Electrical Equipment Maintenance

SAFE OPERATING PROCEDURE Rev.
01
ELECTRICAL EQUIPMENT MAINTENANCE Page 1 of 63
SAFE OPERATING PROCEDURE & GUIDELINES
FOR
ELECTRICAL EQUIPMENT MAINTENANCE
Page 1 of 63
SAFE OPERATING PROCEDURE Rev. 01
PREPARED BY:
ASK-EHS Engineering & Consultants Pvt. Ltd.
NAME: L.B. Sinha
SIGNATURE:
Date:
REVIEWED BY:
NAME:
SIGNATURE:
Date:
APPROVED BY:
NAME:
SIGNATURE:
Date:
Page 2 of 63
Page 3 of 63
Index
Page
Sr. No. Description
No.
1 INTRODUCTION……………………………………………………………………................ 7.
2 PURPOSE………………………………………………………............................................ 7.
3 SCOPE………………………………………………………………………………………….. 7.
4 REFERENCES…………………………………………………………………………………. 8.
5 DEFINITIONS OF TERMS AND ABBREVIATIONS…………………………………….... 9.

6 ROLES AND RESPONSIBILITIES………………………………………………………...... 10.
6.1 Field Superintendent (FS) 11.
6.2 Store Attendant 11.
6.3 Work Supervisor 11.
6.4 Equipment Operator 12.
6.5 Equipment Inspector 12.
7 METHODOLOGY……………………………………………………………………………….. 13.
7.1 Work Method Statement (WMS) 14.
7.2 Process & Preparation 14.
7.2.1 Wear and Tear of the working parts of the machine 14.
7.2.2 Wear control 15.
7.2.3 Care and maintenance of the machines& equipment 16.
7.3 Maintenance 17.
7.3.1 Preventive Maintenance 17.
7.3.2 Reliability Centered Maintenance 19.
7.3.3 Condition-Based Maintenance 19.
7.3.4 Combination of Condition-Based and Preventive Maintenance 20.
7.4 Maintenance and Test Procedures 20.
7.5 Maintenance Schedules and Documentation 21.
7.5.1 Safety during Maintenance 22.
7.5.2 Organizing scheduled maintenance and repairs 22.
Page 4 of 63
8 PROCESS FLOW 24.

8.1 Permit to Work System 24.
8.2 System Custodians and Focal Points 24.
8.3 PTW Cycle 25.
9 OUTLINING SOPs FOR ELECTRICAL EQUIPMENT MAINTENANCE 26.
9.1 General Safety Provision (GSP) 26.
9.2 Operational Maintenance 27.
9.3 Preventive Maintenance (PM) 27.
9.4 Breakdown Maintenance 28.
10 GUIDE LINES FOR SOP FOR THE MAINTENANCE OF ELECTRICAL EQUIPMENT 28.
10.1 Maintenance of Air / Oil Circuit Breaker 28.

10.2 Preventive Maintenance of Generator and Large Motors 34.
10.3 Preventive Maintenance of Disconnect Switch 37.
10.4 Transformers 38.
10.4.1 Station/ Distribution Transformers Under 500 kVA 38.
10.4.2 Instrument Transformers 39.
10.4.3 Dry-Type Power Transformers – 500 kVA and Larger 39.
10.4.4 Oil-Filled Power Transformers 40.
10.5 Engine Generators 41.
10.6 Exciters and Voltage Regulators 41.
10.7 Batteries and Battery Chargers 42.
10.8 Power Cables – Rated 5 kV and Above 43.
10.9 Buswork, Enclosures, and Insulators 44.
10.10 Bushings 44.
10.11 Arresters (of lightning/ surges) 44.
10.12 Control Circuits 45.
10.13 Emergency Lighting 45.
10.14 Ground Connections 46.
10.15 Relays and Protection Circuits 46.
10.16 SCADA Systems 48.
10.17 Security Systems 48.
10.18 Transducers/ Meters 49.
10.19 Fire Detection, Fire Fighting Equipment, and Alarm Systems 49.
Page 5 of 63
10.20 Fuses 49.

10.21 Annunciators 50.
10.22 Personal Protective Equipment 51.
10.23 Maintenance of Electrical Equipment in Hazardous Area 51.
10.24 Live Line Maintenance 53.
11 TRAINING FOR SAFE MAINTENANCE OF ELECTRICAL EQUIPMENT 54.
12 SOP COMPLIANCE 54.

13 MONITORING 55.
14 AUDITING 55.
15 SYSTEM REVIEW 55.
16 UPDATING 56.
APPENDIX: 57.
1 PHYSIOLOGICAL EFFECT OF ELECTRICITY 57.
2 ELECTRICAL HAZARDS 59.
3 MEDICAL & FIRST AID 61.
Page 6 of 63
1. INTRODUCTION
Progressive employers, as part of the duty of care, due diligence, common law and legislation,
provide and maintain safe system of work. Part of this requires the development and
implementation of safe work procedures, as a measure of administrative risk control under the
overall scheme of managing HSE risks.
Here is provided a specific “Safe Operating Procedure and Guidelines for Electrical Equipment
Maintenance” for Bunduq Oil and Gas Extraction Offshore Installation, Abu-Dhabi, in a
technology- rich and best- in- class manner. Electricity poses potential danger to human lives and
limbs with an effect of shock, paralysis and severe burns. Electrical equipment, charged with
electrical energy in course of electricity generation, transmission and utilization, need very careful
and safe handling to save against above mentioned adverse effects, but, even during maintenance
of electrical equipment due care, procedure and optimum precautions are required to be observed
for satisfactory and safe conclusion of the maintenance process. Each electrical equipment,
machines and gadgets, intended to perform certain specific functions and services, needs careful
study of its functioning, the place of work, environment of working and any specific duty assigned to
it, before any worthwhile scheme of maintenance can be planned, prepared, undertaken and
concluded. The present SOP provides enough guidelines from various angles of hazards arising,
their likely consequences, proven means of minimizing the resultant risks and show the way to
conclude the hazardous maintenance of electrical equipment.
2. PURPOSE:
Machine and equipment need timely care, upkeep and correct way of operation, storage,
maintenance, repair and renovation to render optimum services for its full length of designed life.
The purpose of this procedure is to provide the guidelines for the inspection process, shutdown of
the unit adopting Permit to Work Procedure, proper maintenance/ repair of the Electrical Equipment
and its re-assembly/ trial run and final handing out for regular operation; giving due weightage to
designer’s/ manufacturer’s recommendations.
3. SCOPE
Handling of electrical power involves phases of generation of electricity by various means,

transmission of power to long distances, gridding and distribution of power at and from sub-stations
and utilization of power at different points of loads in industrial undertakings, residential buildings
and several other civilian establishments.
This vast gamut of electrical sourcing and application utilizes variety of electrical gadgets,
equipment, machines of rotating and stationary types, measurement and control devices and
instruments and variety of protective means and devices. All of them in various shapes, sizes,
configurations and setup, in course of working, undergo deterioration, wear and tear, loss of
capacity, finally leading to breakdown. The wise course of action calls for timely intervention of
maintenance management to ward off the stoppage of electrical works by means of well planned
Page 7 of 63
preventive maintenance, timely inspection and condition based maintenance (CBM), running
overhauls and capital repairs.
Some classified electrical equipment is as follows:
At generation point Æ
Generators/ prime mover/ auxiliaries
Busbars
Switchgear
Auxiliary system
Transformer
Power cables or overhead lines or busducts
At substation point Æ
Busbars
Transformers
Power cables or overhead lines or bus duct
Control room/ communication/ SCADA systems
Auxiliary systems
At utilization point Æ
Outdoor or indoor substation with
Transformers
Switchgear
Utilization equipment, Motors
Busbars
Power cables or overhead lines or busducts
Controlgear
Control room
Auxiliary system
The manufacturer’s recommendations and guidelines will provide the best, most efficient and safest
course to SOP.
4. REFERENCES
UAE laws and ministerial orders with relevant national and international standards and code of
practice, including that of International Labour Organisation, demand from industrial establishments
to ensure safety, health and welfare of the workmen at workplaces.
United Arab Emirates Federal Law No.: 8 of 1980 requires employers to provide adequate
preventive equipment to protect workers against the dangers of employment accidents and
Page 8 of 63
occupational diseases that may occur during the work, and also against fire and other hazards that
may result from the use of machines or other equipment (Article – 91).
Occupational Safety and Health Administration (OSHA) 29 Code of Federal Regulations

(CFR) 1910 Subpart
CFR 1910.269 Electric Power Generation, Transmission and Distribution
CFR 1910.243 Guarding of Portable Powered Tools
CFR 1910.244 Other Portable Tools and Equipment
NFPA 70B: Recommended Practice for Electrical Equipment Maintenance
NFPA 70E: Standard for Electrical Safety in the Workplace
ILO: Code of Practice—Electrical Safety
BUNDUQ HSE Procedures and Manuals
5. DEFINITIONS OF TERMS AND ABBREVIATIONS
SOP: Safe Operating Procedure; other common names used are
• Safe Work Practices (SWP),

• Standard Work Practices,
• Standard Work Methods,
• Standard Operating Procedures,
• Work Instructions.
SOP outlines all the safety precautions that must be observed to take
care of associated risks while carrying out a specific task safely.
Permit to Work System: The system that allows central control and ongoing monitoring of higher
risk activities on a site and in particular to ensure that activities are
authorized, carried out by qualified personnel using appropriate safety
precautions and that activities with potentially hazardous interactions do
not take place at the same time .
Electrical equipment: Electrical equipment include any power-handling gadget or any

machine/ tool powered by electricity. They usually consist of an
enclosure, a variety of electrical components, and often a power switch.
Page 9 of 63
Intrinsically Safe: an equipment or gadget so designed and constructed that in case of

fault or otherwise, the energy released outside is incapable of igniting a
flammable fluid, gas or solid dust.
Audit: is an independent, systematic and documented process of objectively

obtaining and evaluating verifiable evidences to determine that HSE
controls are complete and consistent.
Safety Training: encompasses the steps necessary to ensure that management,

employees and contractors have the job competencies (knowledge, skill
and values) necessary to fulfill their environmental, health and safety
responsibilities.
Safe: means a condition in which all hazards inherent in an operation have

either been eliminated or are controlled such that their associated risks
are both below a tolerable threshold and are reduced to a level which is
as low as reasonably practicable (ALARP). Risk = Frequency x
Consequences.
Operator Individual, who has been trained, assessed and authorized under
BUNDUQ guidelines as competent person to maintain electrical
equipment.
6. ROLES AND RESPONSIBILITIES
The following is a broad set of responsibilities for the key positions for Electrical Equipment
Maintenance Safe Operating Procedure. It is recommended that they shall be used as the basis for
the development of local rules that more specifically define the key interfaces and responsibilities in
conjunction to other Approved HSE procedures of BUNDUQ Oil Company. These guidelines shall
not be considered as standalone and shall require to be in line with other relevant and existing
procedure like Permit to Work, Job Safety Analysis etc and all the Environment Health Safety
Procedures of BUNDUQ Oil Company.
Only project approved competent personals shall be assigned to oversee the selection, use,
alteration, maintenance and inspection. Only specifically assigned, trained and experienced
personnel shall be allowed to be involved in the Inspection process of any Electrical Equipment.
It shall be insured that competent personnel have complete knowledge about the type of electrical
equipment being used and about their proper care and maintenance.
Page 10 of 63
6.1. Field Superintendent (FS)
The FS shall:
Ensure the implementation and adherence to this Procedure and report violations and/or non-
compliance issues to management for immediate disciplinary action;
Coordinate training for personnel required to work and/or supervise the work of Maintenance
of Electrical Equipment.
Maintain a high standard of quality and content for all SOP System documentation.
Ensure that a system is in place to deliver supplies of the necessary documentation to users.
Control revisions to the SOP System, consulting with user Departments about any changes
that will be made.
Ensure that briefings are delivered on any changes to the System.
Provide training to SOP Area Control Points.
6.2. Store Attendant
Stores Attendant shall be responsible for the procurement and issuance of all the materials
required in the work area.
Stores Attendant shall maintain a current inventory of all the designated materials.
The materials shall be placed in secured areas.
Store Attendant ensures that all the materials in the store are inspected by competent persons
as per the inspection procedure of the company.
Store Attendant shall maintain the maximum and minimum levels of materials as decided in
the stores procedure.
6.3. Work Supervisor
Shall ensure initial and refresher training of the workforce to be engaged in the maintenance
of electrical equipment.
Electrical energy being highly hazardous, maintenance of electrical equipment has to be

