/~IZ~%

Task Order No 804

Contract No PCE-1-00-96-00002-00

Substation Preventive Maintenance

Manual

Prepared By
International Resources Group
New Delhi-Washington, D C

August, 1998

For
USAIDIIndia
Mr N V Seshadri

Env~ronmentalPollcy and Institutional Strengthening Indefinite Quantlty Contract (EPIQ)

Partners International Resources Group Winrock International
and Haward Instttute for Internattonal Development

Subconlractors PADCO Management Systems Internat~onaland Development Alternattves Inc

Collaboratrng lnstirzitzons Center for Naval Analys~sCorporatton Consewatlon Internattonal KNB Englneerlng and
Applied Sc~encesInc Keller-Bl~esnerEng~neertngResource Management Internat~onalInc
Tellus Instltute Urban Institute and World Resources Instltute
 SUBSTATION
PREVENTIVE MAINTENANCE MANUAL
(FINAL DRAFT) I Ij

HARYANA STATE ELECTRICITY BOARD

Prepared Under The

THE UNITED STATES AGENCY

FOR
INTERNATIONAL DEVELOPMENT
Contract No OUT-PACE-I-804-96-0002-00

Prepared by The

IAg INTERNATIONAL RESOURCES GROUP

NEW DELHI -WASHINGTON,DC

PANCHKULA, 3HAIZYAEA INDIA

AUGUST 1998

The development work and complet~onof t h ~ Substat~onPrevent~veklanual was funded bv the Unlted States Agency for International
Develonment (USAID) under an Intcrnat~onnlRasources Croup (IRg) contract w ~ t hUSAID \rllss~onto Indla Contract NO OUT-PACE-I- "
804-96-00002 00 The vlelvs and statements conta~~iedIn the Jlanual are based on lndustrv standard practices USAID published documents
+
n nn .rn I "rn nat ntnn In 1 .r C 4 I n
~ n r rnl rpnr hol I t n hn r a l mhln m n I thprhnr
 TABLE OF CONTENTS

I
Page
I
No

II HSEB SUBSTATIONS STATUS 11-1

III PREVENTIVE MAINTENANCE PROGRAM DEVELOPMENT 111-1

IV TRANSFORMER IMPEDANCE TEST IV-I

V SWITCHGEAR INSPECTION AND TEST PROCEDURES V-I

V1 THERMOVISION SCANNER TO IDENTIFY "HOT SPOTS" Vl-I

Vll-I
VII INCORRECT CONNECTORS REPLACEMENT

VIII REPLACEMENT OF FAULTY EQUIPMENT VI11-I

IX REDUNDANT EQUIPMENT AND JUMPERS REMOVAL IX-1

X CHANGING TRANSFORMER NO-LOAD TAPS MANUALLY X-I

XI TRANSFORMERS COOLING SYSTEMS

XI - I

XI1 FORMATION OF "DRIP LOOPS" IN VERTICAL JUMPERS

X11-'I

Xlll INSPECTING & TESTING LARGE TRANSFORMERS X111-7

XIV UTfLlZATiON OF FUSES, CUTOUTS AND LIGHTNING ARRESTERS

XIV--l
 1 INTRODUCTION

The Internatronal Resources Group (IRG) IS provrdrng technrcal assistance to the

Haryana State Electncrty Board (HSEB) under the Unrted States Agency for
lnternatronal Development (USAID) Contract No OUT-PACE-1-804-96-00002-00
As the rn~tralstep, IRG was to examine the operating efficrency of the existrng
drstrrbutron system Upon the compietron of th~sactrvrty, IRg presented the results
to the Chairman HSEB, Mr Ranjlt Issar, and the Members of the board The
Charrman HSEB, based on the results of IRgJsrnvestrgatrons, requested an
evaluatron of the existing transrnrssion and drstrrbutron substatrons

The IRG team vrsrted a number of substatrons In an effort to rdentrfy the probable
cause of the large number of HV substat~onpower and d~strrbutrontransformer
farlures A presentation was grven to the Chairman and the Members of the Board
on June 18, 1998 The results of the IRg rnvest~gatronsrndrcated the need to
Increase the marntenance qualrty, review and upgrade system protect~on practrces
used on the HV substatrons and on the d~strrbut~ontransformers

HSEB IS procurrng about US$ 60 mrllron rn equrprnent and materral to

upgrade portrons of the heavriy overloaded drstrrbution system
facrlrt~esutrlrzrng funds avarlable from the World Bank as part of a loan to the
Central Government of India, World Bank Loan APL-1

HSEB Charrman requested that a substatron preventrve marntenance program

be developed for rmplementatron by HSEB Thrs document IS a substatron
preventwe marntenance manual that provrdes basrc gurdel~nesto the Haryana
State Electrrc~ty Board (HSEB) It rncludes the procedure to establrsh a
computerrzed equrpment preventive marntenance program prrmarily for
substatrons

The manual also rncludes procedures for the performance of substatron

equrpment rnarntenance These procedures are also applrcable to drstrrbutron
transformers This document IS a complement to the existing marntenance
manual of HSEB For completeness the HSEB Marntenance Manual has been
included as Attachment I

A procedure to develop the necessary equrpment database that would permrt

computenzatron of the marntenance program IS rncluded The development and
use of the computer program wrll ensure that the preventive marntenance
actrvrtres are performed trmely, that equipment failures are properly recorded,
including downtrmes, that spare parts are identrfied and procured trmely and
that ~ndrvrdualequrpment performance tracking IS marntarned
HSEB-Preventwe Maintenance Manual
Chapter I - lntroduct~on
The computer program is to be developed by the Haryana State Electricity
Board personnel using the procedures and guidelines rncluded In the manual
and the preventive maintenance Manuals that were provrded by the
manufacturers when the equipment was purchased It is essential that all guide
line& and recommendatrons made within the body of the Manuals are followed
to achieve therr intended objective for a long-{n-servicelife of the equipment

lnstallatron and construction gurde lrnes for workmanshrp, material, conductors

srzes, fuses sizes, parallel groove and compression type connectors and use of
proper tools must be observed rf the program IS to succeed At present HSEB IS
in need of havrng an rntensrve system upgradrng and maintenance program to
reduce the large number of transformer fariures and equrpment outages

This is a complementary manual to the existing HSEB Maintenance Manual

Throughout thrs complementary manual emphasls is made on quality
control of the varrous maintenance activitres and on safety Implementatron
of the procedures stated herein wrll aid in the reduction of equrpment
downtrme and frequency of occurrence of each of these outages

It is noted that out of the 31,000 d~stributiontransformers that failed every

year, about 20,000 transformers are canniballzed (used) to repair about
11,000 The replacement cost of the 20,000, assumlng an average cost per
transformer of Rs 30,000, and the financial annual impact to the HSEB is
30,000X2O1000 is approxrmately Rs 620 mill~onor about US $ 14 6
m~llion,a rather signrficant amount

Page 2 Of 2 2
 HSEB SUBSTATiONS STATUS

A HSEB SUBSTATIONS

At the present tlme the Haryana Electrtclty Board (HSEB) operates and rna~ntainsall
transrnlsslon ilnes and substations that transfer the electrtcal energy from the generatron
resources to the load centers of HSEB This temporary cond~tlonwill be changrng in the
near future when the HSEB IS divrded into a Generation Company, a Transrnlssion
Company and about three Dlstrrbution Companies The operat~on and maintenance
procedures presented here~nare based on the assumpt~onthat each company will have
access and be responsible for the operation and maintenance of their own substations

Table I1 I ~llustratesthe system voltages and quantity of substattons and distnbutron

transformers that form part of the transm~ssion and distrrbution systems There are
approximately 53,159 circuit-kilometers of high-tension 11 kV (HT) feeders and 102,639
circutt-kliometers low-tens~on(LT) lines

TABLE I f I
SYSTEM VOLTAGE LEVELS AND QUANTITY
OF SUBSTATIONS AND DISTRIBUTION TRANSFORMERS
SYSTEM VOLTAGES (KV) SUBSTATIONS

D~strrbut~oTransformers o n 11 kV feeder s I I
99,524
/
/I Totals 99,942 11
B IDENTIFY SOURCE OF LOSSES

The lack of adequate substation maintenance results in a low degree of equipment

servlce reilabillty, loss of servlce to electric power consumers and In power losses that are
not econom~callyacceptable to HSEB
----
_m -1
HSEB-Preventwe Maintenance Manual
Chapter II - HSEB Substat~onsStatus
- -- - - - -- - - - - -

The marn source of power losses at the substatron IS In the power transformer and auxrlrary
equ~prnent However, there is another source of power losses rn a substatron whrch IS
usually the result of poor connections between the bus and lrne conductors, drsconnect
swrtches, crrcuit breakers, reclosers, and fuse cutouts There are at trmes podrly desrgned
and/or deficient rnstallatrons, and/or use of lengthy and undersized jumpers, use of non
appropriate connectors to ensure a solid connect~on, and the makrng of connections
between copper and aluminum and other materral without the use of appropriate blmetal
connectors The splrcing of non-allke metals results in galvanrc corrosron that eventually glves
rise to a htgh power loss splrce The continues use of non-essent~alequipment (fixed or
rotat~ng)also leads to power losses whrch are not acceptable to HSEB

A vrsual ~nspecttonof the sub'statlonmay lndrcate some deficrencres to the experienced

eye There are, however, many hrgh resistance connectrons and, therefore, htgh power
loss components, w~thlnthe substatron that can only be detected by the use of a specrai
dev~ce called the Thermov~sronscanner

The Thermov~sionscanner is used to detect electric power system components that are
operat~ngat temperatures above their normal desrgned thermal capacity The use of a
Thermovisron scanner by substation marntenance personnel permits to determine the
locatron of 'hot spots' orconnections that are operating at abnormally high temperatures

C APPROACH TO LOCATE AND EVALUATE POWER LOSSES

The locatron of the source of power losses must be rdentlfied prior to the development of
any actron plan to reduce them The basic approach is as follows

1 Perform Thermovisron scannrng of all equipment, conductors, connectors and

jumpers at the time of the substatron peak load

2 Take measurements to determine contact resistance of equipment with scanned

hot spot such as jumpers, connectors, transformers, etc "before" any
corrective actlons are Implemented

3 Visually look for other sources of losses such as operatron of non-esseniral,

overloaded and/or undersized equipment

4 Develop and rmplement solutrons to correct deficrencles and reduce power

losses

Once the losses and their sources are identrfied from the above tests and corrective
measures implemented to reduce these losses Perform the followrng evaluatron to
quantrfy the technrcal and economlc benefits

Page 2 of 6 'I'
HSEB-Preventive Maintenance Manual
Chapter II - HSEB Substations Status
- - - -- - -

5 Take measurements "after" the implementation of the corrective act~onsto

evaluate the benefits, if any, of the changes made Ensure that the implemented
measures are effective rn reducing the energy losses I
/

6 Repeat the Thermovrsions canning of ail the equipment, conductors and

jumpers at the t~meof the substation peak load All previous 'hotspots'should
now have been elrmrnated

7 Compute the reduction or savrngs rn losses and perform an economic

evaluatron to determ~nethe benefits whrch wrll then be used as rnput to the
act~onplan matr~xrncluded at the end of this Chapter

D CONNECTORS

It appears to be a practrce of the HSEB to utllrze whatever materral IS available at the

time of need This practrce results rn the use of wrong connectors for a given applicatron
or no connectors at all Connectors that are not correctly applred are a very common
source of system power losses

To reduce the power losses at the substation, the correct connector for the applrcatlon
must be used

1 A spec~ficapplrcatlon requrres the correct connector to be selected and used The

connector selected must match the configurat~onof the connected equrpment
Adding connectors In serles wrll only add to the overall connector resistance, thus
Increasing the I'R losses Select only one connector per connectron

2 Connectron of drfferent metal types requires the selectron of the correct

brmetallrc connector

3 The correct metallic bolts must be used wrth bolted connectors Applrcatron of
the correct torque value must follow the manufacturer instruct~ons

4 The correct size connectors must be used for the equrpment termination being
connected

5 The correct contact pressure must be reached by using either the correct bolt
torque, or correct gun and cartrrdge for wedge connectors, or correct crrrnper
and dies for crlmped connectors

Page 3 of 6 ,
- -t

HSEB-Preventive Ma~ntenanceManual
Chapter II - HSEB Substat~on Status
E TRANSFORMER COOLING

All substation transformers have an oil and air (OA) ratlng for a winding temper;ature rise
of 65C above the 30C ambient with natural air-cooling Some transformers have an
additional 25 per cent Increase In thermal capac~tyover the OA rattng through the use of
forced coollng air fans The additronal coolrng capacity is derived from the use of cooling
fans use to limit the windrng temperature from risrng above the 65 OC design temperature

If the transformer IS carrying a load that is lower than the normal transformer OA ratlng,
the operation of the fans IS not requlred If fans are turned on manually and kept on
running cont~nuously,this 1s a waste of electrrcal energy and should be eliminated by
turn~ngoff the fans

F TRANSFORMER TAP CHANGERS

It appears that ~ngeneral, the HSEB has available at therr substation transformers that
were purchased with a variety of different tap changers to maintaln bus voltage wlthin the
prescribed operating criterra

There are existing transformers with load tap changers which are defective and are either
frozen on a particular tap pos~tionor whlch can not be operated onto a tap setting under
no-load conditrons

The optimum manual-tap position IS determined by checking voltages on the prrmary

feeders down the line at the time of the system peak load and durrng light load conditions
Then, it IS determined whether the voltage variation for that part~culartap setting IS withln
the acceptable operat~ngcriteria limlt

It IS necessary that load tap changers be rnalntarned perrodlcally to ensure that adequate
voltage levels are rnalntained at the substation's 11 kV bus Incorrect tap setttngs may
have detrimental effects on power factor, voltage and correspond~nglyon power losses

G CONDUCTOR SlZlNG

Jumper and bus conductors must be adequately sized for the main transformer load~ng
Alumlnum jumpers are used to connect equipment terminations that are almost always
made of copper

Not using bimetallic connectors to connect the aluminum jumper to the copper termlnatron
pads of the equipment results ~n high power losses belng generated due to incorrectly
appl~edconnectors

Page 4 of 6
9
 HSEB-Preventive Maintenance Manual
I Chapter I1 - HSEB Substatrons Status
I H CONTACT RESISTANCE
I

~ r e i k e r sand reclosers have finlte contact res~stanceinternal to their tanks o/enclosures

I W~thage and many interrupting operations with cumulat~veeffects, thrs contact resistance
could increase, thus generat~ngI'R losses under heavy load cond~tlons
This contact resrstance should be measured perrodrcally and compared to the
I manufacturers designed values to ensure that they are w~thlnthe tolerance allowed by the
- manufacturer If they are out of tolerance then the breaker/recloser should be taken out of
( service and the contacts cleaned in accordance with the manufacturers 0 & M procedures
before putt~ngthe equrpment back agaln rnto servlce

