation resistance test between capacitor and ground.
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2. Clean the porcelain insulator and inspect for pitting.
5. Low Voltage Distribution Systems
5.1 Motor Control Centers
A motor control center (MCC) is a collection of 480 volt molded case circuit breakers
and contactors, connected to a single main horizontal bus and smaller vertical bus sections. The units
typically feed motors up to about 300 horsepower, along with various area lighting and control power
loads.
Once a unit is checked out and in service, it tends to need minimal maintenance. The
major concern is keeping all electrical connections properly torqued to insure no hot spots develop
within the unit. The best indicator of a bad connection is the generation of heat when there is a current
flow.
1. Thermally scan each unit for excess heat generation at the cable
terminations and control terminations. (The unit must be in service and under
load.) (SMP-073)
1. Clean and relubricate mechanical breaker operator
2. Visually inspect each unit for signs of excess heat generation.
3. Operate circuit breaker using the following sequence:

1. Trip breaker using the manual trip button
2. Reset breaker handle to the off position
3. Close the breaker handle to the ON position
4. Clean breaker cubical
5. Spot check connections for tightness
5.2 Transfer Switches
Various plants have switches that can utilize either of two incoming power sources to
serve a single load. The switch is typically 480 volt, and is break before make in its operation. More
specifically, at no time can both sources feed simultaneously into a single load.
These devices are common in critical power units such as liquid backup system and
control power feeds. The most common is an automatic transfer switch with manually initiated return to
normal power. In the case where normal power is lost, the switch transfers to an alternate power supply
such as a standby generator. When normal power is restored, a manual return push button must be
pressed or computer signal initiated to transfer the load back. This is done to insure that the operator of
the site is in control of the unit when the transfer is made. Also when power is transferred back to
normal power, a brief outage will occur. All starters will drop out during this outage.
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Maintenance for these units is much the same as for motor control centers. (See
section 5.1.) With the exception of functionally testing any motorized transfer circuits. The best
assurance that the system will function, is a periodic routine of full functional tests of the mechanical
operating system. This should be done both by the manual initiation of the transfer and by the
simulation of a loss of power condition.
Thermoscan the electrical connections to locate hot spots. (This test must be done with the
unit in service and under load. Remember that the test will only indicate heat if current is flowing,
therefore only one of the incoming power sources can be scanned at a time. (SMP-073)
1. Clean transfer switch cubicals
2. Visual inspection to check for unusual heating. (This can be none with the
unit energized or de-energized. Special precautions should be exercised
while inspecting any unit with automatic operation.)
3. Functionally test automatic switch for proper operation
5.3 Low Voltage Bus Duct (See SMP-132)
This information is covered within SMP-132 “Preventative Maintenance for

5.4 Power Cable
600 volt power cable is generally very simple in construction. The jacket is a single
extruded material designed to withstand the voltage and any external environmental conditions. When
replacing existing cables, the routing must be taken into consideration. Exposure to mechanical
damage, water, high temperatures and sunlight can prematurely age insulation systems, causing
failures.
Low voltage power feeders have a design life in excess of 20 years. The major
concern in maintaining low voltage distribution systems is the avoidance of mechanical damage.
1. Visual inspection of all readily accessible cable.
1. Perform insulation resistance tests on cables, as they become available. (Do

not remove a cable from service and test unless readily available or a
problem is anticipated.) [This test may take place from the MCC, which
includes the motor. If any abnormal results occur, then the motor can be
disconnected for further investigation.]
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5.5 Uninterruptible Power Supplies
Uninterruptible power supplies or UPSs, are common in control power supply design.
They operate by storing energy in dc form, usually in a rack of batteries. This stored energy is
continually monitored and float charged. When the primary power source is lost, the dc is inverted back
to ac to feed the load. Most UPSs operate with a static switch that is fast enough that the load will not
sense a loss of power.
A UPS also will act as an electrical filter. Due to the rectification and inversion process,
the power delivered to the load is generally very clean and free of spikes.
For a detailed listing of UPS maintenance, refer to Technical Bulletin 2003-13

