THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
Page 1 of 9
i ii
OFF-LINE MAINTENANCE PROCEDURE FOR < 1kV CIRCUIT BREAKERS

Equipment Group: E115 = Circuit Breaker

iii
Equipment Type: E115A = Air Magnetic Circuit Breakers: < 1kV

Scope This procedure defines the requirements and methods for Acceptance
Testing (ACCTST) and off-line Predictive/ Preventive Maintenance
(OVHAUL) for < 1kV Circuit Breakers. The intent is to maximize the
reliability of this equipment at minimum cost through the combination of
testing equipment upon installation and employment of a regularly
scheduled off-line maintenance with the ultimate objective of eliminating all
unexpected failures.

Maintenance of Circuit Breakers above 1kV is described in G7M-1151-00.

Maintenance procedures for switchgear associated with < 1kV switchgear
is G7M-1130-00.

Definition AIR CIRCUIT BREAKER: An interrupting device in which the interruption

occurs in air.

AUXILIARY SWITCH: A switch, which mechanically operated by the main

device for signaling, interlocking or other purposes.

ACCESSORIES: Devices, which perform a secondary or minor duty as

an adjunct or refinement to the primary or major duty of a circuit breaker.

PICK-UP POINT: RMS current level at which the circuit breaker tripping
function is indicated.

OVER CURRENT TRIP: A component, which, for a given pole of a circuit

breaker, detects over current and transmits the energy to trip the breaker
automatically.

UNDER VOLTAGE TRIP: A release mechanism, which causes a circuit

breaker to open automatically if the control voltage fall below a
predetermined value.

INFRARED INSTRUMENT (INFRED): An instrument designed to detect

emitted heat radiation and to convert it to a visible signal.

INSULATION TEST (MEGGER): This test provides an assessment of the

insulation condition of a piece of equipment by imposing a DC voltage
generally between opposing phases or between one phase and ground.

MANDATORY TEST/INSPECTIONS ( ) – These test are considered

mandatory for both acceptance testing and routine off-line PPM. An MOC
approved by the Switchgear TRL is required if these tests are not
completed.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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SUPPLEMENTAL TEST/INSPECTIONS ( ) – In general, all tests are

used for initial acceptance testing. Routine off-line PPM tests are not as
stringent and items marked as supplemental are only to be performed
when there is a suspected problem with the equipment. For example: If
breaker trips without a protective relay flag indication, a MEGGER
inspection may be used to troubleshoot the problem. For this example
case, an MOC is not required for performing the supplemental tests.
However, performing additional tests just for the sake of testing or just
because the tests have been traditionally done at a particular site is not
supported by the Electrical Discipline or Global Maintenance Leadership.
An approved MOC from the Switchgear TRL is required before such
supplemental testing is initiated.

Safety Safety is an integral part of all jobs. As such, all applicable Electrical Safe
Work Standards and Isolation of Energy Sources (IOES) criteria shall be
rigidly applied in the execution of the work described in this PPM
specification.

It is the responsibility of the lead person administering the PPM activities

to assure that all safety related procedures are identified and followed by
individuals involved with the PPM activities. This responsibility however
does not relieve the individual workers from understanding and following
the criteria defined by the Electrical Safe Work Standards and all sub
practices.

Note: It is common for Switchgear, Motor Control Centers (MCCs), Main

Distribution Panels (MDPs) and High Voltage Panels (HVPs) to have
multiple control power sources within the same cubical/assembly. Control
power sources may be from adjacent equipment cells (usually interlocks),
space heater panels, and control system alarms, etc. As such, these sub
control power systems often remain energized within the equipment
compartment even if the main control power source for the compartment
was de-energized. Caution must therefore be taken when performing
PPM work on or around these systems and the ”Test Before Touch”
criteria defined by EWP-30 and 32 is mandated.