-
Typlcal resistances are of the order of 2 30 micro-ohms Srmrlarly, fuse cut-outs and
disconnect switches have mating parts and sliding contacts which, if allowed to
deteriorate, can give rrse to high resistance values
I- Checking for "Hot spotsJ with a scanner at the t~meof the substatron peak load, alerts the

I
users that the particular piece of equrpment needs to have its contact surface cleaned srnce a
h~gherthan normal resrstance IS building up due to corrosron, oxidation, pittlng, etc

I 1 IMPROVISATION OF FITTINGS, CONNECTOR EQUIPMENT

I Using equipment manufactured in accordance wrth a national standard (e g NEMA) is a

guarantee that the equrpment has been desrgned to operate wrthrn rts rat~ngswith no
abnormal temperature rlses

I If, however, the equipment is modrfied or its connections are altered and not in
accordance with the manufacturers recommendatrons, 'hot spots' are to be expected

I since the equipment IS essent~allyput together without passing industry standards

Many trrnes this improvisation has been found to be the source of hot spots A typical
I example is the replacement of fuse barreis and K type fuse links wrth wire hand wound
across the terminals of the link connections Electrrcally this provides continurty to the
I system but from an economic standpoint thls IS a source of very h ~ g hpower losses, as h~gn
contact res~stancesare created
It is an excellent engineering practice to use the manufacturers desrgned equipment for the
I applicatron 1t was rntended for Temporary solution or rmprovisatron must not be allowed to
become a permanent condrtion as these give rise to expensive power losses that must be
avorded by HSEB

Page 5 of 6

i0
HSEB-Preventwe Maintenance Manual
Chapter I1 - HSEB Substations Status
J PROTECTION COORDINATION

A vrsual inspectron of the drstr~butlonsystem lrnes end drstrrbutron trans for me;^ that
HSEB do not use them at all It appears that through trme thrs has become an standard and
expensrve practlce resulting rn many feeder outages and transformer faliures Usually the fuses
on a dlstrlbutron lrne have to be coordrnated wrth the recloser, relay, or another fuse at the 11
kV substat~onsrde HSEB needs upgrade the entire protectlon system by utrlrz~ng fuses,
lrghtnrng arresters, breakers at every substation and to perform coordrnatron studres to
determine relay settrngs and fuse types to prov~decoordinated protection to the HSEB
system Proper system protectlon coord~natlonw~llensure that the operat~on of fuses, located
downstream on a glven feeder, w~llnot take out the ent~refeeder andlor substat~on
The benefit of adequate system coordlnatlon IS that only the faulty sectton IS out of service
and only a few consumers are affected

Also, ground fault relayrng of the substatrons should be set hrgh enough so as not to
cause tr~pprngat the substat~on,for unbalanced loads due to rncorrect balanc~ng,or for
trlpprng of srngle phase lrne transformers whrch would cause a dynamrc unbalance
Ground fault relaylng at the substation IS generally set above 100 amps

K GROUNDING

All equrpment tanks, neutral conductors, etc should be adequately grounded rn accordance
wrth rndustry standard pract~ces Hrgh ground resrstance In neutral conductors could
generate hrgh losses when the unbalanced currents flow In the neutral conductor

Also drsconnectron of neutral grounds dependrng on where they occur could cause
float~ng neutral voltages whrch could glve rrse to hrgh over voltages durrng unbalanced
loadrng condrtions

BASE LOSSES
It should be noted that good plannrng, desrgn, or maintenance couldn'telrmrnate all losses rn
a substatron Every prece of equrpment, conductor and connector has rts own rnherent losses
As an example, the marn transformer has "No load losses" and "load losses" These are
specrfred and predicted by the manufacturers durrng the development of transformer destgn
drawrngs and specrficatrons Transformers can be purchased wrth power losses that are
lower by wrrtrng specifications w~thlow loss lrmrts that are st111wrthin desrgn constrarns
although the HSEB may have to pay a h~gherrnrtral prrce However, over the economlc lrfe of
the transformer thrs hrgher prlce transformer IS the best economlc chorce for the HSEB
Page 6 of 6 I
(
 PREVENTIVE MAINTENANCE PROGRAM
DEVELOPMENT

A GENERAL

The prevent~vemaintenance program descnbed herein must be computerized This will

allow for easy equtpment record keep~ng and for controfllng the actual work performance
of the maintenance personnel It IS also, important that the times taken by different crews
to perform the same maintenance activlty be recorded and analyzed Bonus (monetary,
trme off, others) rncentives are provided to crews whose equipment under their
responsibility has the lowest failure rates In a slmilar manner those crews that fail to meet
a maxrmum equipment farlure rate would be penalized, transferred or dismissed out of
the prevent~vemaintenance group It is understood that at times equipment failures are
beyond the control of the PM Each equipment case wlth high failure rates must be
carefully analyzed for falrness on lmpostng penalties to PM crews

B DATA COLLECTION

The first consideration IS to design the program to meet the needs of the Haryana
State Electricity Board Develop a manual that IS as simple as possible The starting
polnt IS to perform an evaluation of needs The following questions must be answered

1 How much equipment is involved7

2 How many people are available to marntain the equipment7

If it is found that the available staff IS not sufficient to marntarn the equ~pmentor their
qual~fications are below requirements, then HSEB has to evaluate the economlc
benefits of add~ngqualified staff to meet PM objed~ves Once the answers to these
questtons have been obtarned then the overall program development can begrn

There will be need to spend only three to four hours per equipment item to compile all
necessary data Thrs includes reading the matntenance operator's manual, developing
and writing the program, and ordering recommended spare parts The PM
requirements remaln the same and only the equipment data needs to be compiled to
ensure an adequate PM program
HSEB-Preventrve Ma~ntenanceManual
-
Chapter Ill Preventive Ma~ntenanceProgram Development
1 Forms

Forms I through 3 have been desrgned to collect the equrprnent data

necessary to establrsh the preventwe maintenance program I t

FORM I Thrs Form 1 IS the Equ~prnentData Record It IS used to collect

rnformat~onon the equrpment that IS to be maintamed Th~srncludes power
transfomers, voltage regulators, capacitors, distrrbutron transformers, lightning
arresters, disconnect sw~tches, current transformers, potentral transformers,
capacitor controllers, motors, pumps, relays, compressors, batterres, etc

Once all data has been accumulated, an equrpment numberrng system must
be developed The system may use srx-digit numbers (for example, 0021-21)
The fist four drg~tsrndrcate the equrpment type, the fifth and srxth
d~gitsrdent~fythe items - motor, corl or relay - ~neach category Such a
numbering system should be used throughout the program to ~dentrfyand
catalog materrals In addrtron to the equ~pmentdata, rnformatron about spare
parts and assembly list~ngsIS included on the lower half of Form I

FORM 2 - Llst on th~sForm rtems that must be marntarned or verified on each

prece of equipment such as or1 levels, counter readings, loose connections,
or1 leaks, breaker contacts, relay settings, lubrrcate motors, fans, compressors,
check spare parts requrrements, etc Thrs Form 2 also wril show PM personnel
what tools and spare parts are requlred

FORM 3 This Form IS an equrpment-gurde list that rdentrfies each prece of

equrpment In the electrrcal or mechan~calsystem by name, number, and locatron
It simplifies the work for the new PM personnel of locatrng the equrpment to be
marntarned showrng the equrpment name, number and actual physrcai locatlon

Page 2 of 12

D
 HSEB-Preventive Ma~ntenanceManual
Chapter I11 - Preventwe Ma~ntenanceProgram Development
EQUIPMENT DATA RECORD
Equ~pment Equ~prnentNo I

Model no

Vendor

1 Date purchased lnlt~alstart-up date

I
I
Volts

Frame Ratlo Capacity

Others

Item Assembly Part No Manufacturer

Techn~cal
I~stlng I reference

I I
I I
I
I
I I
I
I
I
I
4

Symbol Stores number

Item number
I Spare parts II Locatton
I
I
l
a

Page 3 of 12
HSEB-Preventrve Maintenance Manual
Chapter Ill - Preventrve Ma~ntenanceProgram Development

FORM 3
EQUIPMENT-GUIDE LIST
IDENTIFY EACH PIECE OF EQUIPMENT IN THE ELECTRICAL OR MECHANICAL
SYSTEMS BY NAME, NUMBER AN D LOCATION

Equ~pment Equ~pmentNo

Number Location
 HSEB-Preventive Maintenance Manual
Chapter Ill - Preventive Ma~ntenanceProgram Development
C CREATING THE PREVENTIVE MAINTENANCE MANUAL

Upon the completion of the collection of all equipment data, a computenzed Ftabase
is built and use as the baas for the development of the various preventive
maintenance activitres The system lists what maintenance checks must be performed
on the equipment It also Indicates what tools and spare parts are required

FORM 4 - Thrs Form 4 is the PM MANUAL It IS the heart of the program It contarns a
one-line summary of each PM requirement for each piece of equ~pmentThe manual is
arranged in numerrcal sequence This manual supplies all information necessary to
schedule preventive maintenance, order replacement parts, record equipment hrstory,
and analyze equipment conditions

Included in each section are the PM summary sheets, equrpment data records, and
equ~pmenth~storyrecords In front, an index l~stsall equipment In numerical order All
forms are filed in sequence under the equipment number, beginnrng with 0001

FORM 4
PREVENTIVE MAINTENANCE MANUAL
I Equipment
Equipment no Location
-
I
I
I

I
I

Preventive maintenance assignments

Assignment
Assignment
Number Number

I
1

Page 5 of 12
HSEB-Preventwe Maintenance Manual
Chapter Ill - Preventive Ma~ntenanceProgram Development
D EQUIPMENT HISTORY

FORM 5 The equipment history record, Form 5, is the last page of each sectron
Entnes on thrs Form should include all repairs, overhauls, modifications, and other
non-PM-related funct~onsperformed on that piece of equ~pment Descriptions should
include parts, labor, and dates Thrs record serves as guide to accurately estirnatlng
the need for future repairs of overhauls It marntains the equ~pmenthistorical records
that glve all ~nformat~on repairs to equipment It can point out recurrent problems and
warn of a sertous breakdown Again, the data on these Forms 1s input to the computer
to contlnue the data base development

FORM 5
EQUIPMENT HISTORY RECORD

Equ~pment Equrpment no

Date Worked Performed Labor (hours) Parts Used

I I
I
I
I
I
I
I 1
I
I
I

I
1
I
I
E SCHEDULING

Once the basic information has been collected, maintenance schedules are developed for
each piece of equipment instructing the staff as to when and what type of
ma~ntenancethey are to perform The computerized printout of each schedule IS issued
and each maintenance crew can then transferred to larger forms designed so they may

Page 6 of 12
 HSEB-Preventive Maintenance Manual
Chapter Ill - Preventwe Ma~ntenanceProgram Development
be placed on convenrent buHeting boards alongsrde each other This arrangement
allows reading honzontaily across one line at a t~me,assunng ease In schedulrng
Suggested sizes of schedules are yearly, 20 x 28 In, quarterly, 44 x 28 rn , weekly,
24 x 28 In Space is provided for 50 equipment items Addrtronal schedules may,be
used if necessary

I F~v Year Schedule

FORM 6 The five year schedule, Form 6 , should be filled out first, coverrng
all requirements except weekly Once all equipment numbers and names
have been filled, the scheduling should begin with the first Item Refer to the
PM manual and make the approprrate assignments In each of the four
blocks, each block represents one quarter of the year Quarterly checks are
entered first Semiannual requirements are next and will be scheduled rn two
of the blocks Annual requirements are scheduled last

2 Yearly Schedule

FORM 6 IS also used to develop a yearly PM schedule In the yearly schedule,

srmllar types of PM should be scheduled for the same quarter For euampie, if a
transformer LTC IS to be cleaned and the oil changed quarterly, schedul~ngan
annual c~rcuitbreaker rnspectron for the same time may be advantageous With
this method, only one major shutdown of the main feeders would be necessary
Before the yearly schedule is completed, monthly assrgnments must be
recorded rn the last block The yearly schedule IS completed first and then use to
schedule quarterly PM All rnformation IS taken from the PM Manual

FORM 6
YEARLY SCHEDULE
J

Begrnnrng Year

Equipment no Equipment 1st 2nd 3rd 4th 5m

I
II
I I I
I I I
I I
I I I
I
I
I
I
I
Page 7 of 12
HSEB-Preventwe Maintenance Manual
Chapter Ill - Preventive Ma~ntenanceProgram Development
3 Quarterly Scheduie

FORM 7 Thrs Form 7 allows the development of the quarterly schedtde startrng at
the first block Each of the 13 blocks represents 1 week of the quarter At the top of
each column, the date of each Monday of the quarter should be entered
Informatron for the quarterly schedule IStaken from the yearly schedule and the
PM manual Each of the 13 blocks represents 1 week of the quarter

FORM 7
QUARTERLY SCHEDULE

Quarter Year

Equipment Equrpment 2 Jan 9 Jan 16Jan 23Jan 30Jan

Number

I I
I

I I
HSEB-Preventwe Maintenance Manual
Chapter III - Preventive Marntenance Program Develo~ment
4. Monthly Schedule

FORM 8 Form 8 ISused beg~nnrngw~ththe first week and the tirst equrpment
Item, schedule all monthly asslgnments Each equipment item will be scheduled three
trmes per quarter Because there are 13 weeks per quarter one segment w~ilhave a 4-
week interval Scheduling w11l depend on how much t~meIS
for preventwe ma~ntenance, but try to schedule jobs evenly
throughout the month Otherwise, the crews will be performing all the jobs in
the first week of every month The only t~rnea problem may occur IS if an
assrgnrnent must be rescheduled, and there may not be sufficient time to
accompl~shit

After the monthly assignments have been scheduled, the quarterly, semi-
annual, and annual assrgnments should be added Consult the yearly schedule
for those assignments included in the quarter berng scheduled Refer to PM
manual and schedule simrlar types of assrgnments for the same week

FORM 8
MONTHLY SCHEDULE

Month Year

Equipment No Equipment Week-I Week-2 Week3 Wee k-4

.
I

I
I
1

Page 9 of 12
HSEB-Preventive Ma~ntenanceManual
Chapter Ill
5
- Preventwe Maintenance Program Development
Weekly Schedule

FORM 9 The weekly schedule, Form 9, IS the workrng document for prevent~ve
marntenance An extra column of blocks may be added to ~ncludethe name of
the person respons~blefor a partrcular prece of equrpment

The schedule should have all dally and weekly assrgnments, rf required It
can be covered w~thplastlc so that addlt~onalschedulrng can be done
w~tha grease pencri From week to week, srmply wrpe rt clean and,
reschedule from the quarterly