“Maintenance Guidelines for Uninterruptible Power Supplies”.
5.6 Buildings and Grounds
5.6.1 Lighting
Typical plant lighting systems should be maintained to insure that all areas
are illuminated consistent with the original plant design. When a light circuit is not functional, it should
be reported immediately, and corrected as soon as possible.
No other periodic maintenance items are required.
5.6.2 Air Conditioning
Air conditioning systems in Praxair switchrooms are installed primarily to

keep moisture and condensation out of the electrical gear. Also, certain electronic devices require
ambients below 40°C. If an air conditioning unit fails, temperatures in switchgear buildings may
increased and cause these devices to stop functioning. Air conditioning systems should be maintained
and kept in service. At the first sign of problems, the systems should be repaired. Poorly functioning air
conditioners are inefficient and cost more money to operate.
Refrigerant levels should be maintained and air paths should be periodically

checked for cleanliness. Air conditioning systems require no other routine maintenance.
5.7 Plant Emergency Trip Stations
Each operating plant is equipped with a series of devices that enable the operators to
shut down the process in the event of an emergency. The last and most important shutdown device is
the plant emergency trip station. The station itself is a mechanical switch that is in an energized circuit
maintaining a relay in the main electrical interrupting device. When the switch is opened the relay is de-
energized and the interrupting device opens.
There are several ways to test the plant emergency trip stations. Each station can be
individually opened to insure the mechanical switch will operate. The relay in the switchgear can also
be operated functionally check the interrupter. The only way to fully test the system is to pull the
handle and operate the switchgear.
1. Check the plant emergency trip stations for physical damage and corrosion. If
the plant is down operate the field boxes to insure the handle will move freely.
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The best way to insure the plant emergency trip stations will function properly is to use
them whenever possible. The best way to accomplish this is to keep a log of the system operations and
when the plant is to be shutdown for maintenance, unload the compressors and functionally trip the
gear with one of the stations. As opportunities arise, alternate through each trip station and log any
problems that might occur. An alternate method is to exercise one trip station to confirm that the
breaker opens, then exercise the remainder of the stations, verifying that the PET relay drops out for
each station operation.
This functional check is important as the PET relay is continuously energized or

‘picked-up’. Over time the relay’s spring could relax or mechanical interference, caused by foreign
substance, may prevent the PET relay from opening, allowing a potentially dangerous situation to
continue after the PET station is pulled.
5.8 Protection and Control
5.8.1 Batteries
Praxair facilities may have batteries in many applications. In this section the focus will
be on substation type wet cell batteries. These will typically by Nickel Cadmium (Ni-Cad) or lead acid.
The cell voltages may range from 1.35 volts to 12 volts per cell. Typical uses will be for uninterruptible
power systems, substation dc control power and backup generator starting. The Ni-Cad batteries offer
longer life and easier maintenance, while the lead acid batteries can deliver more power to a load in a
short time. In general terms, lead acid batteries have a life span of about 5-7 years, and Ni-Cad have
a life span of about 20 years with proper maintenance.
All batteries require periodic maintenance. Electrolyte levels must be maintained and
charge rates must be monitored constantly. Over charging can literally cook the electrolyte out of the
cells and could if left uncorrected, lead to an energy release. Undercharging could render the system
inoperative.
1. Perform infrascan on battery connections, battery cell jars, and battery

charger internals to determine if any abnormal temperatures exist that require
attention. (SMP-073)
2. Check electrolyte levels in each battery cell.
3. Place battery charger on high-rate (equalize) charge for 24 hours
4. Measure and document the high-rate (equalize) voltage. Compare this to the
manufacturer’s specified level and adjust if necessary
5. Allow the batteries to equalize for a period of 24-hours following the high-rate
(equalize) charging
6. Measure and document the float / equalize voltage. Compare this to the
manufacturer’s specified level and adjust if necessary
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7. Measure and record each cell voltage, when the battery charger is in float
charge mode
8. Visually inspect intercell connectors and inter-tier jumpers. Remove any