undertaken with meticulous adoption of PTW system considering all the involved hazards. To
ensure positive isolation, adopt LOTO System.
Ensure that the industrial equipment and tools used by operator are in safe working condition.
Monitor work procedures to ensure workforce are performing their duties in a safe manner.
Page 11 of 63
Shall enforce the use of proper PPEs while employees undertake maintenance of electrical
equipment.
Supervisors will communicate to managers about hand and portable power tools needed for
successful maintenance of electrical equipment. All the required tools of right quality should
be available for use before the actual maintenance work is undertaken.
6.4. Equipment Operator
Be attentive and focused while his equipment / machines are under maintenance.
Inspect the work station or job site for potential hazards and ensure that all equipment,
machines and tools are in a safe condition before they are offered for maintenance.
Any specific problems encountered by the operator during operation are to be communicated
to the maintenance crew and rectified.
Operation crew has to be satisfied after the maintenance work has been completed that the
equipment are in a revamped condition and fit for taking over for subsequent operation.
Attend job-specific safety training to become knowledgeable about the hazards associated
with equipment and tools used to perform work.
Use the specified PPE required for the hazards for the task and/or work area.
Maintain the engineering controls (guards, shut-off switches, anchoring devices, etc.).
Operators are prohibited from removing or disabling any of these safety devices without first
getting permission from their supervisor.
Not Operate powered industrial equipment or powered hand tools unless trained, qualified,
and authorized.
Only use powered equipment / machines / tools for the intended purpose in accordance with
the manufacturer’s instructions.
6.5. Equipment Inspector
Equipment Inspector should be qualified by training and experience to pass judgment on the
condition of equipment for use.
Shall be responsible to maintain and update the equipment inspection register.
Shall be responsible to follow prescribed inspection schedule for the equipment.
Shall be responsible to offer for maintenance the equipment classified Unsafe or UNFIT for
use.
Page 12 of 63
Shall be responsible that all the equipment is repaired as per manufacturer’s guidelines.
shall document each equipment’s preventative maintenance schedule based on:
(1) The manufacturer’s recommendations;

(2) Best engineering practices (if manufacturer’s recommendations are not known or
available);
(3) The amount of use (e.g., equipment used daily require more frequent inspections and
maintenance);
(4) The type of environment (e.g., equipment / machines used in dusty conditions or under
temperature extremes require more frequent inspections and maintenance);
(5) The hazard of the equipment / machine (e.g., power-actuated tools, chain saws, etc.,
require more frequent inspections and maintenance);
(6) If an equipment / machine has been subjected to an abnormal load or shock, it shall be
inspected prior to use and offered for maintenance if not found fit.
For assigning competent personnel to perform preventative maintenance inspections.
7. METHODOLOGY
Correct methodology for any set of machinery entails full grasp of the machines, care of the
machinery and there by improving the durability and reliability of its operation and service.
A machine or an industrial installation is a mother unit producing beneficial and golden goods and
services of common use, public consumption, civil utilities, industrial services; like the proverbial
hen laying regularly golden eggs which constantly demands tender care and nursing, without
resorting to greedy and unwise over exploitation on its being.
Care of machinery—Maintainability is a property of machine which is characterized by their fitness

for maintenance and repairs, i.e. for prevention, detection and elimination of failures and
malfunctions. A malfunction is a condition when the machine fails to meet at least one of the
specification requirements or corresponding standards. A malfunction may not cause a failure. A
failure, on the contrary, always is the result of some malfunction or fault.
Maintainability is provided when designing machines. It requires the use of standardized units and
parts, the selection of parts having the same wear rate in each unit, and the ability of an easy and
rapid replacement of units.
System of scheduled preventive maintenance and repairs is to be adopted, mainly on the basis of
the designer’s and manufacturer’s recommendations. Equipment is to be maintained regularly to
prevent breakdown stops or losses in the rated productivity.
Page 13 of 63
Improving the durability and reliability of a machine—During running, the contacting and rubbing
surfaces of the machine wear gradually up to the time when the operation of the mating parts is
impaired, which is indicated by intensified noise and heating, uneven run, vibration and other
malfunctions. The parts subject to cyclic loads and fluctuating temperatures become cracked,
deformed and weak i.e. they wear down. The wear of parts is neither uniform, nor simultaneous.
Each machine has rapidly and slowly wearing parts. The rapidly wearing components determine the
machine operation time, i.e. the time between successive routine repairs.
The property of machines and their parts to retain their fitness for work and the related quality
output is called dependability. The main indices of the quality of machines are—preservation ability,
dependability, durability, maintainability and reliability which are to be ensured by the manufacturer
and supplier. It is, therefore, recommended that purchases should be made from reputed and
quality manufacturers who care for their products and through their products and services, they
care for their customers.
7.1. Work Method Statement (WMS)

A written plan that describes the processes/steps and methodology: be used to safely
accomplish a specific task or activity. For purposes of this procedure, method statements shall
evolve from the risk assessment and be used to verify that real and potential threats associated
with the work have been identified and are understood. Further, that those threats (risks) have
been engineered out and/or protective measures have been put in place to ensure the task or
activity and those performing it are protected and safe at all times. Method statements must also
take into consideration and document requisite emergency plans/procedures to be followed
should an emergency arise.
Minimum requirements:
Scope of Work – Work to be performed.
Engineering Controls.
Required Safety Equipment.
Duration of work
Number of personnel.
Sketch including general work location, adjacent areas and engineering provisions to facilitate
undertaking maintenance of Electrical Equipment.
7.2. Process & Preparation
7.2.1. Wear and Tear of the working parts of the machine:

Wear is a process of gradual change of the dimensions and condition of working surfaces,
or a process of a gradual loss of strength of the material of machine elements, which takes
Page 14 of 63
place during equipment operation as a result of friction, mechanical loads, chemical and
thermal phenomena.
Mechanical loads cause alterations of the pre-set clearances and fits at the contact areas
between rubbing part surfaces, or diminution of the strength of the material of parts due to
fatigue phenomena.
Chemical, electrochemical and biochemical process affect the material and lubricant of
parts, causing various kinds of corrosion that impairs the quality of the working surfaces,
reduces the strength of the material of parts and deteriorates the useful properties of
lubricants.
Thermal processes and, especially, alterations of heating and cooling facilitate the
development of internal breaking stress in the material of parts and cause the so-called
thermal wear accompanied by heat checking, formation of surfaces scale, and warpage
(distortion of the original shape), as well as by a change in the structure, physical and
mechanical properties of the material of the parts.
Normal wear of parts is a slow process. It is the inevitable result of the equipment
operation. The breakdown wear is a rapid and sometimes sudden destruction of parts due
to defects in the machine design and in the material of parts, poor machining, treatment
and assembly of parts, and wrong operating conditions(poor lubrication of equipment, high
overloads), etc.
Physical wear is an extremely worn-out state when a regular major repair is urgent and
further operation of the un-repaired equipment leads to a drop in productivity, loss in the
quality of products, unsafe working conditions or any other subversive consequences.
The material that well resists wear is called wear-proof or wear-resistant. Classification of
materials in accordance with their wear resistance is at present carried out on the basis of
practical data and laboratory research findings, which the designers and manufacturers
must care to incorporate.
7.2.2. Wear control:

The category of part wear and destructions under friction, cyclic loads, mechanical and
thermal fatigues, as well as different types of corrosion may be reduced to the following
main process:
(i) Wear of surfaces due to friction and corrosion—attrition, scoring, tearing off, crushing,
oxidation.
(ii) Wear of surfaces under cyclic loads and heating—cracking, chipping, spelling,
crushing.
Page 15 of 63
(iii) Internal physical and structural destruction of material under cyclic loads, especially in
a high-temperature medium- cracks, fractures, creep, relaxation.
The general measures preventing wear are as follows:
(i) designing the friction assemblies by taking into account the specific loads, fits and
prevailing type of wear;
(ii) selecting the correct materials for the rubbing surfaces;
(iii) treating the friction surfaces to obtain a high hardness and a fine surface finish;
(iv) obtaining a good wear-in of the friction surfaces;
(v) employing the correct lubricants;
(vi) Operating and maintaining the equipment properly.
The time required for wearing-in may be reduced by improving the mechanism accuracy
and fitting of parts, as well as by running in the equipment before putting it into operation.
The friction surfaces in heavily loaded mechanisms must be tougher than those of the
mechanisms operating under light conditions.
The wear of the rubbing surfaces can be reduced through a proper choice of lubricant and
by its rational feed to the friction-couple assembly. The systems of lubrication by oil
circulation significantly reduce the wear of parts and lower the temperature of friction
surfaces.
7.2.3. Care and maintenance of the machines & equipment:

Machinery maintenance envisages a strict adherence to the established lubrication
schedule for all friction assemblies, use of the lubricants of specified grades, regular
cleaning of machines from production wastes (chips, swarf crops, scrap, scale, dust, etc.),
inspection of all fastenings with special attention to the points where connections are apt
to loosing as a result of vibrations or temperature fluctuations. In order to meet all these
requirements the machine operator must thoroughly study the design of the machine and
its operating and maintenance instructions, overhauls and repairs of his machine carried
out crews of fitters and mechanics.
The running condition of machinery shall be checked by:

Shop-manager assistant for supervising equipment—at least monthly;
Shop mechanic—at least twice per month;
Maintenance supervisor—at least weekly;
Shift foreman (team leaders) — daily during shift turn-over
Page 16 of 63
The results of the checks are recorded in an installation log book to indicate all noticed
faults and malfunctions.
Studying the machine design and performance contributes to finding out its weak links and
working out measures that will improve the wear resistance of certain parts and provide for
a uniform slow wear of all identical parts. Apart from increasing its service life, the studying
of the machine may lead to the improvement of the machine design and raising its
productivity.
A regular daily inspection of machines during shift turn-over provides the necessary data
for their repairs and facilitates the work of a repair team while inspecting equipment and
compiling lists of faulty parts.
Machines are inspected by attendant fitters and mechanics, lubricators, operators and
other personnel.
During inspections carried out in the course of a shift turn-over the following items shall be
checked:
(a) First of all, the parts, units and mechanisms in which malfunctions and faults were
detected during the previous shift;
(b) Reliability of the fastenings of the units and parts whose loosening may cause a
breakdown or shut-down;
(c) Operation of starting, breaking and interlocking devices and limit switches;
(d) Degree of heating of friction assemblies, operation of lubricating devices and the
presence of lubricants in them, running condition of all important gear trains and speed
reducers, as well as vibrations and joggles in the drive components;
(e) Conditions of guards;
(f) Cleanliness of equipment and work place tidiness, availability of tools, fixtures and
spare parts.
7.3. Maintenance
Maintenance recommendations are based on industry standards and experience in the facilities.
However, equipment and situations vary greatly, and sound engineering and management
judgment must be exercised when applying these recommendations. Other sources of information
must be consulted (e.g., manufacturer’s recommendations, unusual operating conditions,
personal experience with the equipment, etc.) in conjunction with these maintenance
recommendations.
7.3.1. Preventive Maintenance