To set up the schedule, transfer all ass~gnmentsfrom the applrcable week on the
quarterly schedule and enter the date of Monday of the current week rn the top
space An X should be drawn through ass~gnrnentsas they are completed
Assrgnments that are not completed should be c~rcledAt the end of the week, all
completed assrgnments should be noted on the quarterly schedule Unfinrshed ones
should be circled and entered rn the next weekly block The weekly schedule IS filled
out after the yearly and quarterly has been completed It w~ll serve as the workrng
document for prevent~vema~ntenance

FORM 9
WEEKLY SCHEDULE

Week
Equrpment No Equrpment Mon Tue WedThurs Frl 1 Sat
I I
I
I I 1 I I
I I
I
I I I

I I I I I
I I
I I
I
I I I

Page 10 ot 12 2/
HSEB-Preventive Ma~ntenanceManual
Chapter Ill
F
- Preventwe Ma~ntenanceProgram Development
POINTS TO REMEMBER

It IS rmportant to remember that uncompleted monthly, quarterly, sernl-annual, and

annual assrgnments cannot be carned over rn thrs manner These rr)komplete
asslgnments are left clrcled

The quarterly schedule will become a permanent record of the preventive

ma~ntenance system Sometrmes before the end of the current quarter, a new quarterly
schedule should be filled out Unfin~shedsemrannual and annual assrgnments should
be transferred to it The last block In the quarterly schedule should rnclude those
assrgnments to be transferred All monthly and quarterly assrgnments not completed
wrthrn the quarter should be crrcled

Shortly before the end of the year, a new yearly schedule should be generated Any
improvements rn schedulrng, such as rearranglng assrgnrnents and dates, should be
lncorporated at this t~me

G DISTRIBUTE WORK LOAD EVENLY

The PM IS most effective when jobs are scheduled and completed on an evenly
distrrbuted basis Monthly assignments should be completed 4 weeks apart, and so on
Completron of assrgnments on trme is rmportant In assurrng unrformrty of equrpment
upkeep
H FAILED-PARTI EQUIPMENT REPORT

The failed-padequrpment report, Form 9, provrdes details on work other than PM

performed on the equrpment Thrs report 1s filled out immedrately when repairs or
overhauls are completed A brief summary of the repairs IS placed In the equrpment
hrstory record The completed forms are then filed

Thrs form includes the equrpment name and number, the farlure, and rts cause On
the lower portron of the form, a descrrptlon of the corrective actron and a lrst of parts
used for the reparr should be included

I SPARE PARTS

To formulate a useful list of spare parts, consult or~grnal equ~prnent marntenance

manuals, manufacturer'srnformatron, and, most rmportant, the
~ndrvrdualsrnarntarnrng the equipment These sources can prov~dean accurate
accountrng of all necessary spares The l~stat the bottom of the equrpment data record
can be used as the rnventory of spares, or a separate sheet may be drawn up

Page 11 of I 2 27J
HSEB-Preventive Ma~ntenanceManual
Chapter Ill - Preventwe Maintenance Program Development
After the system has been in operation for a time, manv recurrent ~robiernsw~llbe
noted and adequate parts support w~llbe available A penodtc review of the faded-
part/equipment reports may define some potentrai problem areas
I

FAILED-PARTIEQUIPMENT REPORT
I
I Date W O No

Act~ontaken

Parts List
Part Name Part No Comments
I

Date Repaired

Page 12 of 12
 I

TRANSFORMER IMPEDANCE TEST

Purpose Th~sprocedure covers transformer rrnpedance testrng, one of the

acceptances tests for new transformers, and a method for rout~ne
testing The results of thrs test should compare d~rectfyw~ththe
manufacturer's datasheet

Toois RMS voltmeter

RMS ammeter, or two mult~funct~onmeters w~th0 5% accuracy
0-105 Vac varrable power supply
20 A, 120V, srngle- phase sources
Jumpers of vanous lengths

lmpedance test locates problems w ~ t h ~transformer w~ndingsThe

tests In this task procedure apply to

Single-phase transformers
Three-phase two-w~nd~ngtransformers with and w~thoutburred
tert~arres
Three-phase three-wrnding transformers
Three-phase autotransformers with and without burled
tertrarres

The results of impedance tests performed ~nthe fieid should be

with~n 5% of manufacturer's data Values beyond thrs range
should be investigated by further tests

lmpedance Tests Th~sprocedure covers srngie-phase transformers, three-phase

two-wrndrng transformers with and without burred tertiary
wind~ngs,and three-p hase two-wrndrng autotransformers

1 Set the no-load tap changer to the nameplate voltage before

proceeding w~ththe test

2 Short-c~rcu~tthe secondary terminals together and connect

the voltmeters and ammeters to the hrgh-srde bushrngs
HSEB-Preventwe Ma~ntenanceManual
Chapter IV - Transformer Impedance Test

3 Connect the variable power supply and slowly increase the

voltage to 120 volts Watch for the overcurrent range of the
#'

ammeter, change the scale if necessary

4 Record the voltage, current, and the cornbrnation of h~gh-side

bush~ngs(e g HI-H2, HI-H3, or H2-H3)

5 Disconnect the varrable power supply and move the power

leads to the next high-slde (or low-side) bushrng combination
Repeat Steps 3, 4, and 5 until ail combrnatrons have been
recorded

6 Calculate the percentage rmpedance

Three-phase The procedure for measurement of three-phase three-wrndlng

Three-W~nd~ng transformers and three-phase three-wlndrng autotransformers IS
Transformers the same as for two-w~ndrngtransformers, except that there IS a
total of nrne sets of measurements Instead of three

For 3-phase three-wlndrng transformers, three measurements

are made by the short crrcurt test

Zps = Leakage rmpedance measured rn the primary wlth the

secondary short crrcu~tedand the tertrary open

Zpt = Leakage rmpedance measured ~nthe prrmary wlth the

secondary open and the tertiary short crrcu~ted

Zst = Leakage impedance measured in the secondary

w~lhthe primary open and the tertrary short clrcuited

1 Set the no-load tap changer to the nameplate voltage before

proceeding w~ththe test

2 Short-crrcurt the secondary termrnals together and connect

the voltmeters and ammeters to the hrgh-srde bushrngs

3 Connect the var~ablepower supply and slowly Increase the

voltage to 120 volts Watch for the overcurrent range of the
ammeter, change the scale ~fnecessary

4 Record the voltage, current, and the comb~natronof hrgh-srde

Page 2 of 3 'd
HSEB-Preventwe Maintenance Manual
Chapter IV - Transformer Impedance Test

5 Disconnect the vanable power supply and move the power

leads to the next high-slde (or low-s~de)bushing combinat~on
Repeat Steps 3, 4, and 5 unt11 all combrnatlons have been
recorded

6 Calculate the percentage Impedance The measurements

must refer to the hlgh s~deand the same MVA base

Calculation for Z% for s~nglephase transformers

Percentage
Impedance (Z%) Z% = MVA 100
1sc (KVlJ2

Z% for 3-phase two wlndlng transformers and auto transformers

Z% for 3-phase three-wind~ngtransformer and auto transformers

NOTE MVA and KV,,refer to the prlmary side of transformers

Page 3 of 3
 J

SWlTCHGEAR INSPECTION
AND TEST PROCEDURES

Purpose Thrs Procedure covers the rnspect~onand testrng of switchgear to

ensure that equrpment and connect~onsare all In workrng order

Visual and 1 lnspect for physrcal, electrrcal, and mechanrcal condrtion

Mechanical
Inspection 2 Compare equrpment nameplate lnformatron wrth latest one-
l~ne d~agramand report drscrepancres

3 Check for proper anchorage, requrred area clearances,

physrcal damage, and proper alrgnment

4 lnspect all doors, panels, and sectrons for paint, dents,

scratches, fit, and mrssrng hardware

5 Verrfy rf the fuse and/or crrcurt breaker sizes and types

correspond to the draw~ngs

6 Verrfy if the current and potentla1 transformer ratios

correspond to the drawlngs

7 lnspect all bus connectrons for hrgh resrstance by usrng a low-

resistance ohmmeter Check the trghtness of bolted bus jornts

8 Test all electrrcal and mechan~calrnterlock systems for proper

operatron and sequencrng

9 Closure attempt shall be made on locked open devrces

Openrng attempt shall be made on locked closed devrces

10 Key exchange shall be made wrlh devrces operated In off-

normal posrtrons

1 1 Clean ent~re swrtchgear usrng manufacturer's approved

methods and materials

12 lnspect rnsulators for evrdence of physrcal damage or

HSEB-Preventive Ma~ntenanceManual
Chapter V - Switchgear lnspectlon And Test Procedures
contaminated surfaces

13 Verify proper barner and shutter installatrons and operat~on

14 Verify approprrate contact lubr~cation on moving current

carrying parts

15 Verify appropriate lubrication on movlng and sl~dingsurfaces

16 Exerc~seall actlve components
17 Inspect all mechanical indicating devlces for proper operat~on

Test Values Insulation-reststance test shall be performed in accordance w~th Table 4 I

Values of insulation resistance less than what this table prescribes
should be Investigated Over potentral tests should not proceed
unt~l ~nsulation-res~stancelevels are raised above mlnlmum
values

Overpotential test voltages shall be applied In accordance with

Table 4 2 (derived from ANSIJIEEE C37 20 2)

Test results are evaluated on a passffall bas~sby slowly

rarslng the test voltage to the required value The final test
voltage shall be applled for one (I)mlnute

TABLE 4 I

SWITCHGEAR INSULATION-RESISTANCE TEST VOLTAGES

Max~murn Recommended Mrn~rnum

dc lnsuiatron Res~stance
Voltage Rating Test Voltage In Megohms
500V I
0 - 250V 50
251 - 600V IOOOV 100
601 - 5000V I 2500V 1000
2500V 5000
5001 - 15000V 5000V 20000
15001 - 39000V - --

Page 2 of 3 @
HSEB-Preventive Ma~ntenanceManual
Chapter V - Swltchgear Inspect~onAnd Test Procedures
TABLE 4 2
I
FIELD OVERPOTENTIAL TEST VOLTAGES* /
Rated kV Max~mum

Type of Apparatus Test Voltage kV

ac dc
4 76 14 3 20 3
MC 8 25 27 0 37 5
(Metal-Clad Swllchgear) 15 0 27 0 37 5
38 0 60 0 +
15 5 37 5 +
SC 38 0 60 0 +
(Statlon-type Cublcle Swttchgear 72 5 120 0 +
4 76 14 3 20 3

8 25 19 5 27 8
ME1 15 0 27 0 37 5
(Metal-Enclosed Interrupter 15 5 37 5 52 5
Sw~tchgear) 25 8 45 0 +
38 0 60 0 +
0 76 16 23

MEB 50 14 3 20 3
(Metal-Enclosed Bus) 15 0 27 0 37 5
25 0 45 0 +
35 0 60 0 +
+ Consult Manufacturer'sSpeclficatlons
*Derived from ANSIIIEEE C37 20 2 and C37 20 3

Page 3 of 3
 THERMOVISION SCANNER
I
TO IDENTIFY "HOT SPOTS" I

Purpose Thrs Procedure outlrnes the steps in identlfyrng "Hot Spots" on

equrpment at a substatron utrl~zingthe Thermovrsron camera The
Thermovrsron camera IS capable of rdentlfylng the heat generated
by rndrvrdual substation components operating at temperatures
above therr equrpment deslgn ratlngs Basically, the 12R losses
produce the heat that IS observed by the camera as a "hot spot"
The purpose of the scannrng therefore IS to ~dentlfywhere there are
localrzed losses In the electrrcal systems
Procedure Transmrssron and drstrrbutron Irnes, rncludrng substatrons can be

tested wrth Thermovrs~on equipment to locate hot spots on

conductors and equrpment caused by loose connectrons and
hardware and other defects Thermovrsron equrprnent locates hot
spots by usrng Infrared scannlng to thermally rnspect the equrpment
and lrnes The scannlng equ~prnent can be operated from a
helrcopter, a van or by an operator carrylng the equrpment
Refer to the manufacturer rnstruct~on manual included with the
scanner to be procured by HSEB

Assemble the Thermovrsron Camera, Battery Pack and ail

auxll~ary equrpment (Refer to lnstructron Manual)

1 Calrbrate the equrpment (Refer to rnstructron manual)

2 Select temperature range from 20C to 100C

3 Check the substatron load logs to determrne the Peak load

period All scanning should be done during peak load For
residential loads, this occurs between 7 pm and 8 pm daily
Confirm from load logs
4 Commence scanning from the highside of the transformer and
follow the electrrcal path all the way through to each 11 kV
feeder outgorng Ilne Porntrng the camera lens towards the
rtem being scanned does scannrng

5 Hot Spots show up as lrght blue, yellow, orange, red or whlte on

HSEB-Preventive Maintenance Manual
Chapter VI - Therrnovls~onScanner To ldent~fv"Hot S ~ o t s
a dark blue background The temperature of the hot spot
Increases as the color goes from 11ghtblue to red to whrte
Wh~te being the hottest, (Refer to scanner instruct~onmanual) 1

6 When a hot spot In located, zero In on the hottest area, and set
the record and ~ t stemperature In memory

7 Hot Spots should be checked from d~fferentcamera angles

Relytng on a scannrng from one locatron may glve erroneous
results due to shadow effects of other equlpment Thoroughly
check the electrrcal system circurtry from different angles

8 When all the scannlng has been completed and checked from
drfferent angles and recorded In the memory turn the camera
off Disassemble any assembled components, and return all
components to thelr orlglnal cases for transportat~onback to
the shop

9 Download data and Images w~thall temperature readouts Into

a computer

10 Analyze the cause of the hot spots Perform addrt~onal

resrstance measurement checks, visual checks, and/or follow up
tasks to determine the plan for repairing or replacing the
equipment or Item causing the abnormally high temperatures

Standards To Be 1 The Images and data must be sharp and clear, especrally those
Observed readlng high temperatures

2 The equlpment or locatron where hot spots were recorded i

must be ldentlfied correctly

3 Check that at least 1 or 2 other readrngs were taken from
different angles to confirm the accuracy of the results

Scanning must be repeated when,

1 Scannrng Operator relies on only one shot

2 Readlngs were not taken from different angles as a check on

the accuracy of temperature

3 There were posslble reflections or interference from an

auxllrary hlgh temperature source such as l~ghtbulbs, space
heaters, sun ( ~durrngf dayl~ghthours) or reflected sunlrght

