Attachment C - CHP maintenance tasks.pdf

National Institute of Standards Technology Gaithersburg, MD Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Division of Responsibility - 4160 Volt Switchgear

Daily Monthly Semi- Annual Annual 3 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenan ce

NETA MTS

Months

NFPA 70B

Months

Main Bus Compartment Before servicing the switchgear, follow NIST lockout/tagout procedures and refer to Square D O&M safety precaution information. Be sure there is no backfeed through any feeder circuit. Ground the main and feeder circuits before touching the main bus, bus pads, or primary contacts.

1 Remove the front and rear covers from each main bus compartment. X X X 12 6 2 Inspect the bus bars, primary contact supports, and insulating barrier(s) for damage X X X 12 6 3 Inspect all bus bar connections; if required, torque all 1/2 inch bolts to 55 lb-ft (75

N•m). X X X Inspect 12 12

4 Slight discoloration or tarnish of the silver plate is normal and of no concern.

Severe discoloration of the silver plate is an indication of an improper or loose contact and overheating. Clean the discoloration from the contact surfaces of the busbar and primary contact. Use an abrasive pad such as 3M Scotch-Brite™.

X X X Inspect

Inspect

5 Vacuum each compartment to remove dust, spiderwebs, and so forth. X X X 12 6

Cable Compartment 12 12 6 Inspect the load connectors, stand-off insulators, primary contact supports, and all accessible cable terminations for indications of insulation deterioration. X X X 12 12 7 Vacuum each compartment and wipe off all insulation X X X 12 12 8 Replace removable back covers. X X X 12 12

Circuit Breaker Compartment 12 12 9 Withdraw each circuit breaker from its compartment, and thoroughly inspect each of the moving mechanisms in the compartment for damage and contamination/pollution.

X X X 12 12

10 Inspect the shutter hardware and tighten if necessary. The shutters should raise and lower smoothly with no indication of binding, twisting, hesitation, or hang-up. X X X

12 12 11 Inspect the primary contacts. They should have a silver-gray appearance, indicating good contact with the circuit breaker separable contacts. Slight discoloration or tarnish of the silver plate on the primary contact is normal. Severe discoloration of the silver plate is an indication of excessive heating and should be corrected.

Typical causes are:

- poor contact between the circuit breaker separable contacts and the primary contacts

- loose hardware or otherwise improper contact at the bus connection

X X X

12 12 12 Clean the discoloration and tighten the contact mounting bolts to the proper torque.

See Table 2, page 30 of Bulletin 6055-30 X X X 12 12 13 Inspect the primary contact and support insulators for damage X X X 12 12 14 Inspect the ground contact bar. It should have marks indicating good contact with the circuit breaker sliding contacts. Clean the contact surfaces, removing grease and dirt buildup. Inspect and tighten the hardware and re-grease.

X X X 12 12

Maintenance - 4160 V Switchgear SG4001

System/Description

Periodic Checks and Maintenance Tasks

NISTFrequency Johnson Controls

ATTACHMENT C

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Division of Responsibility - 4160 Volt Switchgear

15 Inspect the stationary control power receptacle, ensuring that the molding is free of cracks, the female contacts are clean, and the assembly is free to move. Clean the front and back surfaces of the receptacle to remove any contamination buildup. X X X

12 12 16 Vacuum the compartment, and wipe off the primary contact high voltage insulating tubes and support insulation with a clean, dry cloth. X X X 12 12 17 Every 50 cycles of the racking mechansim:

— lightly lubricate the primary contacts and the ground contacts with Mobilux® EP 1, Schneider Electric part number 1615-100790

— lubricate all moving joints (shutters, MOC, TOC, and so forth) with Mobilgrease® 28, Schneider Electric part number 1615-100950

X X X

12 None 18 Check all terminal block connections for loose connections and crimps. X X X 24 12 19 Make certain that the hinge wiring to the door is not frayed and has no insulation damage. X X X None None 20 Ensure all wires are routed through the hinge loop. X X X None None

21 Infrared Scan X 12 12

Daily Monthly Semi- Annual Annual 3 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenan ce

NETA MTS

Months

NFPA 70B

Months

Circuit Breakers 21 Consult the individual circuit breaker instruction and maintenance manual for cleaning, adjustment, and lubrication information. Refer to the Type VR Circuit Breaker instruction bulletin 6055-33 (3000 A, 50 kA and 1200, 2000, and 3000 A, 63 kA).