Preventive maintenance (PM) is the practice of maintaining equipment on a regular
schedule, based on elapsed time, run-time meter readings, or number of operations. The
Page 17 of 63
intent of PM is to “prevent” maintenance problems or failures before they take place by

following routine and comprehensive maintenance procedures. The goal is to achieve
fewer, shorter, and more predictable outages.
Some advantages of preventive maintenance are:
It is predictable, making budgeting, planning, and resource leveling possible.
When properly practiced, it generally prevents most major problems, thus reducing
forced outages, “reactive maintenance,” and maintenance costs in general.
It gives managers a level of assurance that equipment is being maintained.
It is easily understood and justified.
Preventive maintenance does have some drawbacks:
It is time consuming and resource intensive.
It does not consider actual equipment condition when scheduling or performing the
maintenance. But, it should definitely take care of the problems witnessed by the
operation and inspection people during the intervening period.
It can cause problems in equipment in addition to solving them (e.g., damaging seals,
stripping threads), sometimes, particularly when over-maintenance is done.
Despite these drawbacks, PM generally has proven to be reliable in the past and is still the
core of most maintenance programs.
Traditionally, preventive maintenance has been the standard maintenance practice in
Reclamation. The maintenance recommendations in this document are based on a PM
philosophy and should be considered as “baseline” practices to be used when managing a
maintenance program.
However, care should be taken in applying PM recommendations. Wholesale
implementation of PM recommendations without considering equipment criticality or
equipment condition may result in a workload that is too large to achieve. This could result
in important equipment not receiving needed maintenance, which defeats the purpose of
PM.
To mitigate this problem, maintenance managers may choose to apply a consciously
chosen, effectively implemented, and properly documented reliability-centered
maintenance (RCM) program or augment PM with condition based maintenance (CBM)
practices.
Whether utilizing a PM, RCM, or CBM, or a combination of these, the primary focus of the
in-house maintenance staff should be scheduled maintenance. This will reduce reactive
(emergency and corrective) maintenance. Scheduled maintenance should have a higher
priority than special projects. Scheduled maintenance should be the number one priority.
Page 18 of 63
7.3.2. Reliability Centered Maintenance

Reliability-centered maintenance programs are gaining in popularity and have been piloted
in a few Reclamation power facilities with good results. The goal of these programs is to
provide the appropriate amount of maintenance at the right time to prevent forced outages
while at the same time eliminating unnecessary maintenance.
Implemented properly, RCM can eliminate some of the drawbacks of preventive
maintenance and may result in a more streamlined, efficient maintenance program. RCM
seems very attractive in times of diminishing funding, scarcity of skilled maintenance staff,
and the pressure to “stay online” due to electric utility industry deregulation.
Some features of RCM are:
Labor intensive and time consuming to set up initially.
May require additional monitoring of quantities like temperature and vibration to be
effective. This may mean new monitoring equipment with its own PM or more human
monitoring with multiple inspections.
May result in a “run-to-failure” or deferred maintenance philosophy for some
equipment with its own PM, which may cause concern for some staff and managers.
May require initial and later revisions to the maintenance schedule in a “trial and-error”
fashion depending on the success of the initial maintenance schedule and equipment
condition.
Should result in a more manageable maintenance workload focused on the most
important equipment.
RCM is not an excuse to move to a “breakdown maintenance” philosophy or to eliminate
critical preventive maintenance in the name of reducing maintenance staff/funding.
For RCM to be a viable program, it must:
Be chosen as the local maintenance philosophy by management.
Be implemented according to generally accepted RCM practices.
Be documented so that maintenance decisions are defensible.
7.3.3. Condition-Based Maintenance
This program relies on knowing the condition of individual pieces of equipment. Some
features of CBM include:
Monitoring equipment parameters such as temperatures, pressures, vibrations,
leakage current, dissolved gas analysis, etc.
Testing on a periodic basis and/or when problems are suspected such as double
testing, vibration testing, and infrared scanning.
Careful monitoring of operator-gathered data.
Page 19 of 63
Results in knowledgeable maintenance decisions which would reduce overall costs by

focusing only on equipment that really needs attention.
Drawbacks to CBM include it being very difficult and expensive to monitor some
quantities. It requires knowledgeable and consistent analysis to be effective, and condition
monitoring equipment and systems themselves require maintenance.
Because of these drawbacks, it is nearly impossible to have an entirely condition based
maintenance program.
7.3.4. Combination of Condition-Based and Preventive Maintenance
A combination of condition-based maintenance and preventive maintenance is perhaps
the most practical approach. Monitoring, testing, using historical data, and preventive
maintenance schedules may provide the best information on when equipment should be
maintained. By keeping accurate records of the “as found” condition of equipment when it
is torn down for maintenance, one can determine what maintenance was really necessary.
In this manner, maintenance schedules can be lengthened or perhaps shortened, based
on experience and monitoring.
7.4. Maintenance and Test Procedures
Electrical maintenance activities fall into three general categories:
Routine Maintenance – Activities that are conducted while equipment and systems are in
service. These activities are predictable and can be scheduled, staffed, and budgeted. Generally,
these are the activities scheduled on a time-based, run-time-meter-based, or a number of
operations schedule.
Some examples are visual inspections, infrared scans, cleaning, functional tests, measurement of
operating quantities, lubrication, oil tests, governor, and excitation system alignments.
Maintenance Testing – Activities that involve the use of test equipment to assess condition in an
off-line state. These activities are predictable and can be scheduled, staffed, and budgeted. They
may be scheduled on a time, meter, or number of operations basis but may be planned to
coincide with scheduled equipment outages. Since these activities are predictable, some offices
consider them “routine maintenance” or “preventive maintenance.”
Some examples are Doble Testing, Meggering, Relay Testing, Circuit Breaker Trip Testing,
Alternating Current (AC) High-Potential (Hipot) tests, High Voltage Direct Current (HVDC) ramp
tests, battery load tests.
Diagnostic Testing – Activities that involve use of test equipment to assess condition of
equipment after unusual events such as faults, fires, or equipment failure/repair/replacement or
when equipment deterioration is suspected. These activities are not predictable and cannot be
scheduled because they are required after a forced outage. Each department must budget
contingency funds for these events.
Page 20 of 63
Some examples are Doble testing, AC Hipot tests, HVDC ramp tests, partial discharge
measurement, wedge tightness, core magnetization tests, pole drop tests, turns ratio, and core
ground tests.
Infrared Scanning – Annual infrared scans of electrical equipment are required by NFPA 70B.
Throughout the documentation, infrared (IR) scanning is recommended as a regular maintenance
procedure. Infrared scanning and analysis have become an essential diagnostic tool throughout
all industries and have been used to detect many serious conditions requiring immediate
corrective action. Several forced outages already have been avoided. Infrared scanning is non-
intrusive and is accomplished while equipment is in service. It can be used not only for electrical
equipment but also to detect mechanical and structural problems.
Therefore, infrared scanning is HIGHLY recommended as a regularly scheduled maintenance

procedure.
Effective infrared scanning and analysis require the following:
The scanning equipment (IR camera and accessories) must be of high quality and correctly
maintained and calibrated.
The IR camera operator must be trained to use the equipment and deal with complicating
issues such as differing emissivities of surfaces and reflectivity.
The IR system operator must be able to analyze results using state-of-the-art software, critical
to successful interpretation of problems.
Experiences in the field have shown that technical knowledge of the equipment being scanned
is highly desirable.
7.5. Maintenance Schedules and Documentation

Complete, accurate, and current documentation is essential to an effective maintenance program.
Whether performing preventive, predictive, or reliability centered maintenance, keeping track of
equipment condition and maintenance—performed and planned—is critical.
The maintenance recordkeeping system must be kept current so that a complete maintenance
history of each piece of equipment is available at all times. This is important for planning and
conducting an ongoing maintenance program and provides documentation needed for the Power
O&M Reviews.
Regular maintenance and emergency maintenance must be well documented as should special
work done during overhauls and replacement. The availability of up-to-date drawings to
management and maintenance staff is extremely important. Accurate drawings are very important
to ongoing maintenance, testing, and new construction; but they are essential during emergencies
for troubleshooting. In addition, accurate drawings are important to the continued safety of the
staff working on the equipment.
Page 21 of 63
7.5.1. Safety during Maintenance

Performing maintenance on electrical equipment can be hazardous. Electrical and
mechanical energy can cause injury and death if not managed properly. A job hazard
analysis (JHA) must be conducted as well. Visitors, contractors, and others working under
clearances must be trained in Hazardous Energy Control Program (HECP) and must
follow all JHA and clearance procedures.
7.5.2. Organizing scheduled maintenance and repairs:
The reliability, durability and productivity of equipment depend on a correct organization of
its maintenance and supervision in the process of its service, a timely replacement of
wornout parts and on the quality of the parts. Equipment should be maintained regularly to
prevent breakdown stops or losses in the rated productivity. Requirement-based repairs
are also needed to be undertaken to liquidate the problems noticed during equipment
inspection or that have been recorded in the shift logbook of operation department.
Running repair is the principal type of repairs, capable of providing trouble-free operation
for the equipment and avoiding recourse to an expensive major repair for long periods of
time.
Described below are—the types, organization forms, techniques and frequency of
maintenance and repair.
(a) Shift maintenance(care and supervision):
It is the main constituent in machinery attendance and care, done by the shop/ area
production workmen and attendants like fitters, lubricators, electricians, during their
shift work.
(b) Regular inspections and light overhauls:
Inspections are necessary to check the condition of parts and units that cannot be
examined directly during daily shift maintenance. The following operations and jobs
are to be performed during inspections:
(1) a partial disassembly (removal of covers), so that parts can be visually inspected;
(2) cleaning and washing of parts and cases and oil renewal, if necessary;
(3) inspection of shafts, bearings, couplings and clutches, guideways and other
components and elimination of small faults;
(4) checking and replacement of sealing devices and threaded fasteners;
(5) testing the machines and installations for accuracy and their adjustment;
(6) Revision of repair scopes indicated in schedules.
Inspections are done by shop repair teams (also known as maintenance teams) with the
participation of operating personnel and attendant lubricators under the direction of a shop
mechanic. Such inspectors are carried out at the end of the intervals specified by a yearly
Page 22 of 63
repair schedule, depending on the operating conditions of plant. The results of inspections
are recorded in production installation service logs.
Light overhauls include determining the degree of wear and flaw detection of critical parts,
finding out the methods of repair and eliminating minor defects.
(c) Running repairs:
Running, or small repairs, are done at the place of plant installation. They include a
partial disassembly of mechanisms, coding, cleaning and overhauling of parts,
determining the degree of their wear, replacement of parts subject to a rapid wear
(called the wearing parts), which have a service life equal at least to one interrepair
period, trueing-up of certain units, renewal of oil in housing and centralized lubrication
system tanks, replacement of seals and gaskets, checking and replacement of
fasteners, checking of clearances, dressing of working surfaces, as well as all of the
operations and jobs to be done during inspections of machines.
Running repairs are performed on the days of plant planned stoppages as per
schedule or during idle shifts, by the shop repair teams under the direction of
production in-charge, to liquidate and take care of discrepancies recorded during
inspections and light overhauls.
On completion of the running repairs, the equipment is tried-out and verified for
satisfactory operation and then it is handled over for operation.
(d) Major repair:
Major repairs include the following operations and jobs:
(i) a complete disassembly of a machine and marking its parts;
(ii) cleaning and washing of all parts and classify them into suitable, repairable and
reject groups;
(iii) replacement or reconditioning of main (base) parts and units (housings and beds,
bed-plates, frames, bodies, cases, etc.);
(iv) a complete replacement or restoration of worn parts;
(v) repair of foundation and replacement of fasteners;
(vi) assembly of machines and truing them up by their axes and centre lines and with
reference to other machinery pieces;
(vii) reconstruction of some units or modernization of a whole machine to alter its
main technological or mechanical characteristics, if necessary;
(viii) adjustment and testing of a machine;
(ix) painting of a machine and restoration of its other protective coatings.
Major repairs are carried out as per schedule, on the basis of the information collected
during inspections, overhauls and running repairs of the plant.
Page 23 of 63
8. PROCESS FLOW
The following section provides a brief over view of BUNDUQ permit to work system and explains
how Electrical Equipment Maintenance is tied within the permit to work system but yet is not a
standalone system. The authorized PTW procedure is to be fully completed before the work is
started. The section is largely referenced from BUNDUQ Guidelines and Procedure for Permit to
Work. Please refer to the procedure for more details.
8.1. Permit to Work System
The purpose of the Permit to Work System is to achieve a safe working environment for both
Bunduq and Contractors personnel. This purpose will be achieved by providing management
control over the various activities that have inherent hazards or present associated risks (e.g.
work in adjacent areas) in course of actual working.
The Permit to Work System has the following key features:
1. It controls the actions of the personnel doing the work by specifying safety precautions and
requirements as well as setting limits to the duration and extent/scope of the work.
2. It allows those responsible for overall site safety to be aware of ongoing activities and to take
a systematic overview that identifies conflicting interactions and allows priorities to be set to
overcome conflicting work tasks.
3. It encourages formal and careful attention to safe systems of working. It allocates
responsibilities by requiring the signature of nominated and trained persons. These individuals
must confirm that all hazards have been identified and either eliminated or mitigated by
effective precautions to a reasonable level.
4. It encourages those responsible for overall site safety to plan the performance of all tasks so
that minimal inconvenience, interference and risks are caused to other tasks.
5. The Permit to Work System requires the involvement of competent and responsible persons
as well as the applications of particular safety measures in a controlled sequence.
The Permit to Work System ensures that responsibility and accountability for safe working
practices is passed, in a logical sequence, to those responsible for the work being carried out at
any given time. It also ensures that specified effective safeguards are provided.
8.2. System Custodians and Focal Points
The PTW System Corporate Custodian is the Head of HSE. He is responsible for providing
steering /direction to ensure that the PTW System meets the needs of BUNDUQ.
The Operational Custodian and Training Custodian of the PTW System is the Chief Safety
Engineer, who is responsible for:
Page 24 of 63
(i) Implementation support and system maintenance.