Page 2 of 3
31
HSEB-Preventwe Maintenance Manual
Chapter VI - Thermovls~onScanner To ldentlfy "Hot Spots
Devrat~onfrom None
Standards
Necessary 1 Scann~ngOperator must be fully conversant wrth th$operatrng
Knowledge and manual for the scanner being used and must know how to
Skills cailbrate the scanner for the arnbrent cond~tions
2 S~ncethe Scannrng Operator will be worklng In hrgh voltage
substations, all safety work practrces, clearances, etc must be
known and observed A mrnrmum of two operators work~ng
together for each scanner IS recommended

3 Both operators should be fully conversant w~ththe scanner

operation, hot spot read~ngs,and record~ngs

4 The operator must be fully knowledgeable with download~ngthe

recorded data and scans onto a computer, transferring scans
onto v~deotape, develop~ngtransparencres and hard coples (in
color) for presentatrons and lor reports

Page 3 of 3
32.
 INCORRECT CONNECTORS REPLACEMENT

Purpose Every connector In a c~rcuitis a potent~alsource of resistance and

therefore, rne following should be noted
1 Number of connectors should be kept to a minimum
2 Resistance of connectors should be kept to a minimum to limrt
I2R losses
3 Corrosion of connectors with time should be avo~ded to
prevent hlgh contact reslstance over trme and therefore htgh
12R losses
The purpose IS to lrmrt the contact res~stanceof connectors in
ctrcuits so as to keep the I2Rlosses as small as poss~ble
Procedure I A Thermal vrsron scan of the electrrcal system at peak load will

grve an rndication of the hot spots In the crrcuit Identify which

of the hot spots IS the result of wrong connector type
2 Survey each clrcuit to determrne the connectors that are in
place, not overheated, but are not necessary These
connectors add series resrstance and are a source of 1 R
losses
3 At all connections between equrpment and jumpers, determine
the equ~pmentmaterial type such as the proper connector can
be selected for use to connect to the jumper to the equ~pment
Usually equipment connectron pads are Copper, and jumper
wrres are alumlnum When diss~rn~larmetals are connected,
blmetall~cconnectors should be used
4 Determrne what type of connector is requ~red on the
equ~pmentpad to connect the jumper wire Determine the
connector configuration, e g , connectron of a 2-hole Copper
pad on the equ~pmentto a 210 Al cable connector In this case,
a 2-hole pad to 210 cable blmetailrc connector IS requrred
Instead of usrng, as an example, a copper 2 hole pad wtth a
210 Cu barrel connector ~n series w~tha bimetallic wedge
connector of 210 Cu barrel to a 210 A1 cable is acceptable from
HSEB-Preventwe Ma~ntenanceManual
Chapter VII - Incorrect Connectors Replacement
a corrosion standpo~nt, but IS unacceptable
because connectors in series are used to perform the work of
one, since the correct connector was not selected to start with ,
In the above example, another altematrve would hav; been to
use a crimped 2-hole Al lug on the Z0 Al jumper to connect
dlrect to the copper 2-hole pad on the equipment The
sandwiched insertion of the copper hinged matenal limrts the
corrosron of the copper-aiumrnum connectron Thus, the
rnrntmurn number of connectors have been used and also
have provided the bimetalllc feature required to prevent
corroslon and high resistance from developing
Therefore when replacing connectors, select one
connector that will
a Match the equipment terminal configurat~onsthat are to be
connected Examples of configuratlons ~nclude
2-hole pad to 2/0 cable or,
4-hole pad to 210 cable
or, stud to 410 cable
or, 2-hole pad to 336 MCM cable at a rlght angle
takeoff
etc
b Match the sizes of both conductor and termrnals to the
connector
Match the bolt pattern on the pads, i e , either 2-hole
pattern, or 4-hole pattern, to the connector
Match the mater~alsbang connected, i e , Aluminum to
Alum~num requlres an all Alumlnum connector AI-CU
requires a bimetalllc connector
e Use the bolts supplred for the connector Uslng galvanrzed
steel bolts w~thCopper will badly corrode the galvanrzed
bolt, thereby greatly Increasing the contact res~stancewrth
time When In doubt, use statnless steel bolts A good test
for stamless steel bolts IS to prove a magnet does not
attract them Galvanized bolts are magnet~c

5 Good contact wlth low contact resistance In the connection

must be malntalned This can be achieved by observ~ng1.f
HSEB-Preventive Maintenance Manual
Chapter VII - Incorrect Connectors Replacement
Any speclfic torque values are specrfied, these should

be followed explrciily I .'I

Crimped connectors are used, the correct crrmprng
tool and correct dres must be used
Wedge connectors are used, the correct gun and
correct cartr~dgesmust be used
Any corrosion lnhrbliing grease IS speafied, the correct
appl~catronand quant~tyshould be adhered to
6 Do not modrfy, cut or rn~ss-apply the manufacturer's
connectors as these have been des~gnedand tested for the
servrce and application specrfied Field modrficat~ons will
render the connector rnvaird for adequacy of current carrying
and designed temperature rlses
7 F~nally,follow the manufacturer'srecommendatrons ctosely
Manufacturer has designed and tested h ~ connectors for the
recommended applrcatron
Standards To Be 1 Connectors must be judic~ouslychosen The manufacturer's

Observed representatrve should confirm correct selectton and appltcation

from vendor's catalogs
2 Do not try to modrfy manufacturer's connectorsto fit a d~fferent
applrcation
3 Select one connector to connect two preces of equipment
together
4 Consrder always the mater~alsto be connected and use the
recommended connector Connectron of dtssrmllar materials
requlres specral bimetailtc connectors, otherw~se, corrosion
develops rn the presence of morsture due to therr electrolytrc
~ncompatrbrlrty
5 Srze connectors rn accordance wtth the equrpment to be
connected Cutttng the strands off a cable or cuttrng a
connector to match the pad, or to obta~nmetal clearances IS
unacceptable
6 Use bolts furnished wlth the connectors Do poJ improvise, or

use volts of a d~fferentmaterial

Necessary 1 Be fully conversant with the manufacturer'sproduct line and

5
Page 3 of 4
HSEB-Preventwe Ma~ntenanceManuai
Chapter VII - Incorrect Connectors Replacement
Knowledge And catalog appl~cation/select~onguide
Skt 11s 2 Be famrl~ar with the requirements of connectors and
configuratrons
3 Have vendors'representatwe confirm the selection you have
made for the application you need
4 Be familrar with cable and wire sizes, NEMA hole spacing,
and bolt slzes, torque requirements
5 Be able to ident~fytermrnals of equipment whether they are
copper (or anodrzed cooper), Aluminum, Galvanrzed steef or
ACSR Thls can be done by performing the followrng tests
Scratch test for copper - brrght red when scratched
Magnetrc test for steel vs Non-rnagnet~cfor stainless
steel
Light werght, s~lvercolor for Aluminum & non-magnetic

6 Ensure that adequate supplres of routrnely used connectors are

stocked When stocks are depleted, and an emergency anses,
it'is then that compromises are made, and a series of connectors
are used to match the end configuratron, b~rnetall~c
requrrements are ignored, configuratrons are modified, and non-
compatible bolts are used Example of the effect on losses of an
~ncorrectand corroded connector In a circuit
An ~ncorrectcorroded connector can have a resistance of 1 5
ohms Thrs connector used rn a loaded feeder carryrng say
80 A develops an I2Rloss = 80 X 80 X 1 5 * 0 5(lf)

Loss In KWhr per year = 4 8 X 365 X 24

At 2 RstKWhr, lost energy costs = 84,096 Rupees

A good contact reststance IS of the order of say 0 05 ohms
Cost of lost energy = 2,803 Rupees
Therefore, cost saving in one connector for a year = 81,293
Rupees In improving one connector from 1 5 Ohms to 0 05
Ohms resistance

Page 4 of 4
Purpose Substatron equrpment IS scanned to detem~neequrprnent and
components operating at temperatures above their designed
temperature rlse ratlngs These locallzed hrgh temperature zones
are referred to a s "hot spots" The reasons for the "hot spots" are
then determrned and corrective actions rdentrfied and
rmplemented to reduce t h e high I2R losses Corrective actions
may include the replacement of faulty equlprnent

Procedure 1 The thermal vrsron scan of the substation may rndicate that specrfic
equ~prnentis the source of the hot spot on the scan
2 The causes of the hot spot must be determ~nedfirst It could
be one or more of the following
a H ~ g hcurrent flow above thermal lrmits overload~ngclrcu~ts
b Poor contact connectors
c Incorrect connectors
I Incorrect size and configuratron

11 Drss~mrlarmaterials wrth no brmetallrc Interface

I I I Incorrect bolts such as size or materral
d Corroded connectors
e Poor contact resrstances w~thrnthe equrpment
f Undersrzed equrpment for the growth of load wlth trme
g Freid modrfied equrpment due to the unavarlabrlrty of
replacement parts
h Deterloratron of current carrying parts wlth trme due to
oxldatron, corrosron, pcttrng, etc

Once the causes of "hot spots" had been ~dentrfied,correctrve

actton must then be taken accordingly Solutions to causes (a)
through (h) enumerated above could be as follows
For (a) replace th e equ~pment w~th adequately rated
current crrcurls
HSEB-Preventive Maintenance Manual
Chapter Vlll - Replacement of Faulty Equrpment
For (b) (c) and (d) , replace the equipment
connectors rn accordance with standard
industry practrces stated elsewhere rn this Manual
Fo r (e), clean th e contacts causrng high resistance For
oil crrcurt breakers, air sw~tches ,a n d reclosers, follow
t h e Manufacturer's O&M Manual lnsiruct~ons
After cleaning contacts, make sur e th e contact resistance is
withrn th e manufacturers recommended tolerances For
measuremen t of contact resrstance, refer to th e Procedure for
rneasunng resistances acros s hot spots
For (9 , chang e out th e equrpment an d size adequately
for th e hrgher current requirements
For (g) , remove th e field mod~fiedequlprnent and replace
with adequately rated manufactured equ~pment , e g ,
fused cut-outs with modified fus e holders, fuses , an d fus e
barrels should b e replaced w ~ t hfus e links, fuse barrels a n d
fus e holders all standard manufactured equipment and d o
not u s e field lnnovatrons o r improvisat~ons
For (h), damage d o r detertorated equrpment n e e d s t o b e
replaced w ~ t h new equlprnent Field modrficatrons,
oftentrmes result in hot spots
Standards to be Follow th e approprrate Procedure for replacement, repair, o r

Achreve d correction of th e exrstrng condttions

Deviation fro m Do not rmprovrse on manufactured e q u ~ p m e ndt u e t o shortage s o r

Standard unavarlabriity of fittings Have complete replacement equ~prnen t

on hand before th e outage for chang e out Using rncomplete
equ~prnen defeats th e purpose of th e replacement whrch cause d
th e problem t o begrn wlth

Necessary I Be f a m ~ i ~wrtha construction practices an d ~nstallatronskllls

Know'edge and 2 B e fam,liar with all-component parts, fittings, an d auxrl~ane sof
Skills th e manufacturer's equrpment and components
3 Be familrar wrth srz~n g and ratrng th e equrpment an d
component parts

Page 2 o f 3

3f
HSEB-Preventrve Marntenance Manual
Chapter Vlll - Replacement of Faulty Equ~pment
4 Be fam~liarwith the metals used in the connectron of the
I
equipment and with the type of connectors needed to ~nclude
I
the replacement equipment in the circuits

Page 3 of 3
 REDUNDANT EQUIPMENT
AND JUMPERS REMOVAL

Purpose Non-essentral equrpment that may have been left In the crrcult
for a number of reasons generates hot spots at each corroded
or hrgh resrstance connect~on Since these connectlons are not
requrred because the equrprnent can already be removed from
service, these addrtronal I2R losses can be eliminated For
servlce contrnurty however, the removed equlpment must be
replaced with a jumper The jumper and rts connectors must be
surtably srzed and selected so as to cause the mlnlmum of I2R
losses
Procedure Redundant equlpment rn the crrcurt ~fnot actually contrrbutrng to

the system operatron must be removed from the clrcuit and

replaced wrth a jumper for service contrnulty In selectrng a
suitable jumper, the followrng tasks need to be performed
1 Determine the ampacrty of the jumper to be used
2 Select cross sectronal area of jumper after decidrng on the
material of the jumpers, I e l check the ampacrty tables for
current ratlng rn free arr for erther CU, AA, or ACSR
jumpers, of the varrous cross-cectlonal areas
3 Select jumper mater~aland cross sectron
4 Measure length of jumper requrred from terrnrnal to terminal
of the connecting equrpment leavrng enough slack for the
"drip loops," if connectlons requrre a vertical jumper
connectron (See Procedure For Makrng Dr~pLoops )
5 Select the connectors required at erther end of the jumper to
connect to the equrpment at either end The selectron of the
connectors wrll depend on the materral of the jumper and
materral of the connectrng equrpment termrnatlons, and
also on the configuratton of the termrnat~ngconnect~ons
(See Task Procedure for selection of connectors)
6 Apply and Install connectors properly and In accordance
wlth the connector requirements, ~f
HSEB-Preventwe Marntenance Manual 2

Chapter IX - Redundant Equ~pmentAnd Jumpers Removal

a When making bolted connectfons use the correct bolts
(material & size) and apply required torque 1,
b Compress~ontype, use proper cnmprng tool and d~es
c Wedge type, use proper gun and cartridge for
type, slze and metal of connectors
7 After installation, measure the true resistance of the jumper
ie jumper ~ncludingconnectors at each end (Use the
Procedure for measurement of Resistance) This resistance
should be less than 0 05 ohms
8 The circuit continu~tyacross the equipment removed and
replaced with a jumper IS now restored with a low loss, rn
Ilne, through connection

Standards To Be 1 Total resistance of jumper including connectors at each end

0bserved must not be greater than 0 05 ohms
2 Not more than one connector is to be used at each end
of the jumper
3 Connecting metals of the connecting equipment and the
jumper must be compatible by judicious selection of the
connectors, using bimetallic connectors ~fnecessary
4 "Dr~ploops" must be configured In all jumpers where
vertical jumpers connect to equipment connectors (See
the Procedure for formation of "Drrp Loops")
5 Free air amp ratings of the selected jumper must be
above maximum expectedldesigned continuous current
rating of the circuit
6 Manufacturers recommended limits for oil characteristics
must be observed Oil must be changed when these
quality assurance limits have increased above or below
the manufacturers acceptable tolerances

Deviatron from 1 If there are trme constraints on the replacement, and the
Standards correct connectors are not immediately available, the
addition of another connector In the jumper circult is
allowable to achieve the necessary connector configuration
However, this is only allowable ~f the overall resistance of
0 05 ohms IS not exceeded

