HV Equipment Maintenance Guidelines - Rev 0

High Voltage Equipment Maintenance Guidelines
Introduction
The following maintenance documents are intended to serve as a resource and guide to assist
the GDF SUEZ Generating facilities in North America to develop a comprehensive preventive
maintenance program for plant equipment operating at 13.8 kV up to 500 kV. The goal is to
ensure continuing safety, reliability and maximum life of the equipment.
The SEGNA facilities have a wide and varied collection of HV electrical equipment throughout the
organization and it would not be possible to cover every aspect of equipment maintenance in a
single volume, as such, this will become a work in progress that will need to be updated and
reviewed from time to time to ensure maximum coverage and accuracy of information.
Industry standards, NERC Reliability Standards, and best industry practices have been used to
establish reasonable and manageable levels of maintenance.
Each facility is encouraged to review specific manufacturer’s equipment manuals for additional
maintenance requirements where appropriate.
The recommended maintenance intervals and testing for protective relaying and station batteries
should be considered as a minimum requirement, unless the testing requirements in the facility’s
Interconnect Agreement are more onerous (or more frequent).
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High Voltage Electrical Maintenance Guidelines Volume 1
TABLE OF CONTENTS
Page No. Document ID
Maintenance Testing Intervals of HV Substation Equipment HVSUB-01
Oil Filled Transformers…………………………………… 1

Protective Relaying………………………………………. 2
HV Circuit Breakers………………………………………. 2
Air Break Switches……………………………………….. 2
Instrument Transformers PTs…………………………… 2
Instrument Transformers CTs…………………………… 3
Isolated Phase Bus Duct…………………………………. 3
Underground Cables……………………………………… 3
Overhead Structures & Transmission Lines…………… 3
Substation Battery Maintenance ………………………… 3
Transformer Oil Preservation System Inspection HVTRAN-01
Sealed Gas Pressure Systems………………………….. 1

Sealed Transformers……………………………………… 2
Free Breathing Conservator……………………………… 2
Conservator With Bladder………………………………… 3
Transformer Oil Analysis Interpretation HVTRAN-02

Dissolved Gas Concentration Limits…………………..… 1
Recommended Actions………………………………….... 2
Oil Tests……………………………………………………. 2
Exercising of Oil Filled Transformer Off Load Tap Changer HVTRAN-03
Oil Filled Transformer Detailed Visual Inspection HVTRAN-04
Transformer Bushing & Winding Power Factor Testing HVTRAN-05
Transformer Instrument & Gage Calibration HVTRAN-06
Buchholz & Sudden Pressure Relay Testing HVTRAN-06
Thermal Imaging of Electrical Equipment HVTHMG-01
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High Voltage Electrical Maintenance Guidelines Volume 1
TABLE OF CONTENTS
Page No. Document ID
Protective Relay Testing HVPROT-01
Mandatory NERC Standards…………………………….. 1

Current NERC Standard PRC-005-1……………………. 2
Maintenance & Testing Intervals & Their Basis………. 2
Maintenance Testing Procedures………………………. 3
Protection Systems Maintenance & Testing…………... 4
HV & MV Circuit Breakers HVCB-01
SF6 Circuit Breakers…………………………………….. 2

Oil Circuit Breakers……………………………………… 5
Air Blast Circuit Breakers……………………………….. 7
Vacuum Circuit Breakers……………………………….. 8
Gang Operated Air Break Switches HVGAOB-01
Substation Battery Maintenance STNBAT-01
Types of Batteries………………………………………… 1
Recommended Lead Acid Flooded Cell Batt. Maint. …. 2
Float & Equalize Voltage Checks………….….. 2
Pilot Cell Voltage Readings………………….… 3
Electrolyte Spec. Grav. Checks & Vis. Insp…. 4
Charger & Monitoring Alarm Inspections ……. 5
Clean & Torque Cell Interconnections………... 5
Capacity Load Testing………………………….. 6
Recommended Valve Reg. Lead Acid Batt. Maint…….. 7
Float & Equalize Voltage Checks……………... 7
Pilot Cell Voltage & Temperature Readings….. 7
Visual Inspection………………………………... 8
Internal Resistance Check Of All Cells…….…. 8
Thermal Imaging & Record Of Cell Temp……. 8
Monitor For AC Ripple……………………….…. 8
Charger & Monitoring Alarm Inspections….…. 8
Clean & Torque Cell Interconnections…….….. 9
Capacity Load Testing……………………….…. 9
Substation Instrument Transformers HVINST-01
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High Voltage Electrical Maintenance Guidelines HVSUB-01
Recommended Maintenance Testing Intervals of HV Substation Equipment
Many factors will influence the maintenance schedule for electrical equipment and should be also
taken into consideration when planning maintenance frequencies.
Location: Outdoor structures will be more prone to damage from corrosion & weather extremes
Loading: Heavily loaded equipment may be more prone to premature failure.
Duty Cycle: Frequent energizing & de-energizing of the equipment may add stress.
Fault trips: Cause stress on the operating equipment.
Age: Equipment nearing the end of its designed life cycle will require more frequent monitoring.
Operating Climate: Altitude, corrosive environment, high humidity temperature extremes &
lightning activity will increase the frequency requirement for maintenance.
Criticality of Equipment: Potential for serious financial impact as a result of failure.