(ii) Organizing training for workmen in association with the respective supervisors of various
sections.
Line Managers are responsible for the implementation of the PTW System, and for appointing
Focal points (see Section Roles and Responsibilities) for the System in each area.
8.3. PTW Cycle
Page 25 of 63
9. OUTLINING SOPs FOR ELECTRICAL EQUIPMENT MAINTENANCE
9.1. General Safety Provision (GSP)
Whenever work is to be accomplished on electrical installations there is always the possibility of a

hazardous situation occurring, which could result in serious injury to personnel. Performance
without injury is a sign of conscientious workmanship and planned supervision. Therefore, safety
is a primary consideration when inspecting and maintaining any of the electrical equipment. The
work area, where an Electrical Equipment is to be undertaken for maintenance, is to be safe and
without risk of injury to the workmen stationed over there and in the vicinity.
The manufacturer’s manuals of the Electrical Equipment to be taken under maintenance explains
safe and accepted ways of installation, startup, operation, inspection, maintenance, removal, and
shutdown which should be strictly followed.
Warnings and Cautions appearing in the Electrical Equipment Manual, if not followed strictly,
could result in damage to, or destruction of equipment and also injury to personnel. Some
common ones are given below:
Do not use gasoline, kerosene, or other low flashpoint solvents at the work place. A serious
explosion may result.
If shafts of the electrical machines are to be rotated, keep hands, feet, loose clothing, and
foreign objects away from inlet and discharge openings, as serious personal injury or damage
to equipment can occur.
Heavy rotating electrical machines, associated pneumatic and hydraulic lines, and electricity
can be dangerous. To prevent injury, before attempting any maintenance be certain the
electrical equipment cannot be energized accidentally. Follow Permit to Work procedure and
apply LOTO for isolation during shutdown.
The place of work must invariably have the following safety provisions and arrangements:
(i) First-aid facility –

(ii) Fire-fighting provisions –
a) Portable fire extinguishers
b) At major fire-hazardous areas, have fixed fire-extinguishing installations.
(iii) Emergency Plan – Well formulated, implemented, drilled and kept in active and ready
state.
Page 26 of 63
9.2. Operational Maintenance:
It is the necessary routine, recurring maintenance work performed to keep the equipment
operating at its designed capacity and efficiency.
People should be aware of the following conditions:
(a) Cleanliness:
Dirt is the principal cause of equipment failure and should be removed immediately by the
operator.
(b) Lubrication at mating surfaces:
Any two surfaces brought together develop friction. When not properly lubricated, these
surfaces wear down, change clearances, and cause equipment breakdowns.
(c) Temperature Change:
Any unusual temperature change which the operator cannot correct should be reported
immediately to the plant supervisor. When the temperature of a piece of equipment rises
rapidly, immediately shut it down.
(d) Vibration:
Vibration is a major source of equipment failure, Equipment not properly secured will vibrate.
This vibration causes loosening of components and possible misalignment of parts, leading to
more serious problems. The operator, in making rounds, should check the bearings, machine
stands, and motor casing for any unusual sound, vibration, or motion. Take immediate action
to correct any problems.
9.3. Preventive Maintenance (PM):
It is a system of routine inspections of equipment recorded for future reference on inspection

records, followed by minor repairs and other necessary preventive measures in advance of major
operating difficulties, or even breakdowns.
PM is the responsibility of the operators and specified maintenance crews. The operator is
expected to do as much maintenance as his technical abilities, tools, and time allows. Specifically
assigned maintenance crews work on equipment where the work to be done is beyond the scope
of the operator.
Scheduling PM is the responsibility of the plant supervisor. Maintain a record card for each major
piece of equipment with entries of the PM schedule, inspections, and operation.
Page 27 of 63
9.4. Breakdown Maintenance:
It is the emergency repair of inoperable equipment performed by operators and maintenance

crews. The plant and maintenance supervisors are responsible for emergency repairs. The Utility
and Maintenance Shops should develop a coordinated plan to efficiently handle emergency
breakdowns.
Troubleshooting is a means of locating the source of trouble when problems occur so that repairs
can be made. Equipment manufacturers will normally provide troubleshooting charts for their
equipment. These charts can be very helpful in diagnosing problems. This chart is not meant to
be a complete source of information. It is a composite list developed by the manufacturers based
on their experience and feed back received from the users.
10. GUIDE LINES FOR SOP FOR THE MAINTENANCE OF ELECTRICAL EQUIPMENT
10.1. Maintenance of Air / Oil Circuit Breaker
Foundation
Check foundation for cracks and settling.
A shift of the breaker tanks may break bushings or cause misalignment of contacts or binding
of operating mechanism.
Frame and Tanks
Daily or Weekly – Check for oil leaks and note tank temperature by touch.
Oil Valves and Plugs
Check condition of paint and repaint as necessary.
Inspect oil valves and plugs and stop oil leaks. See that oil drain valves that can be operated
without wrenches are plugged or locked to prevent unauthorized opening.
Tighten bolts.
Clean exterior of tanks. Inspect underside of cover for moisture and rust, and clean and
repaint as necessary. Check tank liners and interphase barriers.
Oil Levels and Gauges
Daily or Weekly – Check oil level in gauges of the tanks and oil-filled bushings.
Replenish oil if below normal.
Clean dirty gauge glasses and connections into tank. Drain out and replace bushing oil if dirty
or discolored.
Breathers and Vents
Daily or Weekly – Check for external obstructions to breakers and vents.
Page 28 of 63
Check to see that screens and baffles in vents or breathers are not obstructed or broken.
Panels and Cabinets

Check air circuit breaker or other panels of insulation material for cracks and cleanliness.
Check condition of enclosing cabinets including hinges, latches, locks, door gaskets, and
paint.
Bushings or Insulators
Quarterly – Check for chipped or broken porcelain, excessive dirt film, oil level and oil or
compound leaks.
Clean porcelain with water, liquid turtle wax, or other suitable cleaner.
Repair chipped spots by painting with lacquer.
Inspect gaskets for leaks.
Tighten bolts.
Check insulation resistance with contacts closed with Doble test set, Megger, or Hipot.
Check oil sample from bottom of bushing for dielectric strength and dissolved gas analysis
(DGA) and presence of water and dirt which may be entering at top. Replace or replenish oil if
necessary.
Check and clean interior at least once every 5 years.
Bushing Current Transformers and Potential Devices

Checks tap settings and adjustments at terminal board to see that they agree with diagrams.
Check insulation resistance of wiring with devices connected.
Check ratio and phase-angle adjustments of potential transformers if changes have been
made in secondary connections or burden.
Tighten connections, including tap connections into bushing.
Main Terminals and Ground Connections

Daily or Weekly – Check for presence of foreign materials, birds’ nests, etc. in or near
connecting buswork; loose or overheating connections; and loose or broken frame ground
connections.
Tighten all bus and ground connections and inspect for heating.
Refinish contact surfaces if they have been overheating.
Inspect ground cable to see that it is not loose or broken.
Page 29 of 63
Main Contacts
Remove the tanks or drain out oil so that the contacts can be inspected.
Dress contacts, if rough, with a fine file. It is necessary to carefully remove only the projecting
beads. Pits in a flat, smooth surface are not objectionable.
Check contact drop with “ducter” or by direct current millivolt drop with a micro-ohm meter.
Frequency of breaker contact maintenance should be based on number and severity of faults
interrupted rather than a definite time period. Experience will tell how many faults can be
interrupted before contact repairs are necessary.
Data should be kept on each breaker to guide future maintenance.
Inspection schedules might be extended further as oil handling methods, methods for
determining oil condition, and other improvements are made.
The following factors should be established before intervals between inspections can be
extended:
(1) All new breakers must have a complete inspection at the end of 1 year.
(2) Only after breakers have field experience should the inspection periods be extended.
(3) Breakers used on special applications, such as capacitor and reactor switching, should be
considered separately.
(4) If recurring troubles are found on a certain type of breaker, the inspection schedules should be
shortened until trouble is eliminated.
(5) Breakers interrupting a large number of faults should be given special attention to determine
whether or not early internal inspection is required.
(6) When oscillographs indicate abnormal breaker operation, an immediate inspection of the
breaker should be made.
Contact Pressure Springs

Check springs for loss of temper, breaks, or rust deterioration.
Flexible Shunts
Check flexible shunts at contact hinges for overheating and fraying. Tighten connections.
Magnetic, Air, or Oil Blowout Devices

Check arc-rupturing blowout coils, magnetic circuit, arc chutes, de-ion grids, oil blast, or other
interrupters for proper operation.
Page 30 of 63
Crosshead
Check contact crosshead for misalignment, breaks, bends, or looseness on lift rod.
Lift Rods and Guides