Page 2 of 3
HSEB-Preventwe Marntenance Manual 3

Chapter IX - Redundant Equ~pmentAnd Jumpers Removal

2 Due to t~rneconstra~ntsand the unavarlab~ilty of the b~rn~tallrc
connectors, Copper may be connected to Alumlnurn by uslng
'I~beralcoat~ngsof Penetrox grease In the connector where
Copper comes Into contact w~thAluminum Thls reduces the
posslbillty of the galvanic corrosion that occurs between Cu
and AI when ac~d~crnorsture penetrates the jolnt
However, with t~methe grease washes out leading to
corrosion at the joint The greased joint IS a qulck fix only
and must be replaced w~ththe proper bimetallrc connector as
soon as ~tbecomes avarlable
Necessary 1 Be famillar with substat~onopen wlre construct~on

Skllls and 2 Be able to slze conductors

3 Be able to select connectors and apply them correctly
4 Be famllrar w~thohms law and the methods for measurrng
resistance
5 Be familrar w~th011qualrty procedures

Page 3 of 3 fk
 CHANGING TRANSFORMER
NO-LOAD TAPS MANUALLY

Purpose The characterrstrcs of transformers that directiy affect losses are

the rmpedance and secondary srde voltages These determine
the output voltage at no load, and the voltage drop attrrbutable to
the transformer when carrying load Higher transformer
impedance could give rise to hrgher losses (dependrng on load
current)
By uslng full w~nding,the maximum losses occur for the same
load current The taps are adjusted to give the maxlmum
permissible voltage Iim~ton the bus for the avarlable 66 kV srde
prrmary voltage
On a 66 kV - 11 kV transformer wrth 5 taps at f 2 1/2%, +5%
primary winding, Tap 5 glves a ratio of 61,050 11,000 = 5 5
On tap 1, turns ratro = 67,650 11,000 = 6 15
When on tap 1, more of the primary circuit is rnvolved resultrng ~n
a higher impedance
Procedure 1 Remove transformer from all energized sources including the

prrrnary and secondary sources

2 Remove tap positron locking bolt
3 Move tap changer to desired poslrron
4 Secure lockrng bolt
5 Test transformer for proper ratlo, and measure windings
resistance usrng megger
6 If transformer test ratlo (TTR) and Megger tests are
successfui, then energrze transformer
Standards To Be 1 Check that voltage ratio IS equal to the nameplate ratio for the

Observed tap selected

2 Successful megger test results ensure that chang~ngthe tap
position has not degraded the insulation of the windings and
taps have changed correctly as designed
 HSEB-Preventive Maintenance Manual
I Chapter X - Chang~ngTransformer Taps Manually
Dev~at~on from 1 Correct pos~tron~ng the desired tap must glve the exact
I
ratio
I Standards for the TTR test based on nameplate ratros No tolerance IS
acceptable
2 Megger readrngs must remain rn the Megohm range
i Necessary 1 Be fam~lrar wlth turns - ratlo caiculat~ons for tapped

-
Knowledge and transformerwindrngs
2 Be fam~l~arw~thcorrect operat~onof rnsulatron megger
and be able to evaluate resuits

Page of 2 2 qf
 /

TRANSFORMERS COOLING SYSTEMS

Purpose Transformer cooling fans that can b e operated automatic or manually as a

function of the loading on the transformer are furnished by th e
transformer manufacturer Their purpose rs to Increase the
transformer thermal capacrty when rts loading reaches 100
percent of normal ratrng Unfortunately most fan automatrc
control circurts found In some HSEB are now defectrve and to get
the maxlmurn forced air (FA) rating out of the transformer, the
fans, when operattonal, have to be sw~tchedon manually
The forced 011 coolrng system was also found defective wrth
rad~atorsleakrng or d~electr~cstrength below the lrrnits
established by manufacturers The potentral for transformer
fa~luresincreases when these cond~t~onsexrst

Procedure 1 Fan cooled transformers have two ratings, ONFA OA rating

rndicates the maxlmurn current that can be loaded on the
transformer with natural air cooling to give a 65 "C wrnd~ng
temperature rise over a 30 T ambient
2 The FA rat~ngrndrcates the maxrrnum load current that can b e

supplred by the transformer (usually 125% of the OA ratrng)

w~thfan cool~ngto give a 65C rise over a 30C amb~ent
3 When operatrng automatrcaily, the fans are controlled by the

w~nd~ngtemperature, and are turned on when the wnding

temperature attempts to rlse over 95'C

4 Transformers are furnrshed with top oil temperature gages

and when wrndrng temperatures approach 95T, t h e top 011
temperature gage may approach about 65" It is t h ~ sfeature
which IS utrl~zed when trying to control the coolrng fans
manually

The following are the conditrons that have been found durrng the
HSEB-Preventive Maintenance Manual
Chapter XI - Transformer Cooling Systems
substatron performance evaluatrons conducted In the field

1 It was noted that some of the fans were damaged a d therefore,

the extra cool~ngcapab~lltywas not avatlable or transformers
were loaded at the FA rat~ngw~thoutall fans operational

2 Fans electrically d~sconnectedfrom the transformers, agaln

the FA ratrng was not available
3 Transformer 011 was leaklng through the rad~ator at one
substatron on all radiators
4 Or1 drelectrrc strength test results were not wlthln the lrrnrts
stated by manufacturers
5 lnsulatron reststance also was found to exceed the lrmlts
established by transformer manufacturers

Sample c a s e s

When the transformer IS loaded below rts OA current ratrng, and if

the outside amblent temperature IS 30C, then the wrnding
temperature wrll be below 65C Therefore there IS no need to turn
the fans on See Table below

Load Outs~de Wlnd~ng (Observe] Operate

Amps Tem~ Temp 011Temp
-Fans
Case I <OA 30C < 95C ~65C OFF
Ratrng
Case 2a <OA 40C <95OC ~65C OFF
ratlng
Case 2b Less than 40C >95OC ~35C

OA rat~ng
but hrgher
than Case
2a
Case 3 >OA 30C >95"C >65OC ON

Ratlng
Case4 >OA 40C >95"C >65"C ON

ratlng

Page 2 of 3
4
6
HSEB-Preventive Maintenance Manual
Chapter XI - Transformer Cooiing Systems
It can be seen from the above Table that the dec~s~onwhether to
turn the fans ON or OFF depends on whether the 011temperature
IS above or below 65C To allow 'forrnaccuracles, etc use 60C ori
temperature as the cnterra instead of 65C

If fans are to be manually operated the or1 temperature gage

must by observed every hour and the fans turned on or off in
accordance wtth the 011temperature gage read~ng

Us~ngthls procedure the rnaxlmurn FA rat~ngof the transformer

could be utll~zedeven when the automat~cfan cooilng clrcu~t IS non-
funct~onal

Standards To Be The oil temperature gage should be funct~onal and accurate to

Observed wrthin about 5 2OC

Devratlons from 1 If load changes occur very rapldly in the one-hour perrod, around
Standard Peak trrne, ~t may be beneficla1 to check the oil temperature
gage more frequently durrng thrs perrod and operate the fans
accordrngly

2 Also replace transformer or1 when rts d~electr~ccharacteristics

have deteriorated beyond the llmrts established by
manufacturers
Necessary 1 Basic understand~ngof transformer cool~ngparameters
Knowledge and

Page 3 of 3 q?
 FORMATION OF "DRIP LOOPS'' I

I
/
IN VERTICAL JUMPERS

Purpose Jumpers, when in a vertical configurat~on and connected to

equrpment, provide a path for water to tnckle down and flow into
the connector jornts Forming a "Dr~pLoop" at the bottom of the
jumper elimrnates this seepage actlon It also deters corrosion and
electrolytrc actron and thus reduces the I2R losses whrch occur as a
result of the development of high contact resistance

Procedure When vertrcal jurnpers are changed, the measurement for the new
jumpers should include an easy 'S'drip loop before connectrng the
terminal bush~ngsof the equ~pmentto the bottom of the jumper
This type of "drrp loop" is required on all vert~caljumpers that
terminate on outdoor c~rcuitbreakers, reclosers, autornat~cvoltage
regulator etc

When replacrng jumpers In the substation, apply the followrng

steps

1 Select the material and cross section of the new jumpers for
the requrred current carryrng capac~ty
2 Remove all sources of energy from the equipment to be
worked on
3 Apply safety grounds, ground clusters and ground charns to
safely isolate the equ~prnent
4 Remove "old" jumpers
5 Measure length of "old" jumpers but add an extra length of 2
feet to form the "drip loop"
6 Prepare connectron between jumper and the
equ~pmentand select the correct connector
7 Make the connectton of the vertrcal jumper to the equipment
at the bottom end Form a "drip loop" with the slack in the
jumper so that rainwater will run down the jumper and run off
the jumper at the lowest potnt preventing it from flowing Into
the equ~pmentconnector at the end of the jumper
8 Complete the top connection of the jumper
9 Check for continu~tyand proper connections
10 Remove safety grounds
HSEB-Preventive Maintenance Manual
Chapter Xll - Formation Of "Drip Loops" On Vertical Jumpers

Standards To Be 1 Smooth S loops should be formed

Observed 2 The lowest point rn the loop must be below the connector at the
bottom end of the jutnper The difference rn elevation must be
at four inches
3 Conductor loops ~n the two outer phases should fan out from
the conductor loop in the center phase to provide maxlmurn
phase-phase clearance
4 When form~ngthe "S" loops be sure not to let the conductor
strands of the jumper "flare" out Flarrng leads to Increase
power losses
Dev~at~onsfrom None

Standards
Necessary 1 Famrirarrty wrth makrng jumpers connectrons

Knowledge 2 Famlirar with open wlre substat~onconstructron

3 Apprecratron of and knowledge of requrred phase-phase and
phase-ground clearances at different voltages, rn substatrons

Page 2 of 2 (4
 XI11 INSPECTING & TESTING LARGE
I TRANSFORMERS I

Purpose Thts Procedure covers the rnspectlon and testtng of swltchgear to

ensure that equlprnent and connectlons are all In worklng order
When changlng no-load taps or lnstalllng new large power and
substation transformers, tests should be performed to determine if
the transformer should be energized Transformer no load taps, d
not properly set, can increase transformer losses and reduce
revenue
Vrsual and I Compare equipment nameplate information w~thsingle-11ne
Mechanrcal diagram
Inspectron 2 lnspect for physlcal damage, cracked insulators, leaks,

ttghtness of connectlons, and general mechanrcal and

electrical condrtions
3 lnspect impact recorder prior to unloadrng transformer rf

applicable
4 Verify removal of any shipping bracing after final placement

5 Verlfy proper aux~ltarydevice operations

6 Check trghtness of access~blebolted electrrcal connectrons in

accordance wlth the manufacturers recommendattons

7 Verify proper l~quldlevel in all tanks and bush~ngs

8 Perform specific inspections and mechanical tests as

recommended by manufacturer
9 Ver~fyproper equ~pmentground~ng
Efectr~calTests 1 Perform insulatron-resrstance tests, winding-to-w~nding, and

w~ndings-to-ground,utrlizing a megohmmeter with test voltage

output as shown In Table 13 3 Test duratron shall be for 10
minutes with resistances tabulated at 30 seconds, 1 minute,
and 10 mlnutes Compute dielectr~cabsorption rat10 and the
polarlzatron index by dlvrding the 10-minute megohm value by
HSEB-Preventwe Maintenance Manual
Chapter Xlll - lnspect~n gAnd T e s t ~ n gLarge Transformers
the 1 rnfnute megohrn value

2 Perform a turns-rat10 test between windings at ail tap

pos~t~ons The turns ratio IS computed by dlv~drngthe
secondary voltage into the primary voltage the tap voltage(s)
shown on the nameplate

3 Sample lnsulatrng llqu~d In accordance with ASTM 0 9 2 3

Perform ~nsulationpower-factor tests or drsstpatlon-factor tests
on all w~ndlngsand bushings Determrne overall drelectric-loss
and power factor (C,, C, C,,) Test voltages should be limited
to the I~ne-to-groundvoltage ratlng of the transformer wrndlng

4 Perform windrng-resrstance tests on each winding In final tap

position
5 Perform tests and adjustments on fan and pump controls and

alarm functions
6 Verify proper core groundrng rf accessible

7 Perform percent oxygen test on the nitrogen gas blanket, if

applrcable
Test Values 1 Insulat~on-res~stanceand absorpt~ontest Test voltages

shall be rn accordance with Table 13 3 Res~stancevalues

shall be temperature corrected In accordance wtth Table
13 4
2 Polarrzat~on index should be greater than 1 05 The

polar~zatlonindex should be used for future reference

3 Turns-ratro test results shall not deviate more than one-

half percent (0 5%) from elther the adjacent corls or the
calculated ratlo

4 Maximum power factor of liquid-filled transformers

corrected to 20C shall be ~n accordance wrrh
manufacturer'sspecificat~on Representatwe values are
indicated in Table 13 1

5 Bushrng power factors and capacitance that vary from

nameplate values by more than ten percent (10%) should

Page 2 of 5 51
HSEB-Preventive Maintenance Manual
Chapter Xlll - Inspecting And Testing Large Transformers
be rnvestigated

6 Exc~tationcurrent test data pattern Two srmrlar current

readings for outside co~lsand a dissirnllar current
reading for the center coil of a three-phase unlt

7 D~electncflurd should comply w~thTable 13 2

8 W~nd~ng-res~stancetest results should compare

wtth~none percent (I%) of adjacent wlndtngs

TABLE 13 I
LIQUID-FILLED TRANSFORMER INSULATION POWER FACTOR VALUES
Tetrachlor- H ~ g hF~rePornt
011 S111cone ethylene Hydrocarbon
New Power Transformers 0 5% 0 5% 3 0% 0 5%

New D~str~but~onTransformers 1 0% 0 5% 3 0% 1 0%

Remanufactured Power ---

Transformers 1 0% 1 0%
Remanufactured ----
D~str~butlonTransformers 1 5% 1 0%

Page 3 of 5 5p
 HSEB-Preventive Maintenance Manual
Chapter Xlll - lnspect~ngAnd Testing Large Transformers
I

TABLE 13 2
INSULATING LIQUID TEST VALUES
H~ghMolecular Tetrachlor-

011 Weight Hydrocarbon Sll~cone ethylene

Drelectrrc Breakdown 30 kV 30 kV 30 kV 30 kV

ASTM D-877 Mlnrrnurn ~Mrnrrnurn M~n~rnurn Mrnrmum

D~electrlcBreakdown

ASTM 0-1816 @ 0 04'gap

34 5 kV and below

above 34 5 kV

Neutrallzatlon Number 0 03 rngKOH/g 0 1 mgKOH/g

ASTM D-974 Max~rnum Maxrrnum

lnterfacral Tens~on 35 dyneslcm 33 dynestcm

ASTM D-974 or 0-2285 Mrnlrnum M~nlmum

Color 10 NIA 0 05

ASTM D-1500 Maximum Maxrmurn

(D-2129)
Vrsual Condltlon Clear Bnght Crystal Clear Clear, Sl~ght

ASTM D-1524 Pale Straw (D-2129) Plnk lrrdescent

Power Factor 0 I% \ 0 1O/o

ASTM 0-924 @ 25C Maxrmum Maxrmum

Water Content 35 PPM 35 PPM 80 PPM 25 PPM

ASTM D-1533 Maximum Maxrmurn Maxrmum Maxlmum

15 kV and below
above15 k V - 5 PPM

below 115 kV 2 Maxrmum

20 PPM
Maxrmurn

15 PPM
Maxrmurn

Or In accordance wlth manufacturer'sreaurrernents Some rnanuracturers recommend 15