X X X

N/A N/A 22 Inspect circuit breakers after annually or every 1,000 operations, whichever occurs first. Also inspect circuit breakers after severe fault operations and record any contact erosion. Remove the circuit breaker completely from the circuit breaker compartment before performing any maintenance or inspection on the circuit breaker.

X X X

12 12 23 General Inspection: Visually inspect the entire circuit breaker and operating mechanism for loose parts or connections. Examine the circuit breaker for evidence of overheating or excessive dirt or moisture. If necessary, remove the operating mechanism cover (Figure 7 on page 14 of bulletin 6055-33) by carefully unclipping the back of the cover from the mechanism frame.

X X X

12 12 24 Insulating Surfaces: Using a clean, dry cloth, remove all dirt and moisture from the outside of the vacuum interrupters and from the insulating parts. X X X 12 12 25 Vacuum Interrupters: To monitor the condition of the circuit breaker and the vacuum interrupters, perform the following checks. If the measurements consistently differ from target values, contact Schneider Electric for corrective procedures.

X X X

12 36

Periodic Checks and Maintenance Tasks

Maintenance - 4160 V Switchgear SG4001

System/Description

Frequency Johnson Controls NIST

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Division of Responsibility - 4160 Volt Switchgear

26 E-gap: To measure E-gap, the circuit breaker must be completely removed from the circuit breaker compartment. The E-gap is the space between the pivot block, located below the pushrod at the bottom of the pole assembly, and the hex-shaped bias spring sleeve (Figure 23 on page 32 of Bulletin 6055-33). This distance should be measured before the initial installation of the circuit breaker, and then every year or every 1,000 operations.

The distance between the initial E-gap measurement and the current E-gap measurement is the amount of contact erosion that has occurred. When contact erosion exceeds 0.12 in (3.05 mm), the vacuum interrupter may need to be replaced. Contact the factory for information. Follow the procedures in “Initial E-gap Measurement ” on page 19 to measure the initial E-gap before installing the circuit breaker.

X X X

Not Specific

27 Determin contact erosion = initial E-gap measurement minus current E-gap measurement. Follow steps 1–7 to measure contact erosion:

1. Turn OFF all power supplying this circuit breaker.

2. Push the CLOSE (|) pushbutton. The springs may need to be manually charged first.

3. Use pin gauges, feeler gages, or drill bits to measure the space between the pivot block, located below the pushrod at the bottom of the pole assembly, and the top of the flat washer (Figure 23). Accuracy should be in the order of 0.015 in. (1/64 in. or 0.5 mm).

4. Record E-gap in the maintenance log and follow the equation to determine the contact erosion. See “Installation and Maintenance Log ” on page 35.

5. If the contact erosion exceeds 0.12 in. (3.05 mm) or the E-gap measurement reaches the absolute end-of-life dimension, the vacuum interrupter will need to be replaced. Do not reset the E-gap. Notify JCI to discuss replacement with OEM.

6. Push the OPEN (O) pushbutton.

7. Replace all devices, doors, and covers.

NOTE: The E-gap is factory set and should only be adjusted when installing a new vacuum interrupter pole assembly.

X X X

Not Specific 12 to 24

Not Specific

28 Hi-pot (Dielectric) Tests: Hi-pot (high potential) tests need to be performed as part of a series of preoperational tests (see “Hi-pot (Dielectric) Test ” on page 20), regular maintenance, and as a method of determining the adequacy of equipment.

Consistent unacceptable test results may indicate a loss of vacuum. Notify JCI to discuss with OEM.

X X X

24 36 29 Resistance Measurement: The resistance measurement from the upper conductor to the lower conductor on each phase of the circuit breaker should not exceed 50 micro ohms using a low-resistance ohm meter. A reading exceeding 50 micro ohms indicates that either a poor connection exists or that the vacuum interrupter has reached the end of its life cycle. The vacuum interrupter may need to be replaced.