Check contact lift rods for breaks, weakening, or warping, and pulling out at ends. Check
adequacy of guides.
Operating Rods, Shafts, and Bell Cranks

Check for loose locknuts, setscrews, keys, bearings, bent rods, or twisted shafts, etc.
Clean moving parts of rust, dirt, and accumulated grease and oil.
Wash out bearings, pivots, and gears with a suitable cleaner; and operate breaker several
times to work out dirt and old lubricant.
Lubricate with new grease or oil. In cold climates, it is important to use lubricant that will not
stiffen with cold.
Wipe off excess oil. Enclosed dust-tight bearings should require less servicing.
Operating Time
A 2-cycle breaker with dirty or dried out grease in the operating mechanisms, bearings, and
gears will act more like a 6- to 12-cycle breaker the first time it is operated or exercised. After
that, the operating time will be closer to normal until it has again “rested,” at which time, it will
again have unacceptable operating times.
Closing Solenoid Air Cylinder, Motor, or spring

Weekly – Visual inspection to see that equipment is in operating condition. Drain
condensation from air cylinder.
Observe mechanism during several closing operations to see that everything is in proper
working order. Check solenoid plunger for sticking in guides.
Annually – Check coil resistance and insulation resistance.
Dismantle air cylinder and clean and relubricate. Check motor. Check closing springs for
proper tension and closing energy.
Manual Operating Device

See that manual operating lever or jack is kept on hand and in usable condition. See that
breaker will close with it.
Latch and Trip Mechanism

Weekly – Visual inspection to see that mechanism is in operating condition.
Page 31 of 63
Observe mechanism during several tripping operations to see that everything is in working
order.
Annually – Check pins, bearings, and latches for wear, binding, and misalignment.
Clean and relubricate. Check latch carefully to see that it is not becoming worn so that it would
unlatch from vibration or stick and fail to trip. Tighten bolts and screws.
Tripping Solenoid
Weekly – Visual inspection to see that solenoid trip device is in operating condition.
Observe operation during electrical tripping. See that full energy, snappy action of plunger is
obtained. Check plunger for sticking in guides.
Annually – Check coil and insulation resistance.
Solenoid Valves
Annually – Check for condition of valve seat and refit as necessary.
See that moving parts are free to operate. Check resistance and insulation resistance of
solenoid coil.
Auxiliary Switches
Annually – Check condition of contacts and refinish with fine file if burned or corroded.
Check contact springs, operating rods, and levers.
Check closing and opening position with respect to main contacts while breaker is being
slowly closed and opened manually.
Certain auxiliary contacts used for special purposes may require close adjustment in this
respect.
Operation Counter
Monthly – Observe and record reading of operation counter.
See that the operations counter is properly registering the operations.
Position Indicator
See that position indicator or semaphore is properly indicating the breaker position. Check
operating rods or levers for loose parts.
Dashpots or Snubbers
Check for proper setting and adjust as necessary. Clean out and replenish liquid in liquid
dashpots.
Page 32 of 63
Mechanism Cabinet
Check condition of metal and hardware. Repaint as necessary. See that door gaskets are tight
and properly exclude dust and dirt.
Cabinet Lights and Heaters

Weekly – Check cabinet heaters and see that they are in service in cold weather.
Replace burnt-out lamps.
Check heating elements and replace, if in poor condition.
Power Supplies and Wiring

Weekly – See that all power and control circuit switches are closed and fuses are in place.
Annually – Inspect fuses or circuit breakers in all power and control supply circuits.
Check and tighten wiring connections at terminal points. Inspect wiring for open circuits, short
circuits, and damaged insulation.
Check insulation resistance of wiring with devices connected.
Oil DGA and Dielectric Tests

Annually – Check dielectric strength of the insulating oil in the main tanks and oil-filled
bushings.
Filter Oil
The necessity for filtering the insulating oil will depend on the results obtained from the oil
tests and the amount of carbon in the oil.
The oil should be filtered if the dielectric strength is below 25 kilovolts or if there is a
noticeable amount of carbon in suspension or in the bottom of the tanks.
Operation
Some breakers, particularly those carrying high values of current, have a tendency to develop
contact heating if left closed for long periods.
Opening and closing breakers several times at intervals, as system operation permits, may
reduce contact resistance and heating by wiping the oxide from the contact surfaces. This
method also demonstrates that the breaker is in operating condition.
Page 33 of 63
10.2. Preventive Maintenance of Generator and Large Motors
Foundation, Base, or Support

Check concrete foundation for cracks.
Check base or support for broken, loose, or weakened parts.
Check and tighten anchor bolts.
Check sound absorbing base for adequacy.
Frame
Check for cracks and loose or broken parts.
Clean and repaint as necessary.
Check frame ground connection.
Laminations and Pole Pieces

Check for loose laminations and tighten clamping bolts. If laminations vibrate and cannot be
stopped by tightening clamping bolts, force some quick-drying varnish or shellac between the
loose laminations while the machine is out of service.
Check for damaged laminations at airgap due to rubbing or objects caught in airgap.
Check and tighten field pole piece clamping bolts. (Refer to manufacturer’s instructions)
Armature or Rotor
Check squirrel-cage rotor bars or amortisseur windings for loose or broken bars or end
connections.
Check field circuit connections and tighten if necessary.
Check voltage drop across each pole by applying alternating current at the collector rings.
This method will show a turn-to-turn short better than using direct current.
Check pole keys for tightness. Rebalance armature or rotor if vibration is objectionable.
Check overall rotor resistance or impedance.
Air-gap
Check air-gap at four quadrature positions and reenter rotor if necessary. On horizontal
machines, the bearings may need replacing if the bottom air-gap is appreciably smaller than
the top.
Air Fans
Check rotor air fans for fatigue cracks. Check and tighten holding bolts and screws.
Page 34 of 63
Windings
Inspect for damaged insulation, dirt, oil, or moisture. Blow out dust with clean, dry air at
pressure not exceeding 40 pounds per square inch. Clean exposed parts of windings
thoroughly with a nonflammable solvent using suitable brushes for hard-to-reach places.
The use of carbon tetrachloride is not recommended because of the toxic hazard. Revarnish
windings if insulation is becoming hard, brittle, or dull.
Check for insulation deterioration such as tape separation, cracking, brittleness, or evidence
of corona.
Check insulation with high voltage direct current method.
Banding and Lashing

Check wire and string banding on direct current armature windings.
Check end-turn lashing of alternating current stator coils. Apply lashing if end turns vibrate
excessively.
Slot Wedges
Check slot wedges and replace loose ones.
Tighten coils in slots by rewedging, if necessary.
Commutator or Collector Rings

Daily – Check commutator or collection rings and brush operation.
Wipe commutator or rings if needed.
Have brushes replaced if worn too short.
Brushes and Brush Rigging

Turn down, stone, or polish commutator or collector rings if grooved, rough, or eccentric.
Undercut mica if high. If commutator or rings have a good polish, they should not be
disturbed.
Check brush spring tension and brush fit. Tighten bolts, screws, and connections. Reset brush
holders if not properly spaced.
Check brush neutral position. Replace and sand in new brushes if needed.
Clean up carbon or metallic dust.
Shaft and Bearings

Daily – Check bearing temperature, lubrication, and oil level.
During Shutdown/Inspection – Check bearing clearances.
Check oil for dirt, sludge, and acidity, and filter or replace as necessary.
Page 35 of 63
Check end play on horizontal machines. Replace or refinish rough bearings. Inspect bearing
oil piping and cooling water piping for leaks.
Check shaft for wobble and alignment.
Check for shaft currents through bearings on larger machines.
Check insulation of insulated bearings.
Check oil film resistance occasionally with machine in operation with ohmmeter of 6 volts or
less on thrust bearings provided with test terminals.
Couplings, Gears, and Pulleys

See that keys, setscrews, and coupling bolts are tight.
Check parts of flexible couplings for wear or fatigue.
Adjust belt or silent chain tension. Flush out and renew grease in gearboxes. Inspect belts,
chains, or gears.
Check alignment between driving and driven machine.
Cooling Coils and Air Coolers

Check for water leaks in bearing cooling coils and surface air coolers.
Check cooling water flow.
Check external supply and piping for leaks.
Flush out cooling coils with air and water.
Test bearing cooling coils for leaks by applying air pressure to coils.
Observe for air bubbles rising in oil and drop in air pressure with supply valve closed or use
hydrostatic pressure test.
Use hydrostatic pressure test on air coolers. If water scale is present, circulate a solution of
25% hydrochloric acid and water through the coils until clean.
Then flush out thoroughly. Clean external surfaces of coils if practical. A pressure of 75
pounds per square inch is recommended.
Temperature Indicators and Relays, Water and Oil Flow, and Pressure Gauges and Relays
Check indicators, gauges, and relays for correct operation and sticking, dirty contacts.
Check calibration if in doubt.
Page 36 of 63
10.3. Preventive Maintenance of Disconnect Switch
Inspection
Semi-Annual – Observe components visible through inspection windows: switch contacts,
auxiliary devices, wiring, terminal blocks, fuse clips and fuses, insulators and insulating
materials, space heater operation, cable terminations, adequate grounding, cleanliness,
evidence of water leaks, and overheating of parts. Observe stress cones and leakage sections
for cleanliness and tracking. Record loads if equipped with meters.
Weekly – Note whether multiple-shot reclosing fuse has operated. Replace as needed. Check
fuse latching and tripping mechanism for proper operation.
Major Maintenance or Overhaul

Depending on ambient, 3 to 6 years.
Major Maintenance or Overhaul Maintenance to Perform

Structure and enclosure Repair rust spots and paint.
Major Maintenance or Overhaul Maintenance to Perform

Structure and enclosure Repair rust spots and paint.
Check for loose bolts and insecure or inadequate
Base and mounting
supporting structure.
Ventilating louvers and air filters Clean and replace as needed.
Buses, splices, and bolts Check bolts for manufacturer’s recommended torque.
Check for chipped or broken porcelain, excessive dirt
Insulators film, and tracking; clean as necessary; replace broken
insulators; tighten base and cap bolts.
Verify operation or operate continuously to overcome
Space heaters
thermostat malfunction.
See that blades are properly seated in the
contacts; operate the switch several times and see that
Main switch blades and contacts blades are properly aligned to engage contacts; clean
contact surfaces if corroded; lubricate; tighten bolts and
screws.
Check pressure springs in contact and hinge and
Contact and hinge spring and
replace, if not adequate; replace flexible shunts, if
shunts
frayed.
See that blade latches, where provided, are engaged;
check latches for proper engaging and holding blade
Blade latches and stops
against opening force. See that stops are in place and
tight.
Arcing switch blades and contacts Do not lubricate.
Arc chutes or interrupter device Check for condition, alignment, and proper operation.
Page 37 of 63
Switch operating mechanism and Adjust for adequate contact closure and over travel;
linkage lubricate.
Check and tighten bolts, screws, and locknuts; see that
Operating rods, levers, and cranks rods, levers, and cranks are in serviceable condition and
repair as necessary; lubricate pivot points and bearings.
Check gears and bearings; flush out oil or
Gearboxes
grease and relubricate.
Check motor operation and Megger; check adjustment of
Operating motor and mechanism
brake.
Check condition of contacts and refinish with fine file if
burned or corroded; check contact springs, operating
Auxiliary and limit switches rods, and levers; check closing and opening positions
with respect to main switch
contacts, travel, or motor mechanism.
Door and other interlocks Functional test for proper sequence.
Switch disconnect studs and finger
Lubricate unless manufacturer’s instruction says not.
clusters (if drawout type)
Clean and inspect for surface tracking; check
Cable terminations and connections
connections for correct tightness.
Meters Check calibration.
Check clips for adequate spring pressure and proper
Fuse clips and fuses
fuse rating.
Check base and operating handle ground connections;
Grounding
see that ground cable is not broken.
Potential, current, and control
Evaluate and make necessary repairs.
transformers
See that switch operating hot sticks are in good
Switch operating hot sticks
condition and are kept in a dry place; inspect hot sticks
for damage and deterioration; discard suspect switch
operating hot sticks; test hot sticks per requirements.
10.4. Transformers
Transformers convert electrical power from one voltage level to another.
Transformer reliability is essential to the continued delivery of the facility’s services.
10.4.1. Station/ Distribution Transformers Under 500 KVA
Station and distribution transformers generally operate at relatively low voltages and
power ratings. They provide step-down power to supply plant auxiliary loads—for
example, a 480 - 240/120-Vac transformer that supplies power to auxiliary lighting panels.
Maintenance or Test to be carried-out:
Review equipment ratings
Page 38 of 63
Infrared scan, while loaded