PPM rnaxrmum for all transformers

Page 4 of 5 53
HSEB-Preventwe Maintenance Manual
Chapter XI11 - lnspect~ngAnd Testing Large Transformers

TABLE 13 3
TRANSFORMER INSULATION-RESISTANCE TEST VOLTAGES

Recommended
M~n~mum M ~ n ~ m ulnsulat~onm
Transformer dc Resistance In Megohms
Cod Rating Test Voltage L~qu~d-F~lled D~Y-TYP~

0 - 600 Volts 1000 Volts

601 - 5000 Volts 2500 Volts

5001 - 15000 Volts 5,000 Volts
15001 - 39000 Volts 10,000 Volts
Over 39000 Volts 15,000 Volts

TABLE 13 4
TRANSFORMER INSULATION RESISTANCE

TEMPERATURE CORRECTlON FACTORS TO 20c

Temperature Transformer
"C OF
011 Dry

Page 5 of 5
 XIV UTILIZATION OF FUSES, CUTOUTS
AND LIGHTNING ARRESTERS'

Purpose The purpose of th~sprocedure is to ~iiustrate the benefit to

equipment derived from using properly w e d fuses, cutouts and
surge arresters on the distr~but~ontransformers and capac~tors

Current HSEB In the HSEB d~strrbutionsystem, over th e years it has become

Practice on a standard practice to "protect" the distr~butrontransformers by
Fuses replac~ngt h e fuses and cutouts with whatever piece of wire
size and material IS available at the time of need The purpose of
thrs act~on IS to get the transformer back on lrne with complete
d~sregardfor transformer protection
The use of the various wire srzes in place of a properly sized
fuse has resulted rn the large number of drstnbution transformer
farlures On an annual basis the d~stnbutrontransformers failures
have exceeded 31 percent Based on Table I 1 thrs percentage 1s
equivalent to about 31,000 transformers per year
This practrce 1s also extended to capac~torswherever they are
used It IS noted that capacitors are found only at substatrons
The cost of t h ~ spract~ceIS s~gn~ficantin terms of transformer
repairs, procurement of new transformers and loss of revenue
due to consumers out of servlce

'
r At present lightning arrersters are not used on dlstribut~on
transformers and/or capac~torsand at some substatrons large
Current HSEB power transformers Thls equ~pment IS not protected agalnst
Pract~ceon system surges or I~ghtn~ng
L~ghtn~ng
Arresters The continuous sudden changes In system configuratron
resulting from the number outages caused by overloaded
feeders, I transformer failures, and other causes, create large
over voltages Thrs high over voltage travels along the hrgh
and/or low srde of overhead lines connected to transformers or
capac~torsThe effect upon the equipment IS to puncture or
damage the internal ~nsulationof t h e equ~pmentthat may failed
lmmed~arelyor that eventually will fail
HSEB-Preventive Maintenance Manual
-
Chapter XIV Utilization of Fuses Distr~butionCutouts
and Lightning Arresters
Fuses Purpose Fuses are relat~ve inexpensive protect~on dev~ces connected
between transformers, capacitors or other equ~pmentand the high
and low-tension d~stnbut~onsystems Fuses are used to prevent or
lrmit the damage to equipment due to overfoads or short c~rcuits
The fuses remove the transformer or capacitor out of servlce
before the occurrence of damage to the equ~pment
Fuse Operation When the current through the fuse IS excessive the resistance

offered by the fuse metal to the flow of current develops enough

heat to melt the metal, thereby openrng the crrcurt before any
current flow above the equrprnent thermal capacity IS reached
Time-Current A time-current curve is a cutve that IS plotted between the

Curve magnrtude of a fault current and the tlme required for the fuse link
to open the crrcurt The greater the current, the faster the fuse
melts and the shorter the t~mefor it to blow
D~strrbutron Distr~butroncutouts provrde a hlgh-voltage rnount~ngfor the fuse '
Cutouts element used to protect the drstr~butionsystem or the equ~pment
connected to it Distrrbutron cutouts are used with rnstallat~onof
transformers, capacrtors, cable c~rcuitsand sectronalrzing points
on overhead lines
There are varrous types of cutouts, enclosed, open and open ltnk

to name a few Cutouts normally use an expulsion fuse that

operates to sola ate the fault or overload from crrcurt as a result of
the arc from the fault current The current erodes the tube of the
fuse holder produc~nga gas that blasts the arc out through the
fuse tube vents
Lrghtnrng Lrghtnrng or surge arresters are devices that prevent h ~ g h

Arresters voltages from buiidlng up on a crrcu~tby prov~ding a low-

rmpedance path to ground for the current from lightning or
transrent voltages, and then restore normal circuit condrtrons
 ATTACHMENT I

HSEB PREVENTIVE MAINTENANCE

I MANUAL
I
I
I
I
I
I
I
I
 ANNEXURE 'A'
INSPECTION & AlAINTENANCE SCHEDULE FOR
DISTRl BUTION TR 4NSFORMERS

r
St I n s r e ~ l ~ o ~11~111to bc Insp-cl~anNote A c t ~ o nrequired
- ~nspec~eki
-
Freqllcl~c y

- -----
-- Rea~orl s

I) Cllecl lor t~gbtenlngof Replace and re-

connectrons fill worn out
th~mbles
11) Prov~slonof P V C slee- Replace, where
bes, rnsuiat~ngbeeds on neces3ary
the connectors
Clleck for proper 011 level Top-up, ~f ne-
agd~nstthe gauge glass cessary w~lh
tested 011

I hlonlhly

1 hlontbly

I
 Check for leakage of oil Stop any leaks from
drain oft valve, gas-
3 hfontllly hets and tank leaks etc
Check for colollr of s~llca Recondltlon o r
gel and reactlvat~ng,rf nece- replace,as nece-
4 Monthly ssary ssary
Check L As and jumpers
for t~ghtness
5 Monthly Fuses Check for cont~nulty,tlgh- Replace old fu-
(HT & LT) tness and correct r a t r n g ses with new
'.
ones of right
capacr t y
6 L'onthly G 0 Slv~tch Check for pasitron/spark-
Ing of G 0 switch blades
7 Monthly - Check diaphragm for cra-
cks
BEST AVAILABLE COPY
 -. ,-. 11) Check w~ltercontent ln v a l ~ ~ etso
8 Monthly Insulation 11ie 011 water corlt
Relstance 111) JU case c~ucckle lest
Compare ~ l t hvalues at red i n case
9 Quatterly Bushlogs & ~ I I O ~ ~ Sdele1 lora~lol~,colll lmlnal
the tlme of comrnlss~on~ng
nrclng herns 1) Replace these perform dl-electrtc str- Llie 7 /F wl
Check for chlpped and
broken bushlngs rf necessary eogth test ttself shou
11) Examltle & replace the Cleao off nil lvf iceep record of test put to de
damaged gaskets drrt, p ~ ~ ndt results at1011 an3
olher depos~ts out by nlea

111) Adjust the arclng horns fo 011 de-hydr

r alllgnment and pro-p e r sef, till prop
gaps between rllem 1 4 Half Load balas- Check load on three sults are obta
10 Quarterly Voltage
qelrly crng on pliases under n ~ a xload
Measurement of voltage pl~ases cond~t~orlsatld secure
during mau load perlod a t
tbe transformers and at the between the 3 phases
tall end of feeders
11 Quarterly Load Measurement of load uuder In case of over- 15 balanced loadrt~g
maxlmum load condlt~ons, load T/F, re- Quarterly Cat th test- I) t~ghtenthe earth con1lc-
against its rated capacity, duce the load n1g (to be C~IOIIS
by trausfer ol clone dur- -
11) Exanlluc a11d replace
lvad or augment "16 drlesf broken cart11 leads/co~~
the T/F, if nece- part of ductors w t l l proper
ssary tile yea^) s17e
12 Quarterly Barbed wlre, I) Check for proper and Recondltlocl or 111) Measura the elrth rests- I ) ensure tllat

danger plate sufic~en tprovrs~on of replace ba~bed of during driest part of e1rl11 rcslstel
c tc Bsrbed wire wlre, as neccss- year of (a) Neut- arc not more 1 1
ary '"1 of T/F (b) T/P body 2 ollms
11) Check for proper suppo- l'alnt & reprint and o t l ~ e rrnetal parts
rtrng of danger plate at the danger plate I c JI ~ g h l n ~ narrestorsg
suitable he~ght ~f defected,
1 ~Keep) record of test 11) In case of hlgll
13, Half ~ ,testlog 1) Observe coiour of the Perform crackle results values, recond
011 to have ldea of l t s test on the 011 Ion t l ~ erods dee
yearly cond~tlon, samples drawn er into ground ( by
from drain-of1 addrflon of w tcr
through plpe
 ANNEXURE 'B'

I)
I-IOURLYJDAILY SCHEDULE
Two Consgr- Cl)ech for proper comu- Clean the lospe-
INSPECTION AND MAINTENANCE SCHEDULE FOR POWER T/F
}early \ator aicatlon of the conser- ctron glass so that
7 ank vator wlth TJF tank by o ~ love1 1s pro- -
d r a ~ ~ i some~ng all throb- perly visible SI. Inspecrlon Item to be Inspccllon notes Remarks
gh dram cff valve and Elo Frequency l~ispected

w a t ~ b l r ~heg 011in the I IIourly Anlb~ent Note down the tempera-

gaugv glass to drop
11)
I n case the oil does not Temp ture and record the ,maxi-
mum daily amblent temper
drop, luvestlgate ~ n d
ature
remove the sludge (11
2 - do - Wlndlng Check that temp, r ~ s e1s Shut down the
olller: obstructlo~lsalter
d~sassembllngthe tank Temp red~~~\~\ble ' 'I'l? and lovest,-
111) Check for leakage of gate rf either 1s
011 from glass slde persistently h~gber
TWO Acldlty I 3 --do- Orl Temp than normal
Check and test for ac~dl- I) In case acrd~ty1s
ty and sludge formatton 4 -do- Load Check aga~rist rated Note t A11 Impro-
yearly & sludge more thin 0 5 gm
testrng of , KOH/gm recondl-
oll, I I
tion the same (Amperes) figures per tap posltion
In case acrdlty ts can cause excess-
1 1I
more than 10 grn we core loss
KONjgm rest ore 1 5 -do- Voltage
the quallty of oll
by reclalrning wlth 1 6 Dally each 011 level Check agalnst transformer if low, top up
Fullers earth or Shift ln trans- 011 temperature. wltli dry 011, ex-
a c t ~ o n of ~nhlbz- former amme T/F for
tors leaks
---

Complete overhaul of the 7 -do- 0 1 1 level Check for any leakage If low, br~ngit to
Once ~n in bush- the correct all
every- transformer mgs level
five years
8 -do- Rellef vent Check for cracked or Replace ~fcracked
Note , These charts should be displayed in the ofice
room of the Xen and SDO concerned d~aphragm broken or braken
 -
-. hION1 HLY 9CKi D t J L E
9 Dally each For Inter- Check for ally sound or INSPECTlON AN D M41NTENARCE YCHTDULE FOR POWER
Slllft nal unusual excessive chatteting
10 -do- Heaters In For proper aorC~og, XI
Sr I n ~ l ~ c c ( l o l ~111 ms to be jnzpecllon Noles Reruarhs
No 1-1 equenc) rnepecled
Junction prov~ded I M o n l h l ~ Dellydl atlng I ) Check for condltlon/ I) Recondltloa/
11 --do - External Check v~suallyfor t~ghtness
br ea tl~er colour of S~llcaGel place, as nece
connectroo and spark~ng on Jumpers Ensure that alr pass- ary
(Leads/ Bushrngs etc on complete 11 ) 11) Make up 011
Jumpers) darkness age 1s free requlred
1111 Tlght 11d of the brea- 111)Do clean ng
12, -do- Bus bar & Check for any ddmage &
Cab1e slgns of overheatlag a t 1 her for alr t ~ g l ~ t r ~toes s the breathel
Boxes & thelr J O I ~ ~ S avoid eutry of rnolst nlr
IV) Clleck 011 level In ollcup
Cables
v ) Remove 011 from dash
N n t e These Charts sbould be displayed In the pot & pour 111 fresh 011
substations
where requ~red
2 lMonthly B t ~ ~ h l nandg E~afnln efor oracks, Palnt Clcan or rcplacc
gaskets ~ n dl1 t deposrts and gap
ceir~ngsCheck gasket for
leakage
3 -do- Cooler fqn Lubrlcate bearrugs, check Roplace burnt oi
and pump gear box Examlue cout- worn out contact.
bezrrngs acts Check manual control or otl~erpal ts
motors and ?nd ~r~tcrlocks
ope! ?tlng
mecban~sm
4 -do- On-load tap Lubrlcate beanngs. check Replace burnt or
chasger gear box 011 level and ex- worn out contacrs
dr lvlng drnlne contacts or other parts
mechanism:
 I.
G 0
0 T3
 I0
1 2 3 5
4
5 Qunr- ?hymo Check for its normal
terly Syphon work~ngorder
Fillera 1111 Specjfic I<eslstl v ~ t y =Above 10 x 10'"
011 11