Contact Schneider Electric for technical assistance.

X X X

24 36

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Division of Responsibility - 4160 Volt Switchgear

30 Vacuum interrupter pole assembly replacement: If the vacuum interrupter pole assembly must be replaced due to severe interruptions, unsatisfactory hi-pot test results, excessive contact erosion, or high resistance, Notify JCI to discuss with OEM. See “Section 8—Replacement Parts ” on page 34 of Bulletin 6055-33.

X X X

24 36 31 Under normal conditions, lubricate the following after one year or 1,000 operations, whichever occurs first. Wipe clean and apply red Mobilgrease® 28 Schneider Electric part number 1615-100950: 1) Gear teeth in charging motor gear box; 2) Contact surfaces on trip latch; 3) MOC linkage; 4) Primary disconnect contacts; 5) Drive bar.

X X X

12 to 24 36

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Division of Responsibility - 480 Volt Motor Control Center

Daily Monthly Semi- Annual Annual 3 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenance NETA MTS

Months

NFPA 70B

Months

Before servicing the MCC, follow NIST lockout/tagout procedures and refer to Square D O&M safety precaution information.

Inspecting Enclosure

1 Inspect exterior and interior of enclosure for moisture, oil, or other foreign material.

Eliminate all foreign material and clean the MCC. X X X 12 12

2 Clean the interior and exterior of the MCC with a vacuum cleaner if necessary. Do not use compressed air; it will redistribute contaminants to other surfaces. Check the enclosure for damage that might reduce electrical clearances

X X X 12 12

Maintaining Bus Bars and Incoming Line Compartments 3 Perform maintenance of bus and incoming line lug connections at least annually, or more frequently if indicated by service conditions and your established maintenance policy. Follow the steps in MCC Instruction Bulletin 80459-641-01G.

X X X X

24 36 4 Examine all bus bars and connectors. Replace any parts that are badly discolored, corroded, or pitted. Also replace parts subjected to excessive temperatures. X X X 12 24

5 Verify that all bolts at the bus connection points indicated by a hexagon in Figure 85 are in place and properly tightened. Although one specific type of compartment or bus is shown in Figure 85, perform this maintenance on all bolted connections. See Table 6 for torque values

X X X X

24 36 Verify that all main lug, circuit breaker, or fusible switch set screws holding incoming conductors in main lugs are in place and properly tightened (see Figure 87). Use a torque wrench and a 3/8 in. allen bit to torque the lug set screws to the appropriate value (see “Cable Connection Torque Values” on page 78).

X

24 36 6 Inspect all insulators, braces, and barriers; replace any that show signs of arcing damage, tracking, excessive heat, or cracking X X X 12 12 MCC Components Inspection

7 Inspect and perform maintenance as necessary on control unit. Refer to detailed Square D instructions for removal if necessary X X X 12 12

8 Verify proper operation of the circuit breaker or disconnect switch. Inspect switch blades; if evidence of arcing or excessive heat is present, replace the switch assembly. Exercise the push-to-trip feature on the circuit breakers

X X X 12 12

Verify proper operation of the operator mechanism (see Figure 106). Test for proper ON, TRIP, OFF, and RESET positions (F-, K-, and L-frame circuit breakers) or ON, TRIP, and OFF positions (B-, H-, J-, M-, or P-frame circuit breakers). Verify proper door interlock operation

X

12 12 9 Inspect all fuses and fuse clips (see Figure 107). Replace any parts showing signs of overheating or arcing. X X X 12 12 10 Check the starter contacts. Replace any that are badly worn or pitted. X X X 12 12 11 Check for proper operation of starters, relays, timers, and other control devices X X X 12 12 12 Manually trip the overload relay to ensure proper operation. X X X 12 12 13 Before an MCC is re-energized (after regular maintenance), take resistance measurements. Use an insulation tester (megohmmeter) with a potential of 500–1000 V. Take readings between each phase and from each phase to ground, with the branch disconnects off and on. Make sure the main disconnect is off during all insulation tests. Readings from a megohmmeter with all disconnects off will typically be 5–20 megohms.