Equipment value and delivery time should be considered when determining financial impact.
Any combination of the above factors should be taken into consideration when determining the
equipment operating condition.
Always check the equipment manufacturers supplied manuals and utility connection or operating
agreements for additional recommendations.
Oil Filled Transformers
Inspection Type Equipment Operating Condition

Poor Average Good
Oil Preservation System Check 1 month 1 month 1 month
Oil Analysis (DGA, Moisture, Dielectric etc.) 3 months 6 months 1 year
Thermal Imaging 6 months 6 months 1 year
Exercise off load tap changer 1 year 1 year 1 year
Detailed Visual Inspection 1 to 2 years 1 to 2 years 1 to 2 years
Bushing & Winding Power Factor Testing 1 to 2 years 3 to 5 years 3 to 5 years
Instrumentation & Gauge Calibration 3 years 3 to 5 years 3 to 5 years
Sudden Pressure Relay Testing 3 years 3 to 5 years 3 to 5 years
Buchholz Relay Testing 3 years 3 to 5 years 3 to 5 years
Conservator Bladder Inspection 3 years 3 to 5 years 3 to 5 years
Turns Ratio Testing (All tap positions) 3 years 3 to 5 years 3 to 5 years
Core Ground & Winding Insulation Test 3 years 3 to 5 years 3 to 5 years
Deluge System Operational Test 2 years 2 to 3 years 2 to 3 years
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Protective Relaying

Poor Average Good
Protective Relay Testing (Mechanical) 2 years 2 years 2 years
Protective Relay Testing (Electronic) 3 years 3 years 3 years
Protective Relay Testing (Digital) 5 years 5 years 5 years
Transfer & Breaker Fail Trip Tests 5 years 5 years 5 years
CT & PT Wiring Integrity Check 5 Years 5 Years 5 Years
Protection Co-ordination Review* 10 years 10 years 10 years
*Please Note: Protection Co-ordination Review requirements may vary according to NERC regions.
HV Circuit Breakers SF6, Bulk Oil, Air Blast, Vacuum

Poor Average Good
Thermal Imaging & Visual 6 months 6 months 1 year
Annual Routine Operational Check 1 year 1 year 1 year
Contact Erosion & Resistance Check 3 years 3 to 5 years 5 years
Detailed Visual & Mechanical Inspection 3 years 3 to 5 years 5 years
Breaker timing checks 3 years 3 to 5 years 5 years
Under voltage Trip & Close Function Testing 3 years 3 to 5 years 5 years
Doble testing 3 years 3 to 5 years 5 years
Hi – Potential Test (Vacuum breaker bottles) 3 years 3 to 5 years 5 years
Oil Screening Tests (Oil circuit breakers) 2 years 2 to 3 years 2 to 3 years
Density meter Tests (SF6 breakers) 3 years 3 to 5 years 5 years
Manufacturers Recommended Maintenance Per Schedule Per Schedule Per Schedule
Gang Operated Air Break Switches

Poor Average Good
Thermal Imaging 6 months 6 months 1 year
Annual Routine Operational Check 1 year 1 year 1 year
Detailed Visual & Mechanical Inspection 3 years 3 to 5 years 5 years
Contact Resistance Test 3 years 3 to 5 years 5 years
Grounding verification 3 years 3 to 5 years 5 years
Substation Instrument Potential Transformers

Poor Average Good
Visual & Mechanical Inspection 3 years 3 years 3 years
Doble Test (Capacitive Voltage Transformers) 5 years 5 years 5 years
Ratio Check 5 years 5 years 5 years
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Substation Instrument Current Transformers

Poor Average Good
Visual & Mechanical Inspection 3 years 3 years 3 years
Ratio Check 5 years 5 years 5 years
Burden Measurements 10 years 10 years 10 years
Isolated Phase Bus Duct

Poor Average Good
Visual & Mechanical Inspection 3 years 3 to 5 years 3 to 5 years
DC Hi-Potential or Doble 3 years 5 to 7 years 5 to 7 years
Underground Cables