6 -do- Earth (Earth 1) Check for t~ghtllessof 1) R e c o n d t ~ ~ oor~l at 27nC

Reslstence earth connections replace where
11ecessarv IV) Neutral1z.tt13:1 v ~ I u e;-0 5 or less
testlng - . -.-
1"g 1(OH/gn1 of 011 ( A C I C I I ~ ~ )
to be done 11) Measure earth res~stanceof 11) Ensure that V)
the (a) T/F body neutral test results are Sludge=Non-det ectable
during for decalis o f n~alntet~nnceof 011
driest part and other metal parts, not lnore than
( b ) K e e p proper ~ e c o r d 2 ohms In caqe ISS 1866-1978 may be referred to
of
of test results of h~gllervalues, 10 Yearly 0 1 1 filled Test oil for d~electrlc Filter or rcp
the season)
recondltlon the (or em- Bushings st~erlgth as necessary
rods deeper
her ~f
into grourid or
by addltion 01 I n ~ ecr ~ con -
water through I venrently be
taken out f o r
1
PI Pe
I chackrng)
7 Half 011cooler Test for piessure
yearly 11 -do- Cable Cllcck for s e a l i ~ ~arrasg- Replace gdslc
kw-23
8 -do- On-load tap Inspect all molv~rlgparts, Clean, adjust o r gelnenh for filling holes lf leaklllg
cban8er contacts, brakesl~oes,Mo- replace as reqlr- 1
Exarn~ne con~pourld for
drtving tor etc ed 12 -do- Surge cracks
mechaolsm Exarnlne for cracks and Clean o r replar
9 Yearly Oil lo TIF Check amdlty, PPM, Tan F ~ l t e ror replace diverter dirt depos~ts
(or earller delta,Sp resistivity sludge Acceptable vdlues
I and gaps
~f trans- as per ISS 1865- 13 Yearly Gasket Check for t~ghfnessof Replace danl~ge
former can Joln ts bolls to avoid uneven pr- gaskets
conventen- essure
tly be taken I1 14 -do- P~pe Check 011 plpeq, valves and
outfor -
i) Water contents - Connecflons plugs for tigbtuess and
For equrpment Voltage> 170 KV= 20 PPM proper functlon~ng
I
 1 2
4 5
1 2 3 4 5 - 3

15 Yetlrly 2 1 Yearly Dlverter Check for worn out con- Replace worrt
Fdundatron Check for cracks ~f any
or after switches {acts, Pllter 011 rrrcspective out parts,
d r d settl~ng,
10,000 for tap- of 011 test
16 --do - Buslllllgs 'Iestthe Lushrngs wlth a . .
Opera- changer
hrpot busllrng tester , ~ n d trons havlng non-
comparing wrth pre! lolls arcing sele-
figures ctor swrtch
17 -do- Temper- Pockets hcld~ng thermo- 011 to be reple- 22, Two 011conser- Internal lnrpectlon,
Should be tharo-
years vator ughly cleaned,
a ture meters sl~ouldbe cheched, nlshed,rf required 23 -do- Buchholz
lndrcatlon Mecehanlcal inspectroo Adlust Boat, swr
IS -do- D ~ atypel Check pointer for free- Adjust, r f requlr- relay tchest etc, as req-
uired -.
.-

or1 gauge dom ed

24 TIlrec Non-arclng General lhspcctlon Rcplaco worn outI

19 -do- Palnt work Should be ~nspected Any patntlng or years or selector1 : ' 4 parts F~lttli011
retouch~agshould after swltch of .. . -
I I

be done, ~fneces- 15,000 On load tap +

sary operations changer IIIJ
- $1 - -r
1

i r . A -- I 47
I

20 -do- Conser- I)Check for proper corn- Clean the nspec- 25 7 t a 10 0v;rall 'it;spSct~on ~nciu! by holing
vator Tank mun~catlonof the conser- tion gass so that years ding' llft~h$%f: 'core and down *lth ~1e.u
vator w ~ t hT/F tank by so that oil level 1s cdl~ht 13!llf~d'
properly v ~ s ~ b l e
I
dry oil T~ghten
drarnlng some oil thro- I J I d

1
1.
1-
ugli dram off valve and all bolts, nuts toll
watchlng the 011 In clarnp~ngscrews.
Major overhaul (complcts)
gauge glass to drop of transformers. .I I,

-.
I

11) In case the 011 does not 56 1) Once in

drop, lnvest~gate and 3000 KVA and below I
ALL
7 years L
remove the sludge or 11)Once tn
other obstructrons after 10 yearsr
d~s-assemblingthe tank
Note T h m Charts should be d!;playod in'tbe
111) Check for leakage- of 011 substattons .-
from glass srde --c
 ANNEXURE 'I)'
INSPECTION & MAINTENANCE SCHEDULE OF CT/PT
14 A ~ J I L I Operat~ng~ Check and trghten bolts, scr- Sr lnrpccl~on lams to be Dlatls of lnspec~ton
rotlsLevers ews loduut, See that rods, No Frrqucncy ~nspccred Rcmarka
and cranks levers and craahs are ln servlce- I
able col~d~lronand repnlr as Montbly insulator Cheok far any crack o r damage
necessary Lubr~cnte plt'ots
Y

to porcelain ~nsulater
and bearings, 2 -do- (111 Check for 011leakage and when
15 --do- Gear Boxes Check gears and bearings Flu- excessive the level be also checked
a

sh out oil grease dnd relubrlc- 3 -do- Earth Check that Earth connect~oos
ate,
Operating
conncctron are properly made
16 -do- Check working of motor and 4 -do- Jumpers Check that jumpers, nuts, bllts,
motor and mechanism, Nut Bolts clamps are properly tight and
mechanish
etc
17 -do-- Lochs & Check out locks and keys
5,
- do- are of proper s ~ z e
Secondary Check that secondary wlrmg 1s
inter -locks operate as rntended Check w~rlng properly made and routlog is
J
mechanical - interlocks, such as
-- --
-7

not disturbed, The conncetlons

t I I
between,# maln dlscannect~ng %
in the panel are Intact
sw~tchesand ground swltch for
6. Half I R Value Check I R values of prtrnary
I ,1, fool proof operation.
yearly, and secondary wlndrngs,
18, -do-- SwltB "
lnipdot woodenJoperatlng stlc- -do-
6
I
7 Eartb res~s-' Check earth rcslsianca
st~cks ks for( crack;; splinters, loose tancc
(where : heads eto
8. -do- Secndary Check secoodary taps br
11

appll~able),~~* $

tap4 tlghtne~~to avoid overheating,

.
Note Thasc Charts shouid be dtsplaysd ln the substation 9 yearly 011test
1
Check dtelcctnc strength of
011 and toplng o f 011, adlush
10 -do- Tap scttlng Check tap ssft~nga n d
merit a t tcrmlnal board 10 see
that they agree wlth dlag&ms,
...
Note. These charts should be d~splayedin the subrtaclon
 ANNEXUR E 'C' I2 3
--- -- --------_I_

4 4
8 Aflnual We.llhcr
INSPE~TION~r MA~NTENANCESCHEDULEFOR See [bat ~ e ~ t b slledsr alld
s h e d s and hooks of o x ~ d efilrn arrestels
LIGHT NING ARRESTORS
flnoks are securely fastened III place,
repalnt ~f necessary
9 --do- Lllm and Check and trghtcn ll~le and
Ground gr~ull d counectlons check
11 Weekly Surge Note and record operation in-
connectloll ground lead for colros~onor
or at the Counter d ~ c a t o rreadlog dmag e below grourrd jlne
Check ground resistance See
that all leads are as short and
former
tripplug
direct as poss~ble
10 -do - bperatlon 1 o check the
2 Monthly Base & Usual ~ n s p e c t ~ tondetect cmck- tests (Surge- of 11ghtnrogarresters by M & p
working
Support mg settllng o r shlft~ngof base
! gcnhrat~ng d~vlslbns
or supper t S
Check that surge moultor is equlprnent
3 -do- Surge under pro-
Monltor properly connected and 1s in curement)
worklog order & shows a lea-
E (M k' P I J ~ b ; L l a&;tt
NOTE 1) and Hissat should prasu
kage current, I
,I I

t ~ setso each of field testrng k ~ fopt llg{tnm; nrresfe

4. Annual Jumpers and Check jumpers and clamps for , for thew clrclc
clamps tightness
5 -do- Porcclaln Clean porcelalh ~nsul&torsand
shells and1 arrestor unlt shells, Repart
~nsulators chipped spots on procelaln wlth
lacquel suc h as red glyptal

6 -do- Gradlog Check and tlghten grading r ~ n

r lugs 1 g s on hlgh voltage arrestors
7. -do- Gaps Check external gaps Smooth
1 OK arc burned spots and read
just spaclng
 I 2 3
4 5
..

Bulb or dry See that copper o x ~ d eor rtle- 22 Annual liydrot~le(erClieck cond~t~ollofbydrometer
I6 Half
yearly ihtlfier nium ~ e c l ~ l ielementsr are llot and tbermo- and l l ~ e r r n oter~~ ~ eC I I ~ C11,~-
element operatlog to0 hot, t h ~ s wlll melers drorl~etcrs and tberslome[ers
shorten then ltfe used for dally and n~outillv
-- -J
readlugs agalnst spare u n ~ t helds
17 -do- Rheostat Check that sl~dlngmecharl~sm of In reserve
the rheostat 1s tn order and
clean the sltdlog contacts, l f 23 -do- Sink, See tllat the sink, futlnels,
requ~red Check contact heat Funnel and fillers a n d othr dlst~lledwater
log and sprlng pressure
fillers and a c ~ handllng facll1[les kept
Check metalrc structureslparts c h ~ and in good useablc con-
18 Annual Battery located In the room for corro- dltlon
Room and
ventillatlon slon and clean and p a ~ n t as 24 -do- Water st111 Check st111for proper operatton
necessary, check ventllat~on and adequacy and purlty of
system fan etc for proper oper-
at~on,to make sure that no distlllcd water delivered 'See
explosive gases ate belog accu- (hat equipment 1s kept cleah
-
mulited m , b h ~ e room~ due to 25 Yearly or as - Complete overhaul or the
excessive gasslng ur poor ven- recommend- battery
, 1-
ttlattbn 11I ed by manu-
Inspect concrete base or wood-en facturer
19 -do- Base racks for deterroratlon Repa~rand
o r rack Note 1 illese cllarts should be displayed in the
r ,
rpaint
e p aas~'necessary ..-
n twith acid res~stdnt
Substation,
I Check base pad of shoet rubber,
'sahdor othi;dmaterlal for de-
20 -do- Casc Pad terrorat~onfrom a c ~ dor otherI

I causds

21, -do- Jnter Cell Clean acid corrosion from con-

conltltctors nectors and terrnrnals should
and "'" be lead coated, Tlghten terml-
term~nals nals and apply petroleum ~ e l i y
for exposed surface
26 -do- Manual C h e c k that manual operatlr~g Check earth reslstarlce of
Operating lever or jack a kept on band Res~stance body
-
I
-do
Devlce and 1s in v~slblecondltton See 33 Slaw doslog Jlils test may be conducted
- do- that Breaker IS closable with ~t test W d also check that nll the
27 Latch and O b s e r v e mechanlsm durl~lg three contacts are nlade
Trlp general t r l y p ~ n goperat~onsto s3ruul taneouslv
.d

mechanism see that every t h ~ n g1s ~n worklog 34 -do- Adjustlnellt T l ~ egap may be checked and
o r d e r Check plns, bear~ngs of gap (for adjusted l o Ole repulred vnluc
and latch for wear, blndlng and MOCB) &
m i s a l ~ g n m e n t Clean aud other type
lubricate the movltlg parts Check l o clleck tile
presc~lbed
Iatch carefully to see that it IS Items by tllc
n o t becomrng worn so as to
nianufacturet
- -
unlatch from vibration or stick 35 --do- Wlrlllg Cbeck a n d trgllten wlnng
or fall to trlp Tsghterl bolts connect~ou connectron a t telnllnal polnts

28 -do- Trtpplng
and skrews
Observe oyeratlon during
I Inpect wrr~ngfor open clrcult.
short c ~ r c u ~andt dnlllnged
solenold ansulatron.
electrical t r ~ p p ~ n Seeg that full
 1 -- -
- -- - 4 5
-- - - 2 3
1
- -_
1 2 3 - - ---- - - -_ _-__- ---- 5
.-..
46 ~rnu111y Rilaln Tfgllterl L ~ l ln l l l c I I I C ~ ull(l
52 fZl'flu3lly Llfl rods (Iliecl colltsct for kft rod$ rol
tcrmInals connect~ons Mcfinl\ll Julllt Guldcs b ~ a k mweaken~ng,or \irapplnp,
,,nd mating surr,icc, l f the\ 1~je ~11ld1~ul11ngout at e ~ l d s C I I ~ ~ ~
c r n n c c t l o i l ~beell 01 er Ilcated I~~I'LC~ crdcquacy of gurdcs
glorrnd cable lo see t h l t lt IS 53 -do O ~ ~ ~ r d t j l Checkl~: fur luoce l o c ~ . , ~se~t ~ ~ ~ ,
not loose or broken fells, sllafls SClcIY, keys, b ,trlngs bent rods
al'd bell o r tmlsted s11'1fts etc Clean
-dc- Ma~n Retllove the t a d s or dralll out
47 looseness
contacts 011. so that Ihe colltrlcts call be Ilft
jnspecleri drec ? cailtacts,
lough 1~1th n flne file Clleck
c o n f ~ c l svoltage drop with I

millivolt meter after 1n5peCtlnF I

reasonable current rrcquency
of contact malntznance shoulrl
be based on number and severity
01 faulis ~nterrupted, rather
than a definite p e r ~ o d Check
adjustment of gap when required
contact Check for loss o f temper
48 -do-
pressure damage or other deterlorallon
sprltlgs
Check flex~bleshunts at colllact
49 -do- ~ l ~ ~ ~ b l e
Shunt hinges for overheating or
damages Tighten connections
Magnetlet Check arc r ~ p l u r l n gblow out
50 -do-
air or cotls magnetlc clrcnlt arc
blow out chutes, deion grrds, 011 blasts o r 1
devices other lUterlUpt@rS for proper
operat~on
Cross heads Check contact cross head Tor
51 -do-
m~sal~gnmentbreaks bends o r
J
s4
-do--