X X X

24 24 14 Infrared Scan X X X 12 12

Maintenance - 480 V Motor Control Center MCC-7

System/Description

Periodic Checks and Maintenance Tasks

NISTFrequency Johnson Controls

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Div. of Responsibility - 4160V to 13.2 kV Step-up Transformer

Daily Monthly Semi- Annual Annual 3 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenance

NETA

MTS

Months

NFPA 70B

Months

Before servicing the transformer, follow NIST lockout/tagout procedures and refer to Virginia Transformer O&M safety precaution information.

General Inspections

1 Check and record oil temperature X X 1 2 Check and record winding temperature X X 1 3 Check and record gas space pressure X X 1 4 Record ambient temperature at the time of taking readings X X 1 5 Record load current at the time of takng readings X X 1 6 If gauge readings never change, confirm gauge accuracy X X 1

7 Check the bushings and tank surface for signs of corrosion in areas with a medium to high pollution rate. Pollution here is described as areas with damaging fumes or vapors, high amount of abrasive or conducting dust, corrosive or explosive gases or dust, salt deposits or very wet conditions.

X X

12 12 8 Check for obstructions in the ventilation path of the transformer, and more specifically for obstructions in the radiators such as bird nests, windblown debris, etc.

X X 12 12

9 Check breathers and vents opening on cabinets and enclosures for cleanliness. X X 12 12 10 Test and record the resistance of the transformer tank to ground. X X 12 11 Test the operation and correct rotation of additional cooling equipment {fans and/or pumps). X X 12 12

12 Check for signs of rodents or pests and take corrective action if signs are found. X X 12 12

Mechanical Inspections 12 1 Check for oil leaks around the tank with focus on radiators, flanges, bushings, instrument ports and weld seams. X X 12 12

2 Pressure relief device (PRD) should be checked for oil leaks on conservator jobs, or drop in gas pressure for sealed unit and gas-blanket jobs. X X

12 12 3 Check for and remove where possible, layering of dust or dirt on the radiators to maintain cooling capacity. X X 12 12

4 Check for signs of corrosion on the tank or radiators. If found, clean and use touch-up paint as required. X X

12 12

Electrical Inspections 12 1 Visually inspect bushings and arresters for signs of damage. X X 12 12 2 Take Infrared imagery of the bushings in operation to identify hot-spots X X 12 12 3 Listen for abnormal noise or vibration from the transformer and/or the additional cooling equipment. X X 12 12

Oil Analysis - Dielectric-breakdown voltage, acid neutralization number, specific gravity, interfacial tension, color, visual condition, water in oil, and power factor X

24 12

Maintenance - 4160 V to 13.2 kV Step-up Transformer TL-1301

System/Description

Periodic Checks and Maintenance Tasks

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Div. of Responsibility - 4160V to 13.2 kV Step-up Transformer

Daily Monthly Semi- Annual Annual 3 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenance

NETA

MTS

Months

NFPA 70B

Months

Long Term Inspections and Testing - Instrumentation 1 Where possible, perform end to end testing on the pressure relief device (PRD) alarm or trip function. X X 24-36 36-60

2 Where possible, perform end to end testing on oil and winding temperature alarm and or trip functions X X

24-36 36-60 3 Where possible, perform functional tests on the oil level gauge and on the alarm and/or trip functions. X X 24-36 36-60

4 Where possible, perform end to end testing on the sudden pressure rise alarm or trip function. X X

24-36 36-60 5 Where possible, perform end to end testing on the Buchholz relay alarm or trip function. X X 24-36 36-60

6 Exercise the cooling fans by operating them in "Manual" mode. X X 24-36 36-60

Long Term Inspections and Testing - Bushings 1 Perform close detailed inspection on the bushings to identify signs of treeing, discoloration or cracks/chips in the insulation sheds. X X 24-36 36-60

2 Power factor and capacitance testing on the bushings. Clean the bushings before testing, as contamination will skew results. X X