corrosion or contaminant buildup. (Lead-acid battery systems can be
cleaned with a baking soda solution, Ni-Cad systems can be cleaned with a
Boric acid solution.)
9. Visually inspect electrolyte level of each cell. Top off with distilled or
deionized water as needed to reach the proper level as specified by the
manufacturer
10. For lead-acid battery cells only, take and document specific gravity levels
11. Visually inspect all cell jars and covers for cracking or other physical damage.
This is to include damage due to ultraviolet radiation on plastic battery cases
12. Rinse flame arrestor vent caps with distilled or deionized water and let air dry
13. Inspect battery charger internals for any signs of unusual heating
14. Clean / vacuum internal components and external enclosure surfaces to

maximize heat dissipation
1. Battery systems should be discharged with each cell being monitored. Any
weak cells should be drained and equalized. If they remain weak they should
be replaced.
5.8.2 Metering
Electrical metering systems provide information that affects computer control

and external billing functions. Most metering circuits are relatively stable and are not typically subject to
drift.
The interval in which a metering device is maintained and or calibrated

should be determined by the person requiring the metered information. On non-critical meters such as
unit ammeters and switchgear voltmeters, no routine maintenance is required. On billing meters, the
calibration interval should be spelled out in the contractual agreement. On meters required for
computer control, the mappers should have the final call. If it is suspected that the meter has drifted, the
repair process should be initiated immediately.
5.8.3 Relays
This section is particularity for the maintenance and calibration of switchgear

type electromechanical protective relays. These devices are typically very stable, especially in climate
controlled environments. Digital protective relays are becoming common in newer installations, and do
not require periodic recalibration. These units undergo a self-test to assure proper operation. If a relay
indicates a self-test error, it is to be replaced immediately.
15
Electro-mechanical protective relays must be maintained to insure the
reliability and coordination of the electrical system. A reliable major electrical service company should
be contracted to perform this specialized calibration.
1. Calibrate all electromechanical protective relays in accordance with

protective relay data table and curves. Any deviations are to be
investigated.
2. Confirm that the settings of digital protective relays are in

accordance with issued protective relay data table and curves. Any
deviations are to be investigated.
5.8.4 Wiring
Low voltage control wiring in circuit breakers and starters requires no

particular special preventative maintenance. When routine maintenance is being performed on the
individual distribution units, the control wiring should be inspected for mechanical damage and loose
connections. Wire insulation should also be checked for early signs of embrittlement, which could lead
to failures. During the infrascan tour, this control wiring can be scanned to indicate any ‘hot-spots’ that
have arisen. (SMP-073)
5.9 Variable Speed Drives
Variable Speed Drives (VSD) (or Variable Frequency Drives (VFD) or Adjustable
Speed Drives (ASD)) are electronic devices, generally installed at 480V in MCCs, that are used to vary
the speed of an induction motor. The VSDs can also vary the speed to above nameplate speed by
changing the frequency to the motor to above line frequency. Most drives work by taking a line
frequency supply and rectifying it into dc power. Through electronic switching the dc is converted to a
variable frequency ac output. Because the ac output is composed of a series of pulses, a filter (or
motor designed for inverted duty service) is recommended. Special care is taken during the design of
these systems as the feeder cable to the motor and the motor can be adversely affected by the
electronic switching of the drive.
VSDs require only minimal maintenance activities. Much like the modern digital
protective relays, they have self-test features internal to their programming.
1. Include VSD on infrascan tour to indicate any temperature abnormalities. (Be

advised that the inverter process will generate heat and that heating around
the chassis and heat sink is not abnormal.) (SMP-073)
2. Assure that the ventilation openings are clear and free of debris. Vacuum out
ventilation openings as needed.
3. If applicable, change out or clean filter media.
4. Perform visual inspection of the VSD case.
16
1. Remove VSD cover and perform visual inspection. Items to be aware of
include:
• Internal screws and connections
• Observe dc link capacitor or any leaking / swelling
• Relay contacts for any pitting or roughness
• Wiring and conductors for physical abnormalities
• Observe resistor insulation for any cracks
5.10 Electrical Process Heaters
Electrical process heaters require periodic maintenance to assure the condition of the
heater elements. As listed below this maintenance can be completed in one of two fashions,
depending on the operating state of the heater at the time of the maintenance.
OFF LINE METHOD (unit is deenergized)
1. Inspect for signs of mechanical looseness or other physical abnormalities
2. Measure and document resistance of each leg, phase-to-phase
3. Perform insulation resistance test at 500Vdc between the three phase legs
and ground. Record value
ON LINE METHOD (unit is energized)
1. Inspect for signs of mechanical looseness or other physical abnormalities
2. Measure and record the current on each phase leg. Verify reading with
heater rated output to assure that heater is functioning properly
6. Transformers
6.1 Oil Immersed Power Transformers
6.1.1 Substation Type (See SMP-132)