Doble test if oil-filled
Dissolved gas analysis if oil-filled
10.4.2. Instrument Transformers
Instrument transformers convert power system level voltages and current to levels safe to
feed meters and other low voltage and current devices. Voltage or potential transformers
generally have output in the 240/120-Vac range, while current transformers have output in
the 2.5- to 5-ampere range. Voltage transformers may be integral to other equipment or
stand alone. Typically, current transformers are integral to other equipment (circuit
breakers, transformers) but occasionally may be stand alone.
Over the course of time, instrument transformers (particularly current transformers) may
become overburdened with the addition of more devices in the secondary circuit. This may
lead to saturation during a fault which may cause the relay to misoperate. Periodically,
measuring secondary burden and comparing it to the transformer rating will indicate if this
is a problem.
Instrument transformer secondary wiring always should be checked for integrity after any
work that may have disrupted these circuits.
Instrument transformers that are oil-filled will fail catastrophically and cause hazards to
workers if not maintained properly. Any oil leak should trigger immediate Doble testing and
replacement planning.
Burden measurements
Doble test if oil-filled
Visual inspection
Infrared scan
10.4.3. Dry-Type Power Transformers – 500 KVA and Larger
Dry-type power transformers are air cooled, having no liquid insulation. Typical
applications include station service and excitation system transformers.

Infrared scan
Temperature alarm check
Page 39 of 63
Visual inspection/cleaning
Check fan operation
Clean fans and filters
Turns ratio test
Megger windings or Hipot
10.4.4. Oil-Filled Power Transformers
Oil-filled transformers generally deliver power to and from the main units of the facility—for
example, generator step-up transformers. These transformers are generally located
outside the building in a transformer bay or in a switchyard. These transformers may be
two-winding or more and include autotransformers.

Preventive maintenance
Transformer physical inspection
Bushings – visual inspection
Bushings - check oil level
Bushings – cleaning
Transformer and bushings - Doble test
Transformer and bushings - infrared scan
Insulating oil - DGA, physical, and chemical tests
Core - Megger test
Leakage reactance, Turns Ratio tests, SFRA test
Cooling fans – inspect and test
Oil pumps and motors -inspect and test
Heat exchangers –inspect
Conservator and bladder – inspect
Top oil and winding thermometers
Oil level indicator operation
Pressure relief device
Sudden pressure relay
Page 40 of 63
Buchholz relay
Inspect foundation, rails, trucks
10.5. Engine Generators
Engine generators are critical systems at industrial installations and other water based facilities.
They must be maintained and tested regularly to ensure they will perform as expected.
Manufacturer and NFPA standards should be followed.
Engine generators provide essential power to supply critical loads in the event of loss of normal
power source. Critical loads may include fire pumps, important auxiliaries and battery chargers.
All Emergency Power Standby Systems (EPSS) components

EPSS
Generator sets
Generator set battery
Transfer switch
Circuit breakers
10.6. Exciters and Voltage Regulators
Exciters and voltage regulators comprise excitation systems which provide appropriate DC
excitation for the field of generators and synchronous motors. Excitation systems may be rotating
or static.
Some components of excitation systems (e.g., transformers, circuit breakers, protective relays,
annunciators, and buswork) may require maintenance similar to that described in like sections of
this document.
However, excitation system manufacturer maintenance requirements supersede requirements

specified in these sections.
Automatic voltage regulator performance testing (“alignment”) is a specialty, requiring specialized

training and unique equipment as well as knowledge of current power system stability
requirements. The following shall be attended:
Automatic voltage regulator (AVR) and power system stabilizer (PSS) performance testing
Page 41 of 63
Infrared scan
10.7. Batteries and Battery Chargers
Battery systems provide “last resort” power for performing communication, alarm, control, and
protective functions when other sources of power fail. Battery system maintenance should have
highest priority. Computerized, online battery monitoring systems can greatly reduce maintenance
required on battery systems and actually improve battery reliability and increase battery life.
Battery chargers, important to the health and readiness of battery systems, require regular
maintenance as well.
Flooded, Wet Cell, Lead Acid Batteries
Visual inspection
Battery float voltage
Cell float voltage
Specific gravity
Temperature
Connection resistance
Capacity testing
Safety equipment inspection
Infrared scan cells and connections
Battery monitoring system
Valve Regulated, Lead Acid (Gel Cel) Batteries
Visual inspection
Cell float voltage
Temperature
Connection resistance
Internal resistance
Capacity testing
Page 42 of 63

Vented Nickel Cadmium Batteries
Visual inspection
Temperature
Intercell connection retorque
Capacity testing
Battery Chargers
Infrared scan cables and connections if visible
10.8. Power Cables – Rated 5 kV and Above
High voltage cable conducts power between the power plant and switchyard. The cable may be
solid dielectric or oil-filled. In the case of critical circuits, periodic maintenance tests are justified
during the life of the cable to determine whether or not there has been significant insulation
deterioration due to operational or environmental conditions.
Direct current Hipot tests effectively reduce inservice failures from faults of the cable or its
accessories. When done properly, maintenance tests can detect problems in cables that are
approaching failure without accelerating the deterioration process.
Except for infrared scanning, de-energize the cable circuit before maintenance.

DC Hipot test (stepped or ramped voltage method)
Oil tests (dissolved gas analysis [DGA], dielectric, acidity, color, interfacial tension, water
content, power factor)
Visual inspection and infrared scan, while loaded
Page 43 of 63
10.9. Buswork, Enclosures, and Insulators
Buswork conducts current from one part of the powerplant or switchyard to another. Buswork is
usually constructed of flat or round copper or aluminum busbar and can be either isolated-phase
or nonsegregated. Except for infrared scanning, bus maintenance must be conducted de-
energized. Standoff buswork insulators provide isolation of “live” power circuits from ground and
other circuits. Failure of insulators will cause a power system fault and a forced outage.
Buswork and Enclosures: 5-15 Kilovolts (kV)

External visual inspection, Check and tighten connections, Check and clean enclosures
Hipot (to ground and between phases) or Doble
Infrared scan, while loaded if possible
Buswork Insulators
Doble, Hipot or Megger, individual insulators

Infrared scan, while system is loaded if possible
10.10. Bushings
Bushings are critical components of medium and high voltage circuit breakers and transformers.
Bushing maintenance is usually conducted at the same time maintenance is performed on the
circuit breaker or transformer, or at least during an outage on that equipment.
Refer to the circuit breaker and transformer maintenance sections of this document for bushing
maintenance requirements.
10.11. Arresters (of lightning/ surges)
Lightning or surge arresters provide protection for important equipment from high-energy
surges. These arresters are static devices which require fairly infrequent maintenance. Most
maintenance must take place while the associated circuit is de-energized. However, crucial
visual inspections and infrared scans can take place while energized.
Review equipment rating
Page 44 of 63
Visual inspection with binoculars

Clean insulator and check connections
Doble test (power frequency dielectric loss, direct current [DC] insulation resistance, power
factor)
Replace all silicon carbide arresters with metal oxide varistor type
Infrared scan
10.12. Control Circuits
Control circuits (usually 125 V dc, 250 V dc, or 120 V ac) provide the path for all control
functions for major equipment in the powerplant. Reliability of these circuits is paramount.
Although tested during commissioning, these circuits can become compromised over time
through various means:
Modifications and construction work which unintentionally break circuit integrity or introduce
wiring errors.
Age and deterioration of wiring rendering the system nonfunctional.
Connections that become loose.
Failure of individual control and protection devices due to misuse, old age, or inadvertent
damage.
Verifying the integrity of the control devices and interconnecting wiring requires a “functional
test” of these circuits. Functional testing of control circuits may be considered completed in the
course of normal plant operation. However, control circuits that rarely are used should be
functionally tested on a periodic basis.
Functional test control circuits
10.13. Emergency Lighting
Reliable plant emergency lighting is essential for personnel safety.

Functional test
Page 45 of 63
10.14. Ground Connections
Equipment grounding is an essential part of protecting staff and equipment from high potential
caused by electrical faults. Equipment grounding conductors are subject to failure due to
corrosion, loose connections, and mechanical damage.
Grounding may also be compromised during equipment addition and removal or other
construction-type activities. Periodically verifying grounding system integrity is an important
maintenance activity.
Visual inspection, tighten connectors
10.15. Relays and Protection Circuits
Protective relays monitor critical electrical and mechanical quantities and initiate emergency
shutdown whenever they detect out-of-limits conditions.
Protective relays must operate correctly when abnormal conditions require and must not
operate at any other time.
Electrical protective relays are calibrated with settings derived from system fault and load
studies. Initial settings are provided when relays are installed or replaced. However, electrical
power systems change as new generation and transmission lines are added or modified. This
may mean that relay settings are no longer appropriate. Outdated relay settings can be
hazardous to personnel, to the integrity of the power-plant and power system, and to the
equipment itself.
Therefore, it is necessary to periodically conduct a fault and load study and review protective
relay settings to ensure safe and reliable operation.
Protective relays include electro-mechanical, solid-state, and microprocessor-based packages.

Calibration and maintenance recommendations differ from type to type because of their different
design and operating features.
Calibration: This process usually includes removal of the relay from service to a test
environment. Injecting current and/or voltage into the relay and observing the response
according to the manufacturer’s test procedure verifies the recommended settings. Calibration
of electro-mechanical relays is recommended frequently since operating mechanisms can wear
and get out of adjustment.
Calibration of solid-state and microprocessor-based relays is recommended less frequently

since there are fewer ways for them to get out of calibration.
Page 46 of 63
Relay Functional Test: This process verifies that the protective outputs of the relay (e.g.,
contact closures) actually operate as intended. This can be accomplished as part of the
calibration procedure in most cases, but relay functional testing should be verified according to
the maintenance schedule.
Protective relays operate into protection circuits to accomplish the desired protective action.
Similar to control circuits, protection circuit integrity may be compromised by construction,
modifications, deterioration, or inadvertent damage. A compromised protection circuit may not
provide the system and plant protection desired. Periodic functional testing is recommended to
ensure the integrity of protection circuits.
Protection Circuit Functional Testing: This process verifies that the entire protective “trip
path” from protective relay through circuit breakers (or other protective equipment) is intact and
functional. This requires actually operating the entire circuit to verify correct operation of all
components.
Protective circuit functional testing is accomplished as follows:
Conduct a Job Hazard Analysis.