24-36 36-60 3 Check the oil levels in the bushings, as applicable. X X 24-36 36-60

24-36 36-60 Long Term Inspections and Testing - Ancillary Equipment 24-36 36-60

1 Exercise the de-energized tap changer (DETC). Transformer must be de-energized before operating the DETC. X X

24-36 36-60 2 Inspect the conservator bladder for signs of oil leakage, by a visual inspection of inside the bladder. X X 24-36 36-60

3 Maintenance on the load tap changer (LTC) should be performed as per manufacturer's recommendations. X X

24-36 36-60 4 Exercise the cooling fans in "manual" mode, as applicable. X X 24-36 36-60

Long Term Inspections and Testing - Electrical Testing 1 Perform testing on oil, especially

a. Disolved gas analysis (DGA) on transformer main tank

b. DGA on LTC tank, where applicable

c. Dielectric test on transformer and LTC tanks

d. Oil quality tests including but not limited to lnterfacial tension, acid number, inhibitor numbers, power factor, furans, degree of polymerization and moisture.

X X

24-36 36-60 2 Perform Insulation resistance of the windings and cables X X 24-36 36-60 3 Perform DC resistance of the windings X X 24-36 36-60

Periodic Checks and Maintenance Tasks

Maintenance - 4160 V to 13.2 kV Step-up Transformer

System/Description

Frequency Johnson Controls NIST

Energy Savings Performance Contract ECM 10.1 CHP Plant Addition

Routine and Preventive Maintenance Schedules Div. of Responsibility - 4160V to 480 V Dry Type Transformer

Daily Monthly Semi- Annual Annual 2 Years

Johnson Controls

Inspection

Johnson Controls

Maintenance

NIST

Inspection

NIST

Maintenance

NETA

MTS

Months

NFPA 70B

Months

Inspections Before servicing the transformer, ensure all static charge has been discharged by grounding the coils with an appropriate grounding device. Refer to Square D O&M safety precaution information and follow NIST lockout/tagout procedures.

1 Clear away any debris or other foreign objects from all ventilation openings. If the transformer design includes an optional solid base, make sure air can flow through the bottom grills of the enclosure.

X X 12 12

2 Check the enclosure for deterioration. If deterioration is present, determine the cause and correct (if possible). Repaint deteriorated areas. Replace corroded hardware, as required.

X X 12 12

3 Cleaning the transformer: Wipe down all parts of the core, being careful not to cut yourself on any sharp edges or protrusions. Use an industrial vacuum cleaner to clean the ventilation openings and remove dirt and dust from the core, coils, insulators, and remaining structures. Remove all rags or other maintenance equipment from the coil ducts and check for tools when finished. Confirm that the coil ducts are clear.

X X X

24 24 Inspections and Testing after a Major Fault

1 Before inspecting the transformer, ensure all static charge has been discharged by grounding the coils with an appropriate grounding device. Refer to Square D O&M safety precaution information for de-energizing the transformer and follow NIST lockout/tagout procedures.

X X

2 Remove the enclosure panels and inspect the transformer core and coil assembly for any physical damage. If damage has occurred, notify JCI and contact the Square D Medium Voltage Transformer facility at 704-283-7411.

X X

3 Using a torque wrench, ensure all bolted connections are torqued according to the torque guidelines in Table 2 on page 14 of Square D O&M information. X X

4 Perform the tests described in “Section 5—Start-Up Testing” on page 16. DO NOT re-energize the transformer if the test results are not acceptable. If no damage has occurred and all test results are acceptable, perform maintenance by following the procedures in “Section 7—Maintenance” on page 21.

• Insulation Resistance: Measures the resistance of the insulation between the primary and secondary windings and from each winding to ground.

• Turns Ratio: Measures the ratio of the primary to secondary turns to check for possible insulation degradation in the windings.

• Core Megger® Test: Measures the resistance to the flow of current through and over the surface of the transformer insulation. Results can indicate possible insulation

X X

Maintenance - 4160 V to 480 V Dry Type Transformer TD-4001

System/Description

Periodic Checks and Maintenance Tasks