6.1.2 Pole Mounted Transformers
A pole-mounted transformer is design is a smaller version of the substation

type oil immersed transformer (see SMP-132, section 3.1 for details). In most cases the Praxair site
would not own and therefore not have maintenance responsibility for the unit.
No specific routine maintenance is required on pole mounted transformers. In

most cases the units are sealed such that oil samples are difficult or impossible to attain.
1. Visually check the tank for leaks or damage.
17
2. Thermally scan the connections for unusual heat.
6.1.3 Tap Changers (See SMP-132)

6.2 Dry Type Power Transformers (See SMP-132)

6.3 Potential and Current Transformers
Instrument transformers can be separated into two basic categories. Potential and
current transformers. Potential transformers operate in the same manner as dry type power
transformers and serve two basic functions. They provide power to instruments and monitoring devices
within the distribution equipment and provide a reference voltages for metering and protective
equipment. Current transformers provide instrumentation equipment with a ratio of the current in the
system. This can be used for monitoring, billing or protective purposes.
Instrument transformers, in general, have a dry construction and are not prone to drift
or failure. The wiring systems must be maintained, especially in circuits fed by current transformers. In
no circumstance open a current transformer circuit under load. A current transformer must
constantly feed a load or shorted jumper or it will fail, sometimes violently. The current transformer, if
opened while in service, will start to build up an increasing potential (voltage) that will eventually arc
through the insulation to ground.
1. Visual inspection for:

- Loose secondary wiring.
- Mechanical damage.
- Evidence of corona.
- Heating.
2. Thermoscan connections and main body.
1. Clean with dry cloth and inspect for damage.
2. Note any abnormalities on either the transformer case, termination, or fuses.
3. Verify calibration if drift is suspected.
6.4 Neutral Grounding Resistors (See SMP-132)

18
7. Drives
7.1 Form Wound Motors (operating above 600V)
7.1.1 Induction (See SMP-131)

Electric Motors 2300V and Above”.
7.1.2 Synchronous (See SMP-131)

Electric Motors 2300V and Above”.
7.2 Random Wound Motors (Operating at or below 600V)
7.2.1 NEMA Frame
Small motors, typically 10 to 250hp and 3600 or 1800 rpm, are manufactured
on a frame outlined in the National Electrical Manufacturers Association (NEMA) guidelines. This allows
the motors to be interchangeable between manufacturers. This fact, and the ability to rewind most of
the motors in less than a week, make these motors almost disposable.
The chief maintenance item in NEMA frame motors are the bearings. On the
larger machines, the bearings are typically frictionless. In NEMA machines the bearings are either ball
or roller bearing type. These bearings have a finite life and must be replaced. The life can be monitored
by vibration detectors.
The electrical windings of the motor are extremely difficult to inspect. The
best method of electrical inspection is a 1000 volt dc insulation resistance tester.
NOTE: Economic consideration is to be made on the application of these maintenance items on

readily available NEMA frame motors. For motors that are readily available, the items below may not
be practical to complete based on the cost and availability of a new motor as compared to the cost of
the maintenance effort. This decision is to be jointly made with the region Electrical Specialist and
Plant Management personnel.
1. Lubricate bearings if required. Refer to manufacturer’s

documentation for details regarding lubrication characteristics and
frequency (SMP-001).
2. Include motor on infrascan tour and note any temperature

abnormalities on the body (frame) or bearings of the motor. DO
NOT INFRASCAN INTERNALS OF MOTOR TERMINAL BOX.
(SMP-073)
3. Verify that the motor is adequately grounded and that all connections
are secure and free of corrosion.
4. Visually inspect the motor for any abnormal conditions.
19
1. If predictive tools are not used to monitor bearing conditions, replace

bearings.
2. Perform insulation resistance test at 1000 volts dc.
3. Inspect connection box for heat or loose connections. Verify the

installation of a protective bushing.
4. Verify existence / condition of conduit entrance bushing into motor

terminal box.
7.2.2 Above NEMA Frame Size
Random wound motors above NEMA frame are extremely uncommon in