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

Test Equipment Other Equipment

Approved Voltage tester per EWP-32 Manufacturer’s Instruction Manuals

1000V Megger Cleaning Materials

Ductor (Micro ohm meter) Personal protective equipment such as
Nomex clothing, high voltage rubber
gloves, and flash equipment when
necessary.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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Test Equipment Other Equipment

CT Test Set (for breakers equipped Torque Wrench, Screwdriver, Flashlight

with CT’s)

3∅ Variable Test Source Breaker Timer/Recorder

AC/DC control schematic for the

systems that are included in the
PPM activities.

P/PM Schedule The required frequency for P/PM inspections for < 1kV Circuit Breakers is
established via the Condition Based Electrical PPM web site.

Data Form For execution of the above-mentioned Acceptance Testing and

Predictive/Preventive Maintenance tasks, a combined Data Form G7M-
1131-01 is available. This Data Form refers to the actions described on the
following pages and shall be used as a checklist and record for final data
entry into the GEMTS system. GEMTS should capture only the Service,
Reason, and Cause codes, and only test data by exception using the text
comments for the work order. Additional results or information, like
replacement of electrical or mechanical parts, modifications and notification
of critical conditions, which should enter the history or could effect the P/PM
schedule should also be recorded in the text comments of the work order.

Preparation Follow the steps below before starting the tests and inspections on the
equipment.

OVHAUL
Step Service Action P/PM ACCTST
offline

Plan and schedule the inspection as

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

2 PREP Review the AC/DC control schematic of

the disconnect switch assembly. Look
for possible control power sources from
interlocks, alarms, remote controls,
space heaters, etc. that may be present
within the equipment compartment.

3 PREP If control wire modifications are included

in the scope of the PPM process,
complete the requirements of G7M-
1000-00 and G7M-1000-A (Risk
Management Methodology for
Instrument, Electrical, Analyzer, and
Process Control Equipment) prior to
initiating work.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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OVHAUL
Step Service Action P/PM ACCTST
offline

4 PREP Complete all electrical clearing of

equipment per the criteria defined in the
Electrical Safe Work Standards and
Isolation of Energy Sources (IOES).

5 PREP Review all technical specifications,

operating manuals and previous
inspection data if appropriate.

6 PREP After de-energizing, appropriate

lockout/tagout, and grounding if
required by EWP-33, open all breaker
/disconnect doors and remove
breaker(s).

Perform the “test before touch” per

EWP-30 and 32. Be aware and take
necessary precautions against contact
with energized systems (wires, relays,
7 PREP terminal blocks, etc. If power is found
on a system that should not be
energized (per review of control
schematics - Step 2 above), STOP THE
JOB and investigate.

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

Step Service Action OVHAUL ACCTST

P/PM
offline
Compare equipment nameplate
1 VISIN1 information data with actual operating
conditions, drawings and specifications.

Inspect the physical condition of the

breaker such as arc-chutes, main and
arcing contacts, springs, disconnecting
devices at rear of draw out type circuit
2 VISIN1
breakers according to manufacturer’s
instructions for deterioration; corrosion;
leakage; missing, broken or loose parts;
etc.

Perform mechanical operational tests in

3 VISIN1 accordance to manufacturer’s
instruction manual.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

4 VISIN1 Check cell fit and element alignment.

Tighten main current carrying part (bus

system, runbacks, switch, etc.) to the
manufacturers torque specifications. If
6 TORQUE
such information is not available, tighten
in accordance with Engineering Practice
G7M-0020-26.
Tighten control, VT, CT, and metering
7 TORQUE wires on all devices and terminal

blocks.

Clean circuit breaker and all electrical

contacts with a burnishing tool including
finger clusters contact points and
8 CLN
lubricate using approved methods and
materials in accordance with
manufacturer’s instruction manual.
Lubricate contact surfaces and moving
assemblies using approved methods
9 LUBAF
and materials in accordance with
manufacturer’s instruction manual.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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Electrical Tests Follow the steps below to perform electrical tests on the equipment.

Step Service Action OVHAUL ACCTST

P/PM
offline

Using a 500V megger, measure the

insulation resistance of the breaker
1 MEGGER
control circuit. The minimum Megohm

value should be per G7M-0020-08.

Perform insulation resistance tests on
air circuit breaker: Pole to pole, and
each pole to ground and across open
2 MEGGER contacts. The test voltage and minimum
acceptable value shall be in accordance
with manufacturer’s instruction manual
and G7M-0020-08.