55 -do--

56
-do-
 Annually Operatloo t ~ m e sat intervals, as system
j7 Annllally ['oslllon Chech t h a t ~ o s l t l o nlndlccttor 1, operation wrll permlt and may
~ n d ~ c ~ i ~properlyr ~ n d ~ c a t t ntheg bre'lher allcvlate the heatrng by w1p1.g
posluan Chech aperat~ngrods t h e o x ~ d efrom the contact
or levers fo r loose parts surfaces, as well as demonstrate
58 -do-- 1)nshpotS C i l ~ c h f o rproper settlng and that the breale r 1s in operating
63 --do- condltron
zdjust as l ~ ~ c e s s a r yClsnn o u ~ BusLog Check top seltrng & adjustments
and replen~sh 11quld In Irquld current a t terminal board to see
d'ishp?~~ transfa rmers that they agree wlth dtagrams
59 -do- Mecl~anrsm Check c l~dltronof metal and and potenllal Check lnsulat~onreslstance of
cablnets hdldwa~eRepaint as neceqsary dev~ces wirrng wlth devlces connected
See thdt doors gaskets are I
Check ratro & phase angle
ilght and properly excl~lcic adjustments, of potcntcal devlces if
dust and dlrt ch~nge ehay& been made in
60 Annunlly Paner lnspect fuses of clrcurt brenher secondary connectton and
Supply & In all power and control supply, burden Tlghten connections.
wlrlng crrcults Check u p ~nsulat~o n - --

lncludlng potentla1 dev~cetop in

reslstance of
devices connected
wlrlng, wllh ' 64 Oncetn - to bushlng
Tqstlug of oil rn or1 filled
two years bushlngs
61 -do- 011dlelectrlc
test 6
Check dtzlectr~cstrength ofthe
lnsulailng 011 In t h e main tanks 65 -do-
- Clean~ngblast tube roternally &
checktng clamping down nuts,
acrd~tytest, and 011 filled bushtngs 011 Overhaul and checktng
67 Five yeally
dependent
on actual
should be filtered or replaced
if d~electrtc strengr 11 1s found
- efficiency of maln campresser
Complete overhaul o f t h e ..
OCB
trtpping to be below 25 KV, o r if ihere
1s a noticeable amount of (The perlod
canbe changed
carbon in suspension on the dependtng upon
bottom of the tanks Also check the load cycle of
the equipment
the actdt(y of the 011 & manufdcturer's
62 -do- Operatton Some breakers partrculnrly recomendat~ons)
those carrylng llrgh values of
current have a tendency to NOTE These charts should be drsplayed in the subltatlon.
develop contact heatlng ~f left
closed for long periods Opening
and clos~ngIn breakers several
 gz
%
n
ij=5
$ 2
- -
a 2

a"" n=

!z
rn
z
~3hnz;t; C M O v ,
= a

EJEilC u
GgpEf=a J
gggasg $
" ",-
0-
- e g %g -

f!
*

m u - - 0

eo 2-2 a
Z
Z F o C
0 CI
g 0,
-rD E 0
D

cno= - a4
p e z 2
t u
r: z
$ 0-
3 I z,
>
n
 - -
1 2
r- 3-4----5
Qu lrterly f'lult joint locatcrs
2uart crly 111)Cxccss~ved e p o ~ nfdustls~ lltl
coal and oilier pollullon should be made to
I V ) Kxcesslve rusting of fit~ngs detect over-heated
Joints
- do- Conduc- Check for the followlllg
IX )Broken conductor strands
tors and 1) Examrne,lf securely t~e dto tile x ) Nlchrng near insulator
earthw~re ~risuI~tor~polelcross-arm neck and/or nea'r conductor
11) Proper sag clamps
111) Proxlmlty of trees and other Tree branches X I ) B~ndingwtre has not
objects ~nclud~ngbuilding, witllln 1 8 m become loose in d open
etc from the l ~ n e X I I )M ~ d s p a njoints have n o t
on its ellller crached
slde should be XIII)
All joints and jumpers of
removed
alumtnlum cond~lctorshave
iv) Suffic~entclearance p;o dr chmps/jolniln ~
between conductor and slee6s
earthw~res, and also from
the ground 6 -do- Jumpers & Chec? for the following
I

V) Suficlent clearancess from , o t h e i line I ) ~ r o & rsuGortlng and PO elampa should

other electr~c/telephone
I
accessorles jo!nting two ends o f be used BI-rnotallic
the.-jumcers wrth clamps s h o u l d
i
lines passing along, below 4..

o r aboveit sultable clamps be u s e d where

vi) Earthwlre is properly alurn~n~um/ACSR&
supported copper conductors
are jolnted to a v o ~
\

v ~ i )All the llnes guards are d bimetallic action.

Intact and installed, where 11)) Sil@cieht clearance
necesqary befw&n jumpors on
vnl) Tf joints In the jumpers & Use of "thermode- the 3 pbsises .
conductors appear all right tector" as dev~sed 111)Sufficient clearances of
by CPRI nangalore jumper; from metal
o r any other
worhs/stays so as no t
sultable i~ifra-red
 3S - - -
1 2 3
4 5
'x
Quarterly to slvlng close eriough
Quarterly ~ 1 1 1 )Proper and complcte
to strike a n arc I f tke g r e a s
fitllng of 11181e contacts runs, t]le swltc
IV) Provls~onof proper 1 Insul,~tlngbeeds In to the female ones requlres c a r 1
insulalioil or jumpers or PVC sleeves IX Arciug horns are rntnct atlerltloll and
should be
its n ~ o k e s ,
provlded dargerous cor~dlt
v) Slgns of over heating 2 Use of tdpe should
and burnlngs on be avotded as far r 5 assumed, t 11
s\vltch requlrc
jutnpers and other as possible lrnmedrate attent](.
fittlngs Llglllnlng Check for ;lie f o l l ~ w l ~
VI)Loose / defecllve cla- arrestors i g I ) Broken/dnmnged
mps, jolntlng sleeves, po~celaln
bolts and nuts, and 11)Intact and tlgllt, l ~ t &~
other fittlngs e enrth connectrons
G 0 Swrtch Check for the follow~rig A method ior field 111) External lndlcatron of
(wrth fuse 1) Tor smooth operation I fused/spark-over
anit) test~ngfor swrtch arrestors
11) Evrdence of over-heatrngl contacts with llve 11 KV cable Check for the following
b u r n r n g, corrosion/ lrne conststs rn
and cable 1) Propcr supporting of
prttlng on tbe swrtch uslng an rnsulated boxes the cable and the cable
contacts rod (for 11 KV) boxes
n ~Broken) or damaged adjustable he~ght 11)Damaged rnsulators
insulntors having at its upper 111) 011 and compound
iv) Proper and trght eal th end a tallow candle leaks and that the cable
connections fixed ~na clip Ilold box 1s properly topped
v ) Fuse l ~ n k sfor contrnulty, the candle agalnst up wrth the
trghtness of connectlons the hot contact for compound
and Intact
and correct ratlng a few seconds & 111)
vlj Proper locklng arrange- then exarnrne If connectrons
men t the grease sl~ghtly V) Proper ear tblng
'vri) Proper allgunlent of melts, mark the VI) Ovetall condltlon of the
swltch contacts contact for 8tte11troIl cable and jolnt
 C l ~ c ~forh t l ~ h tand lnillct Half-] early jumper jorned by
Quarterly Earth~ng
earth connections of all btndlng wtre
systerr vll) Check for the condltlon
metal wo~hsof the Irne of sleeves over the
1) Check for broken or ~ d m p e r sand replace,
burnt strands of the where necessary,
jumpers and r e ~ l a c e ~ 12 Hdlf-yearly G 0 Swstch I) Cleanliness I Clean
where necessary
(with fuse U D I ~ ) all dust and other
11) Check for tile proper
(Its deposrts wlth neat and
mater~al and size of ma~ntenance dry cloth
the jumpers for the I
may be done
given conductors I even earller 11) Swltch contacts ,
111) Check for 1 o o s e
connect~ons& signs of as the 1) c%eck for alignment, I) These polntr
over-heat~ngspecially functlonlng adequate contact should be
OJIc o p p e r to of G 0 Pressure and smooth particularly
alunlrnlum connections sw~tchesIS OPeratIon & adjust checked when
iv) Check for crowding generally in where necassary. contacts arc
or jumbling of wires dlsorder and replaced
and jumpers at the is always a 2) ~ x i h b fore burnlag/ 11) F 8 x .d
teeoff po~nts& adjust source of ovetaeating o r other and moving
where necessary trouble) dam8ges Recondl lion contacts may
h i &place, where
3
v) Check f o r general I t #
be dressed by
cond~t~onof other line
I
neceisary, "
using a fino
accessories such as L I
file/fine sand
d~fferent chtnpst papor. Uso
I
~olntlngsleeves & other of rough sand
paper ,be ,
I
fittings, etc re-adjust
& replace, where avolded 1
necessary 3) Irisulators 111) ~ e t r o l ~ i l m ' j q l l ~ /
vl) Replace the binding It 1s quite 1) Check for cracks, wliltd
wire J O I ~ ~ofS jumpers common to find c h i d p ~ n g& other of othbr duitablo i
by proper clamps the two ends of defects, replace, where dhntaat lubricant
% a w-3 M
" O Z O O ~
8 g g 8 5 4
0 0 (-Zu,
D o -:
Qn x
c"=
 for decay of wood an d lest should bc 111) Repllce the brohen d a y
~~eosettinglascuertreatment performed by ~nsulator/recondlt~or~tllc
may be done, where hammering earth
requlred the pole at I \ ) P ~ o v ~ suffic~entdbntbed
some potnts wrre/catlle guards on the
on the upper stcy to avold rubb~ngof
portlon and cattles
a t 0 3m below 16 Annually C r o ~ arms I ) Replace the broken /
the ground
spllttcd/ cracked1 bent /
I

level w ~ t ha
cross-arms by ne wones
one kg hammer i 11) Brlng In posltlon the
A clear r ~ n g
1s ladtcat~on slrpped cross- arms /
of healtliy clamps/br,lclngs
wood, w h ~ l e IU)Palnt the steel CI oss-arm
a hollow rrng and bractngs, etc, rf
IS a slgn of excess~velyrusted
decay Provlde 17 ( T h e Insulators and I) Clean and check for
butt j o ~ n t s ~nsulators fitt~ngs cracked/ chlpped am1
where decayed be checked punctured ~nsulators
wood IS
twice a year Replace,where necessary
removed
preferably 11 )
Examine for the surface Do not u
11) Ex,qmlne for burn~ngof before and contam~nat~on n n d cotton wnsl
wood at hardware after (monsoons) remove ~t by wrplng
qttachment pornts and \
with a soft cloth If the
recond~lron, where deposrt has set hard,
nccessary~ a weak acldrc solufron
I
Cyrneot Pole No detalled may be used.
mqlntepance required 18 Annually Conductors I) Tlghten loose blndlngs
1) Tlghten the loose stays and earthwlres and replace damaged
15 Annually Staya
11) Replqce the broken1 ones 1
damaged stays and stqy-
bows n) Examlne for corrosion 'at To avo]
I
1 2 3 4
- -
-- 5 - --
An~lually the ~ o l n fofs conductors corros~onthe Annually cldmps Tlghten dl1

a n d ~nsulators Clean dt condrrctors 10 -do- Llghtnrng clamps and fitt~ngs

1) Clean andexamlne
renew, R here necessary shotrld a l a a y ~ ar restor ~nrulatorsfor crrtcks nr-
be secured fl hover Replace, where
-

with p 1 11 necessary
~nsulators 11) P a form impulse vollage Tl~ese tests
by means of spmkover test & leakage can be
btndlng wrrc of current test to hnow the performed by
the same metal condltlon of lhe arrestor, using Jlgh[n.
as that forn~rog 1 replace case of 1ng arrestor
the o u t c r strand
I unsrtlsfactory results testlog hlf
of the conductor developed by
311) Exanilne closely for C p R I ,
broken stra~ldspdrtrcu- Bnngalore o r
larly, at the clamps any other
and insulators due ava rlable
to vqbrai~onand repalr, Instruments
where necessary. To know the
IV) Examlne general c o n d ~ t ~ o n
condltlon of
of the conductor and the arrestor the
earthwlres, I e for klnks, test results be
crusl~edspots, overlunder compared
tenslonrng, ctc , and w ~ t h the s
tandardl
recondrt~on, where manufacturer's
necessary3 speclficat~ons
v) Examlne for any loosel
cracked joints of
conductors In the
.meggar
A1ternamay
t ively
be
used for
mldspan and recondrtlon, detectrng
faulty l~ghtnlng
where necessary arrestor
V I ) Examlne for s l ~ p p ~ nofg
ill) Keep records of test
conductors from the results
 I
i INSPECTION cSr. ANNEXURE 'I'
MAINTENANCB SCHEDULE FOR
Annually iv ) Check and t~ghte nall I
L T LINE
ltne connectrons and I Sr brcquctlc) ol Equ~prnent/rterns Jtl~rect~orlNoic Aclroll Requrred/
cart11 leads
No l~ispect~o~l Lo be inspected liemarks
20 -do - 11 KV Cable 1) Clean and examltie for 1
and cable boxes damaged busblngs 1 2 3 4 :

11) Check for compound 1 Four-lnon~lrly a) Poles Same as recommended

level, ~f there IS leakage
111) Perform rnsulation b) Stays for these ~ t e n ~unders
c ) Cross-arm Schedule for X i T
resistance test, i d) Conductor LllleS
recondrtron or replace,
where necessary i e) Insulators (Wbc ther cobwebs, Thls becomes
krte strings, etc , source of the
rv) Keep cont~nuousrecords
of insulatton reslstanco hanglag on the heavy lcdkage
21. -do- Earlhtng Replace all broken earth f) Connectors conductor ) when wet
System leads and trghten others
g ) Cable boxes
Measure earth resistance
of varlous earths wrth eatth e tc
tester In case of low values, 2 Mouthly L T Swltch Check for the
I *
recondltlon them, follonrng
-
11)

Ill
22
I
I ) If the swltch with
-do ~ ~ t ~ - ~ l ~ m~belcnog~ d l t l othen antlcllmblng
devlces and devices s u c h as cover IS Intact
11) If the cable/sw~tcI~
barbed wrre, locks, etc ,
I
danger plales
etc paint and r e p r ~ n t the -
I
ruontng ho t
111) Broken cut-outs
danger plates if defaced'
NOTE * charis should be drsplnyed m the oEc e rooms of the Xen IV) Signs of over-heating/
burnlag on contacts
V) Proper slze of fuse
wrre -
I

and SSE/SOO concerned

vl) If the swttch IS
properly earthed
~ 1 1 )Safety from ram water
Half yearly L T ~ w l t c h 1) e t c the
3 Check lead on
L T Clrcu~t and
 5r,
- --
1 2 3 4 5
-
- -- _I-

-
I l ]If-VL,t l j I rpl,icc l l ~ eL T cable/
L 1 s?r~tchby h ~ g h e
l capdclty one, wherc n
e~e~sdry
1 1 ) i<epliice t l ~ ednn\ngecl
L T cable wlth uew
clue of the r1g11t
cnpaclty
111) f x Inllne the s\r ~ t c farl~
smoo t 11 opera1 J ~ J I
I V ) Replace the burnt f
cracked cut-outc
v) Recondltlon tile swltch
contacts
VI) Repltice the old filses
w ~ nbw~hone or rlght
c~lpaclty
V I I ) T~gbienall connections
V I I I ) Ensure that the lalet
of the cable ~ n t othe
swltch is plugged w ~ t h
plastjc con~pound to
avold entry o f rain
water Refill, where
necessary,
IX) Clean of thz cob-web
and other nests, etc ,
from the ~ n s t d eo f the
a) roles swltcll
4-One to two Same as recommended for
yearly b) Stays these item under Schedule
(Depending c ) Consuming for I3 7 Llne
upon the d) Conductor
volume of e ) Insulators
warh) f ) Connectar
g) Cable boxes
etc rooms of the Xen
NOTE These charts sl~ouldbe d~splayedIn Ille aflice
and SDO concerned,
----