Praxair Plants. They are identical in construction to the smaller NEMA frame motors. The major
difference is the lack of interchangeability between manufacturers.
The only real maintenance item in NEMA frame motors are the bearings. On
the larger machines, the bearings are typically frictionless. In NEMA machines the bearings are either
ball or roller bearing type. These bearings have a finite life and must be replaced. The life can be
monitored by vibration detectors, but the most practical maintenance practice is to replace the bearings
at a predetermined interval.
The electrical windings of the motor are extremely difficult to inspect. The
best method of electrical inspection is a 1000 volt insulation resistance tester.

See Section 7.2.1 for maintenance items

See Section 7.2.1 for maintenance items
7.3 Generators
7.3.1 Cogeneration Type
These units contain several pieces of equipment each having specific

maintenance requirements. Each piece of equipment interacts with other equipment. Based on this
interaction and the overall complexity of this equipment it is strongly recommended that the
manufacturer’s maintenance manual for the specific cogeneration equipment be used exclusively to
determine maintenance requirements.
7.3.2 Standby Generators
In Praxair facilities there is often a need for an backup power supply. Whether
it is to support a liquid backup system or to keep a computer system on line the design is about the
same. Most Praxair generator systems are induction generators driven by a diesel or natural gas fired
motor.
20
The major concern in this type of a generator system is making sure that the
generator functions properly under the fully loaded condition. The most practical way to accomplish
this task is to load the generator (by operating load, fixed load bank, or installed load bank) on a regular
basis. This is the most straightforward method of assuring reliable generator operation.
Because of the various tests involved with this equipment, it may be

beneficial to contract the maintenance to generator service contractors to assure the operational
reliability of this equipment.
The manufacturer’s documentation should be used to direct various

maintenance activities, however in absence of such documentation NFPA-110 Figure A.8.3.1(a) can be
referenced for direction
ROUTINE MAINTENANCE ITEMS
1. If practical (i.e. installed load bank) exercise generator for at no less

than 50% load on a weekly basis for 30 minutes. Record any deficiencies or abnormalities.
1. Check engine coolant and oil levels
2. Change engine oil and filter if necessary
3. Check all belts and hoses for cracking and wear. Replace as
necessary
4. Verify proper operation of cooling air intake and exhaust louvers
5. Clean air filters. Replace as necessary
6. Test the engine starting batteries and battery charger. Repair /

replace as necessary.
7. If installed, confirm that built-in load bank is set up for automatic

operation and is functioning properly
8. If built-in load bank system is not installed, perform load test with
portable load bank or actual system load
9. Verify that fuel supply system is functioning properly
10. Verify condition of exhaust system
11. Perform other engine maintenance according to manufacturer’s