Verify that testing will not disrupt normal operation or endanger staff or equipment.
With lockout relays reset, initiate lockout relay trip with the protective device.
Verify the lockout relay actually tripped from the protective relay action. Verify that circuit
breakers actually tripped (or other protective action occurred) from the lockout relay action.
Activate the lockout relay from each protective device. After the first full test of lockout relay
and breakers, it may be desirable to lift the trip bus from the lockout relay so as not to
repeatedly trigger the lockout—a meter may be substituted to verify contact initiation.
Caution: Do not forget to reconnect the trip bus to the lockout relay when testing is
complete.
Where functional testing of ALL protection circuits is unfeasible, testing of the most critical
protection circuits and devices is still recommended.
Reclamation standard design for lockout relay and circuit breaker control circuits includes the
use of the red position/coil status indicator light to monitor the continuity of the circuit through
the trip coil. These lights should be lit when the lockout relay is in the “Reset” position or when
the breaker is closed. If the light is not lit, this may indicate a problem with the coil integrity
which should be addressed immediately.
Fault/load study and recalculate settings

Electro-mechanical relays Calibration and functional testing
Page 47 of 63
Solid-state relays Calibration and functional testing

Microprocessor relays Calibration and functional testing
Protection circuit functional test, including lockout relays
Check red light lit for lockout relay and circuit breaker coil continuity
Lock out relays Cleaning and lubrication
10.16. SCADA Systems
Supervisory Control and Data Acquisition (SCADA) systems are computer-based, real-time
control. Since these systems are in operation continuously and are in many ways self-
diagnosing, regular maintenance and testing is not necessary except as recommended by the
manufacturer. However, circuits that are infrequently used may require periodic functional
testing to ensure they will be operational when the need arises.
Periodic audits, Critical Infrastructure Protection Plans (CIPP), and regularly scheduled security
training are important requirements of SCADA security.
Functional test circuits
Failure mode tests
Security – audit
Security - CIPP updated
Security – training
Uninterruptible power supply test
10.17. Security Systems
Security system plays an important role for protection plant personnel, the public, and facility
equipment. Most security systems are site specific including many different manufacturers of
cameras, receivers, card key systems, gates, gate controls, and other types of equipment.
Therefore, it is imperative that personnel at each plant understand and follow manufacturers’
instructions for maintenance and testing the particular equipment installed.
Page 48 of 63
10.18. Transducers/ Meters
Transducers convert data collected in one format into electrical signals used by meters and
computerized monitoring and control systems. Accuracy of transduced signals is important to
alarm and control functions. Examples of transduced data include:
Bearing oil level or temperature read by a meter or scanning equipment

Mega Watt or Mega VARs as input to the SCADA system
Transducers
Calibration
Meters
Calibration/inspection
10.19. Fire Detection, Fire Fighting Equipment, and Alarm Systems
Fire detection and alarm systems provide indication and warning of fire in the facility. They are
crucial to safety of personnel and the public. Correct operation may also minimize damage to
equipment by an early response. Regular maintenance of systems in unstaffed facilities is
particularly important because O&M staff is not usually present to detect problems.
All circuits - functional test

Visual inspection of detection and control equipment (fuses, interfaces, lamps, light emitting
diodes, primary power supply)
Visual inspection – batteries
Lead acid battery 30-minute discharge and load voltage test
Ni Cad battery 30-minute discharge and load voltage test
Other maintenance
Fire hoses
Fire extinguisher maintenance
10.20. Fuses
Fuses provide power and control circuit protection by interrupting current under certain overload
and fault conditions.
Page 49 of 63
Some fuse failures are self evident. Loss of meter indication or control circuit operation may
indicate a blown (open) fuse. Other fuses that are critical to equipment operation may be
monitored and their opening alarmed. However, some fuse operation cannot be detected
remotely and should be assessed by regular maintenance. It may be as simple as looking for
the “fuse operated” indicator on the fuse, or it may require checking with an ohmmeter.
Failure to do so may result in more significant failure leading to an outage.

Check fuse mounting clips, etc.
Visual inspection and infrared scan, while loaded or immediately thereafter.
10.21. Annunciators
Annunciators provide essential plant condition status information to O&M personnel. Two
aspects must be considered:
correct operation of the annunciator itself and
Integrity of the alarm devices and interconnected wiring.
Annunciator operation is easily tested using the “Test” button provided on most annunciators
and is considered an “operations” activity.
Verifying integrity of the alarm devices and interconnecting wiring requires a “functional test” of
these circuits.
Functional testing is accomplished by:
resetting the annunciator,

closing (or opening) contacts at the alarm device, and
verifying that the correct annunciator window is activated. It is recommended that the alarm
device actually be triggered, where possible, for best assurance; however, it may be
necessary to simulate contact operation with a “jumper” (or lifted lead) when device
activation is not possible.
Caution: Operating the alarm device may trigger unwanted control or protection actions
as well as annunciation.
Know what “should happen” by consulting up-to-date drawings before triggering alarms.
Annual functional testing of annunciators is recommended for best assurance of integrity.
However, this may be considered too extensive for time and resouasascases, functional testing
of those alarm points that indicate impending shutdown or failure that could be mitigated by
operator action is still recommended.
Page 50 of 63
Functional testing of annunciators also is recommended after a major outage or after

modifications that affect wiring and cabling in the plant.
Operational test
Functional test
10.22. Personal Protective Equipment
Personal protective equipment is used by maintenance workers to provide protection from

hazardous electrical energy. Integrity of this equipment is paramount, so maintenance should be
scheduled and accomplished similar to equipment maintenance.
Safety ground – visual inspection
Safety ground – millivolt drop test
Hot stick cleaning, inspection, and electrical test
Gloves, sleeves, blankets tests
10.23. Maintenance of Electrical Equipment in Hazardous Area
Effort should be directed towards detecting any changes in condition which may invalidate the
certification of a piece of equipment. As such, most inspections are of a visual nature which can
be carried out with the equipment running.
Inspection, Test and Measurement:
External Inspection:
No visible unauthorized modifications.
Bolts, cable entry devices and blanking elements are of correct type, complete, in good
condition and tight.
No obvious damage to cables.
Sealing of trunking, ducts, pipes and/or conduits is satisfactory.
Earthing and bonding connections are in good condition and tight.
No undue accumulation of dust and dirt.
Enclosure, glasses, sealing gaskets and/or compounds are satisfactory.
Circuit identification present and correct.
Ducts, pipes and enclosures are in good condition.
Page 51 of 63
Protective gas is substantially free from contaminants (water, oil, dirt).

Protective gas pressure and/or flow is adequate.
Internal Inspection:
Earth connections maintain integrity of type of protection.
Safety barrier units, relays and other energy limiting devices are of the approved type,
installed in accordance with certification requirements and securely earthed where required.
Motors, Generators, Switchboards, Boxes, Sockets--General condition, and tightness of
electrical connections.
Test and Measurement:
Protection devices operate within permitted limits.
Other points to be noted:
Prior to the replacement, repair, modification or adjustment of hazardous area equipment, it
should be confirmed that the equipment will remain suitable for use in the area in which it is
installed.
Special Requirement for Moveable Apparatus.
Moveable electrical apparatus (hand held, portable and transportable) is particularly prone
to damage or misuse and therefore the interval between formal inspections needs to be
reduced
Type of protection 'd'.
When flameproof enclosures are re-assembled, all flameproof joints should be thoroughly
cleaned and lightly smeared with a suitable grease to prevent corrosion and to assist
weatherproofing. Blind holes should be kept free of grease. Only non-metallic scrapers and
non-corrosive cleaning fluids should be used to clean flanges.
It is normally not necessary to check the diametrical clearances of spigot, shaft, spindle and
thread joints, unless there is evidence of wear, distortion, corrosion or other damage, in
which case reference should be made to the Manufacturer's documents.
Type of protection 'e'.
Motor protective devices are selected so that the tripping time from hot when the locked
rotor current of the motor is carried, with the motor in the stalled condition, is less than the
stated time t E on the motor nameplate.
Page 52 of 63
10.24. Live Line Maintenance
Principles of live line maintenance

Live line maintenance is necessary for high voltage AC and DC line, Busbars, etc. when
deenergization of line/ substation is not permitted as continuity of service is essential or when
testing is required on energized equipment.
Person working in the vicinity of a live conductor is subjected to electric field stress. If the
person is insulated earth, he will be charged by the alternating electric field. The charging will
depend upon the position of the person and the field strength. If the person is touching the
grounded part, current will flow through his body to the earth.
The person is provided with shielding metallic cage “ FARADAY CAGE” which is connected to
the live part but it is insulated from earth.
Thereby the electric field stress across the person is eliminated. From theory of electric field, a
closed cage of conducting material does not have any electric field inside it. This principle is
used. Suitable cages open on the side for movement of hand etc. is provided. The man stands
inside the cage. The cage is insulated from earth but it is connected to the live line. The degree
of shielding depends upon the rated voltage of line and the type of maintenance work.
The maintenance person stands in the working cage open one end. The working cage is
mounted on a metallic platform. The total working cage is mounted on insulating sky-lift which
can be raised, rotated, held in desired inclined/ vertical position by means, of the control on the
ground level. The metallic working cage and platform is connected to live conductor by means
of flexible conductor. Thereby the platform and the cage assumed the same potential of
conductor and the maintenance person is subjected to negligible current flows through his body.
Care should be taken to avoid encroachment in the cone between two phases.
Special Tools for Live Line Maintenance:
Insulating ladder, usually made of laminated epoxy resin bounded wood section
Insulated tongs
Clip-on – instruments
Rods for installing earth connection clamps
Sky-lift (platform and Faraday cage which can be raised, lowered, rotated held in position
from ground control.)
Telescoping insulating platform
Insulating gloves, shoes, mats, supports
Temporary guards
Special dress with embedded wire-mesh which can be earthed to the cage
Page 53 of 63
Special Work-Permit and Safety Precautions:

Live line maintenance is not permitted unless following safety conditions are satisfied:
Special work permit procedure for live line maintenance is established
Experienced and trained responsible engineer, trained supervisors and technicians are
available.
Live line maintenance tools and facilities are available.
Check list of safety precautions is made.
Wireless communication is established between work site and feeding substation control
room for emergency switching off of the line.
11. TRAINING FOR SAFE MAINTENANCE OF ELECTRICAL EQUIPMENT
One of the major responsibilities of the Line Manager in a work-area is to train and supervise
people in the safe maintenance of electrical equipment ensuring safety and health to the working
people. Formulation of Safe Operating Procedure for different types of equipment are to be followed
by training to the supervisors, and with his association, training to actual workmen who perform the
work in different areas such as Off-shore operation, Drilling Rigs, Construction Zone, Electrical
Areas etc.
BUNDUQ will also develop and provide comprehensive Cold and Hot Works training for Permit
Applicants, Permit Holder, and authorized persons as defined by this procedure. No person shall
perform the functions of Permit Applicants, Permit Holder, and authorized persons, nor will they
supervise the work unless they have been through the BUNDUQ training program and until such
time as they are authorized by BUNDUQ ES&H to perform such tasks.
12. SOP COMPLIANCE
After the preparation of ground for SOP, such as, training of the controlling supervisor and the
group of workmen of different trades deployed on the maintenance work of Electrical Equipment,
respective SOPs are required to be introduced, people groomed and necessary inputs and back-up
resources provided to them, teething troubles faced and solved patiently and objectively.
The language and method of communication to workmen and their supervising staff have to be
perfectly suitable to their level of understanding, knowledge of language, length of experience,
surrounding of workmen-giving utmost emphasis and importance to the prevailing practical aspects.
Compliance, being a process of human adoption and having a bearing on habits and behavior of
workmen, needs human and psychological approach to be adopted and practiced by the
supervisor, with full backing of the line management.
Page 54 of 63
13. MONITORING
After systematically introducing SOP and providing tender nurturing, it is to be kept under constant
watch to check that people are complying with the system truly and in work-culture spirit; and that
SOP is meeting the objective of efficient and quality output, ease to workmen, improved working
environment, and conformance to all regulatory requirements and above all job-satisfaction to
workers.
During their regular rounds and sometimes during scheduled inspection, the Manager and
Supervisors should do spot checks of SOPs, interact with the workmen to convince them to adopt
correct and safe way of operation, to take all relevant safety precautions, use right types of PPEs.
14. AUDITING
To keep the Safe Operating Procedures of Hand and Power Tools on right track, it must be
subjected to regular and timely audits as per the prescribed procedure of the company.
15. SYSTEM REVIEW
Frequency and Objectives
The SOP System Custodian is to arrange for the system to be reviewed on an annual basis. The
objective is to ensure that any changes required to the system, or its operation, are incorporated.
Review Mechanism
The SOP System Custodian should conduct the review in conjunction with appropriate personnel
from the area operating the SOP System and other involved parties such as the Training Custodian.
The review is to deliver recommendations for changes to the system, based on consideration of the
following:
a) Audit Reports
b) Incident Reports
c) Proposals for Change
d) Change to appropriate industry guidance documents
e) Change to Company Organization
Copies of the recommendations from the review should be circulated for agreement prior to being
implemented.
All resulting changes to the Manual or other documentation are to be done in accordance with
appropriate document control procedures.
Page 55 of 63
16. UPDATING
In case, the work–situation has changed new sets of technology and machines have been
introduced, authorities in–charge of Review of the system propose for change in SOP system in
order to effect improvement, updating should be done by the management.
Page 56 of 63
APPENDIX: 1
PHYSIOLOGICAL EFFECT OF ELECTRICITY
In addition to fire and electrical shock, other known hazards include arc flash and arc blast, intense
light, and concentrated noise. Damage to body tissue from magnetic fields and plasma is another
possible hazard about which little is known.
Injuries from electrical hazards include electrocution (which always means fatality) from electric shock,
burns, reaction injuries such as falls caused by electrical contact, and injuries from flying parts and
pieces in an electrical explosion. Other injuries from arc flash, such as damage to eyes and ears, have
only recently been recognized.
A body resistance model would indicate approximately 1,000 Ω from hand to hand, or about 1,100 Ω
from hand to foot. It is believed that the greatest number of injurious shocks involve a current pathway
that is either hand to hand or hand to feet.
Page 57 of 63
Effect of 50 Hz. AC current on human body
Page 58 of 63
APPENDIX: 2
ELECTRICAL HAZARDS
Electric shock:
Electric shock is the physical stimulation that occurs when electric current flows through human body.
The symptoms may include a mild tingling sensation, violent muscle contraction, heart arrhythmia, or
tissue damage.
Severity of electric shock depends on:
Path of current flow

Magnitude of current
Duration of current
Frequency of current
Burns:
Burns caused by electric current occur from the inside of the body. This means that the growth centers
are destroyed. Electric-current burns can be especially severe when they involve vital internal organs.
Cell wall damage:
Research has shown that cell death can result from the enlargement of cellular pores due to high-
intensity electric fields. The electroporation effect allows ions to flow freely through the cell membranes,
causing cell death.
Page 59 of 63
Asphyxia:
Asphyxia occurs when the passage of continuous current through the chest cavity causes the chest
muscles constantly to contract, interfering with breathing.
Page 60 of 63
APPENDIX: 3
MEDICAL & FIRST AID
Shut off the electrical current if the victim is still in contact with the energized circuit. While you do
this, have someone else call for help.
If you cannot get to the switchgear quickly, pry the victim from the circuit with something that does
not conduct electricity such as dry wood. Do not touch the victim yourself if he or she is still in
contact with an electrical circuit! You do not want to be a victim, too!
Do not leave the victim unless there is absolutely no other option. You should stay with the victim
while Emergency Medical Services (EMS) is contacted. The caller should come back to you
afterwards to verify that the call was made. If the victim is not breathing, does not have a heartbeat,
or is badly injured, quick response by a team of Emergency Medical Technicians (EMT) or
paramedics gives the best chance for survival.
Once you know that electrical current is no longer flowing through the victim, call out to the victim to
see if he or she is conscious (awake). If the victim is conscious, tell the victim not to move. It is
possible for a shock victim to be seriously injured but not realize it. Quickly examine the victim for
signs of major bleeding. If there is a lot of bleeding, place a cloth (such as a handkerchief or
bandanna) over the wound and apply pressure. If the wound is in an arm or leg and keeps bleeding
a lot, gently elevate the injured area while keeping pressure on the wound. Keep the victim warm
and talk to him or her until help arrives.
If the victim is unconscious, check for signs of breathing. While you do this, move the victim as little
as possible. If the victim is not breathing, someone trained in CPR should begin artificial breathing,
then check to see if the victim has a pulse. Quick action is essential! To be effective, CPR must be
performed within 3 minutes of the shock.
Page 61 of 63
CPR Technique
What is CPR?
The letters in CPR stand for Cardiopulmonary Resuscitation, a combination of rescue breathing
(mouth-to-mouth resuscitation) and chest compressions.
Cardiopulmonary resuscitation, or CPR, is an emergency procedure performed on people suffering

cardiac arrest. The purpose of CPR is to provide a continuous flow of oxygen to the lungs and brain
until the person regains consciousness. The human brain can only survive an average of five minutes
without oxygen, after which time permanent damage is done. By performing CPR on a victim, the
rescuer is upping the chances for a full recovery. However, it is important to remember that CPR alone
is rarely enough for a person to survive. The true purpose of CPR is to keep the heart pumping and the
oxygen flowing until emergency care arrives.
When is CPR needed?
CPR is most successful when administered as quickly as possible, but you must first determine if it's
necessary. It should only be performed when a person isn't breathing or circulating blood adequately.
First, determine that it's safe to approach the person in trouble. For instance, if someone was injured in
an accident on a busy highway, you'd have to be extremely careful about ongoing traffic as you try to
help. Or if someone touched an exposed wire and was electrocuted, you'd have to be certain that he or
she is no longer in contact with electricity before offering assistance, to prevent becoming electrocuted
yourself. (For instance, turn off the source of electricity, such as a light switch or a circuit breaker.)
Once you know that you can safely approach someone who needs help, quickly evaluate whether the
person is responsive. Look for things like eye opening, sounds from the mouth, or other signs of life like
movement of the arms and legs.
3 Steps of CPR:
1. Call:
Check the victim for unresponsiveness. If there is no response, Call concerned emergency no. and
return to the victim to attend to resuscitation and pulmonary treatment, either alone or with some
trained body if available.
Page 62 of 63
2. Blow:
Tilt the head back and listen for breathing. If not breathing normally, pinch nose and cover the
mouth with yours and blow until you see the chest rise. Give 2 breaths. Each breath should take 1
second.
3. Pump:
If the victim is still not breathing normally, coughing or moving, begin chest compressions. Push
down on the chest 1.5 to 2 inches 30 times right between the nipples. Pump at the rate of
100/minute, faster than once per second.
Note
If breathing and heartbeat both are stopped, attend to them one after the other in the following ratio
(a) one blow and five pumps—if two persons attend
(b) Two blows and fifteen pumps—if only one person attends.
END OF THE DOCUMENT
Page 63 of 63

Electrical Equipment Maintenance

Uploaded by

Copyright:

Available Formats

Electrical Equipment Maintenance

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Electrical Equipment Maintenance

Uploaded by

Copyright:

Available Formats

SAFE OPERATING PROCEDURE Rev.

ELECTRICAL EQUIPMENT MAINTENANCE Page 1 of 63

SAFE OPERATING PROCEDURE & GUIDELINES

ELECTRICAL EQUIPMENT MAINTENANCE

ELECTRICAL EQUIPMENT MAINTENANCE Page 2 of 63

ELECTRICAL EQUIPMENT MAINTENANCE Page 3 of 63

ELECTRICAL EQUIPMENT MAINTENANCE Page 4 of 63

5 DEFINITIONS OF TERMS AND ABBREVIATIONS…………………………………….... 9.

ELECTRICAL EQUIPMENT MAINTENANCE Page 5 of 63

8 PROCESS FLOW 24.

10.1 Maintenance of Air / Oil Circuit Breaker 28.

ELECTRICAL EQUIPMENT MAINTENANCE Page 6 of 63

10.20 Fuses 49.

11 TRAINING FOR SAFE MAINTENANCE OF ELECTRICAL EQUIPMENT 54.

12 SOP COMPLIANCE 54.

ELECTRICAL EQUIPMENT MAINTENANCE Page 7 of 63

Handling of electrical power involves phases of generation of electricity by various means,

ELECTRICAL EQUIPMENT MAINTENANCE Page 8 of 63

Some classified electrical equipment is as follows:

ELECTRICAL EQUIPMENT MAINTENANCE Page 9 of 63

Occupational Safety and Health Administration (OSHA) 29 Code of Federal Regulations

CFR 1910.269 Electric Power Generation, Transmission and Distribution

CFR 1910.243 Guarding of Portable Powered Tools

CFR 1910.244 Other Portable Tools and Equipment

NFPA 70B: Recommended Practice for Electrical Equipment Maintenance

NFPA 70E: Standard for Electrical Safety in the Workplace

ILO: Code of Practice—Electrical Safety

BUNDUQ HSE Procedures and Manuals

5. DEFINITIONS OF TERMS AND ABBREVIATIONS

SOP: Safe Operating Procedure; other common names used are

• Safe Work Practices (SWP),

Electrical equipment: Electrical equipment include any power-handling gadget or any

ELECTRICAL EQUIPMENT MAINTENANCE Page 10 of 63

Intrinsically Safe: an equipment or gadget so designed and constructed that in case of

Audit: is an independent, systematic and documented process of objectively

Safety Training: encompasses the steps necessary to ensure that management,

Safe: means a condition in which all hazards inherent in an operation have

6. ROLES AND RESPONSIBILITIES

ELECTRICAL EQUIPMENT MAINTENANCE Page 11 of 63

6.1. Field Superintendent (FS)

 Ensure that briefings are delivered on any changes to the System.

 Provide training to SOP Area Control Points.

6.2. Store Attendant

 The materials shall be placed in secured areas.

6.3. Work Supervisor

 Electrical energy being highly hazardous, maintenance of electrical equipment has to be

ELECTRICAL EQUIPMENT MAINTENANCE Page 12 of 63

6.4. Equipment Operator

6.5. Equipment Inspector

 Shall be responsible to maintain and update the equipment inspection register.

 Shall be responsible to follow prescribed inspection schedule for the equipment.

ELECTRICAL EQUIPMENT MAINTENANCE Page 13 of 63

 shall document each equipment’s preventative maintenance schedule based on:

(1) The manufacturer’s recommendations;

Care of machinery—Maintainability is a property of machine which is characterized by their fitness

ELECTRICAL EQUIPMENT MAINTENANCE Page 14 of 63

7.1. Work Method Statement (WMS)

 Scope of Work – Work to be performed.

 Required Safety Equipment.

7.2. Process & Preparation

Ensure that briefings are delivered on any changes to the System.

Provide training to SOP Area Control Points.

The materials shall be placed in secured areas.

Electrical energy being highly hazardous, maintenance of electrical equipment has to be

Shall be responsible to maintain and update the equipment inspection register.

Shall be responsible to follow prescribed inspection schedule for the equipment.

shall document each equipment’s preventative maintenance schedule based on:

Scope of Work – Work to be performed.

Required Safety Equipment.

Results in knowledgeable maintenance decisions which would reduce overall costs by