Functional Tests Follow the steps below to perform functional tests on the equipment.

Step Service Action OVHAUL ACCTST

P/PM
offline

Perform minimum pickup voltage tests

on trip and close coils. These values
1 FUNTES should fall within manufacturers
published time current characteristic
tolerance band and voltage.
Manually operate circuit breakers to
2 FUNTES determine satisfactory operating
condition.

Verify breakers have proper

engagement of contacts/stabs with
mating receptacles on the contact
3 FUNTES surfaces using grease or dye and that
breakers cannot be disengaged from
the main bus while in closed position
without it automatically tripping.

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ELECTRICAL G7M-1131-00
GLOBAL 19-MAR-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

Operate circuit breakers from each

control point. Trip by manually and
electrically operating every control trip
4 FUNTES
device. Alarms, targets and remote
indications shall be confirmed to
operate properly.
Verify that closed breaker mechanism
springs discharge when the breaker is
inserted into or removed from the
5 FUNTES cubicle and that breakers are correctly
labeled with proper warning signs and
operating instructions are in place or
posted.
Check charging motor (if applicable) for
6 FUNTES proper operations of motor,
mechanisms and limit switches.

Check alignment of breaker and cell

auxiliary switches and interconnecting
mechanisms. Confirm proper operation
and alignment of the auxiliary switch
iv
7 VISIN1 assemblies. Auxiliary switch
alignment must be fully
representative of the breakers
position (not partially closed or
open).

Check annunciators, alarms, targets

8 ALMTST and remote indications shall be
confirmed to operate properly.

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Calibration Tests Follow the steps below to perform protective device calibration tests
(overcurrent, undervoltage, etc. settings) on breakers equipped with these
devices.

Step Service Action OVHAUL ACCTST

P/PM
offline

Perform steady-state tests to determine

pickup and/or dropout values for each
operating element at the specified
1 FUNTES
settings. These test should be repeated
several times to arrive at an average
value.

Perform steady-state tests to determine

2 CALCHK operating times for the specified
settings.

Verify proper operation of targets, reset

3 FUNTES
mechanisms, and seal-in units.

Perform special tests as described by

the instruction manual to determine that
4 CALCHK
the specific operating characteristics
are functioning properly.

Perform complete tripping and

operational tests to verify that the
breaker protection unit initiates the
5 FUNTES appropriate control circuit action (alarm,
breaker trip, supervisory control, 86
lockout, close inhibit, remote tripping,
etc.).

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GLOBAL 19-MAR-2007
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Return to Operation Follow the steps below to return the equipment to operation.

Step Service Action OVHAUL ACC TST

P/PM
offline
After all testing is complete, visually
inspect the breaker to ascertain that all
safety grounds have been removed, all
doors properly closed, all appropriate
1 PREP
red tags removed, and any other items
compromised during the test returned to
their original operational state before
releasing to owner.
All test forms and data sheets are to be
2 PREP submitted to the appropriate authority
for entry into GEMTS.

Issue additional work orders as

3 PREP
necessary to make additional repairs.

When racking-in, closing, and tripping

breakers, follow the criteria established
4 PREP
in EWP-21 (PPE for Arc Flash
Hazards).

i
19-MAR-2007; MOC 2007_04416; By: Paul Gabba; Supersedes Issue Date 08-DEC-
2004; Reviewed. Updates throughout as a result of the Plaquemine Poly A Arc
Flash Incident.
ii
18-AUG-2003, MOC2003.1100.110, By: Paul Gabba, Supercedes Issue Date 06-
MAY-2003, Complete rewrite for the Condition Based PPM program.
iii
08-DEC-2004, MOC 2004_02277, By: Paul Gabba, Supercedes Issue Date 18-AUG-
2003, Corrected Equipment Type
iv
08-DEC-2004, MOC 2004_02277, By: Paul Gabba, Supercedes Issue Date 18-AUG-
2003, Added STEPS 7 and 8 at FUNCTIONAL TEST.

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