documentation
1. Perform insulation resistance test on generator windings at 1000Vdc
2. Inspect connection box for signs of heating or loose connections
21
3. Load generator to at least 80% of nameplate rating
8. References
The following documents may be consulted for additional information regarding equipment
maintenance:
NFPA 70B: Recommended Practice for Electrical Equipment Maintenance
NETA MTS: Maintenance Testing Specifications
Manufacturer’s instruction / operational documentation
22
Appendix A: Earth Resistance Testing
There are four methods commonly used to determine earth resistance.
1. Direct
2. Slope
3. Fall-of-potential
4. Intersection
For Praxair plants we will use the fall-of-potential and intersection methods. The fall-of-potential
method is the most common and will be used on all small grounding systems (less than 100 feet at the
longest diagonal). The Biddle Ground Resistance Tester will be used for both tests.
FALL-OF-POTENTIAL METHOD
The fall-of-potential method is the most widely used of all the accepted ground tests. It is practical on
small and medium sized systems.
The test is accomplished by providing a measured amount of current between a current electrode and
the ground system being tested. A voltmeter will measure the voltage difference between the ground
system and a potential electrode which should be located on a straight line between the ground system
and the current electrode. By moving the potential electrode to various positions between the current
electrode and the ground system a plot of resistance relative to distance can be generated. The
resistance will increase as the potential electrode moves away from the ground system. As the
electrode approaches 62% of the way from the grounding system to the current electrode, the slope of
the graph should approach 0. This is the point where the resistance is out of the spheres of influence
of the ground system and the current electrode. This is the equivalent impedance to earth of the
system is being tested.
The Biddle tester will have specific instructions on probe spacing and lead connection. Although the
62% rule applies in most cases, the graph should be generated to ensure that the probe spacing is
sufficient to generate accurate results.
A qualified contractor should be contacted to perform the ground measurement test. For further
information contact the regional Reliability Center.
23

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SMP-030 PREVENTATIVE MAINTENANCE MAJOR ELECTRICAL EQUIPMENT

1. Purpose and Contents

1. Purpose and Contents ....................................................................................................... 1

This document serves as a tool to aid in the standardization of preventive maintenance

3.1 Circuit Breakers and Switches

3.1.1 Oil and SF6 Circuit Breakers

In general, these devices require minimal maintenance under normal

PERIODIC MAINTENANCE ITEMS

2. For O. C. B.s, visually inspect for oil leaks around bushings.

3. Perform a thermographic scan of all exposed current carrying

7. If applicable (only on pneumatically controlled breakers), bleed

8. On pneumatically controlled breakers, verify & document pressure

9. Operate the breaker if possible. Do this only if the facility is down.

MAJOR MAINTENANCE ITEMS

1. For pneumatically controlled breakers only:

B. Check pilot valve for proper operation and replace if

2. Check control mechanism (breaker should be operated several

3. Exercise trip and control loops.

4. Check calibration of pressure switches against the value stamped on

5. Measure average breaker trip & close velocities

6. Check the breaker opening and closing timing

7. Check the contact resistance using a high current digital low

8. Confirm operation of circuit breaker control cabinet space heater

9. Verify circuit breaker trip-free operation

3.1.2 Isolating Switches

High voltage isolating switches are typically used in substation applications to

These devices require minimal maintenance. The primary concern is the

PERIODIC MAINTENANCE ITEMS

MAJOR MAINTENANCE ITEMS

4. Lubricate and verify operation of all key interlocks and sequencing of

5. Clean and grease all operator components

6. Visually inspect the insulators

3.1.3 Motorized Isolating Switches

High voltage motorized isolating switches are typically used n i substation

These devices require minimal maintenance. The primary concern is the

PERIODIC MAINTENANCE ITEMS

MAJOR MAINTENANCE ITEMS

1. Inspect all electrical connections to the drive motor

6. Clean and grease all operator components

7. Visually inspect the insulators

3.1.4 Manual Grounding Switches

Manual grounding switches provide a positive means to ground a section of a

These devices require minimal maintenance. The primary concerns being

PERIODIC MAINTENANCE ITEMS

MAJOR MAINTENANCE ITEMS

4. Lubricate and verify operation of all key interlocks and sequencing of

5. Clean and grease all operator components

6. Visually inspect the insulators

The maintenance on this equipment consists of continual good housekeeping

PERIODIC MAINTENANCE ITEMS

1. Visually inspect for damage, corrosion and abnormalities.

2. Thermographically inspect all electrical connections while the system is in

MAJOR MAINTENANCE ITEMS

1. Repair all structural defects

2. Inspect insulators for any defects (arcing, tracking, or pitting)

4. Thoroughly inspect lightning arrestors for any defects or other abnormalities.

3.3 Ground Grid

PERIODIC MAINTENANCE ITEMS

1. Visually inspect all above ground mechanical connections.

MAJOR MAINTENANCE ITEMS

4. Medium Voltage Distribution Systems

4.1 Circuit Breakers and Switches

The use of oil circuit breakers in Praxair Facilities in medium voltage