Poor Average Good
Termination Thermal Imaging & Visual 1 year 1 year 1 year
DC Hi-Potential 3 years 5 to 7 years 5 to 7 years
Overhead Structures & Transmission Lines

Poor Average Good
Thermal Imaging & Visual 1 year 1 year 1 year
Detailed Line & Post Insulator Inspection 3 to 5 years 5 to 7 years 5 to 7 years
Lightning & Surge Arrestor Testing 3 to 5 years 5 to 7 years 5 to 7 years
Substation Battery Maintenance

Poor Average Good
Float & Equalize Voltage Checks 1 month 1 month 1 month
Electrolyte & Visual 1 month 1 month 1 month
Termination Thermal Imaging & Visual 1 year 1 year 1 year
Impedance Test 2 years 2 years 2 years
Charger & Monitoring Systems Inspection 3 years 3 years 3 years
Battery Load Test (Lead Acid Flooded Cells) 1 year 5 years 5 years
Battery Load Test (Lead Acid VRLA Cells) 1 year 1 year 1 year
Substation Grounding & Fencing

Poor Average Good
Visual Inspection 1 years 1 years 1 years
Step & Touch Potential Gradient Testing 3 years 3 years 3 years
Hazard Signage Review 5 years 5 years 5 years
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Information Sources
NETA Maintenance Testing Specifications for Electric Power Distribution Equipment & Systems.
ANSI/NFPA 70B Section 18-16 (Infrared Inspection)
ANSI C57.104
IEE (UK) Power Series 24 Power System Commissioning & Maintenance Practice
ABB Management Services Service Handbook for Transformers.
FM Global Data Sheet 5-20
NPCC Maintenance Criteria for Bulk Power System Protection
NFPA 70B Recommended Practice for Electrical Equipment Maintenance
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High Voltage Electrical Maintenance Guidelines HVTRAN-01
Transformer Oil Preservation System Inspection
Guidelines for inspection and maintenance of oil preservation system

Periodic inspection of the transformer oil preservation or sealing system is very important to
prevent accelerated degradation of the winding insulation system.
The purpose of the transformer sealing systems is to preserve the oil & cellulose insulation
materials within the tank by preventing the oil from coming into contact with oxygenated air and
moisture. Oxygen in combination with moisture causes greatly accelerated deterioration of the
cellulose materials (paper & pressboard) used for the winding insulation, and will reduce the
dielectric strength of the insulation system. This oxygen-moisture combination will greatly reduce
service life of the transformer.
There are numerous types of transformer preservation systems (most common are the sealed &
free breathing types) used throughout the GDF SUEZ facilities as follows:
Sealed Gas Pressure System (Fig 1)

This system is designed to maintain a constant positive pressure by venting nitrogen gas as the
transformer temperature & oil level rises and re-supplying nitrogen as the temperature and oil level
falls, preventing the ingress of air & moisture
Fig 1
Typical Sealed Gas Pressure System
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Maintenance Recommendation
The gas pressure control components should be verified monthly to ensure that the gas space
pressure remains within the operable pressure range as determined by the manufacturer.
Low pressure alarm function should be confirmed each time the cylinder is changed out and the
pressure switch calibrated every 3 to 5 years.
Important: Do not use any nitrogen that does not meet or exceed ASTM standard D1933 Type III
It must have a dew point of -59 deg C or lower. Investigate & rectify excessive nitrogen consumption
promptly.
Sealed Transformer Without Conservation System

This style of transformer has no conservation system and relies upon constant internal pressure to
prevent moisture and other contaminants from entering the tank. The transformer internal tank gas
pressure is directly related to the thermal expansion of the transformer liquid and varies with
temperature and load.
The sealed type transformer should always be maintained at a slight positive pressure of 3 to 5 psi
If the pressure drops below 1 psi, then nitrogen should be added to ensure ambient air & moisture
does not get drawn into the tank (confirm with manufacturers recommended value).
If the combination pressure/vacuum gage remains constant for a long period under varying
temperature & loading then the gage should be tested for proper operation.
Free Breathing Conservator (Fig 2)

This system allows for the transformer tank to be completely filled with oil and allows for expansion
to take place in the conservator tank, the tank is fitted with an air drier, usually dessicant filled to
absorb moisture, a small exchange of oxygen & moisture takes place with this design and it is not as
effective as other conservation methods.
Fig 2
Typical Free Breathing Conservator
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Check the air drier desiccant at least once per month and change as required.
The conservator Buchholz or gas relay should be tested & verified every 3 to 5 years.
Conservator With Bladder (Fig 3)

This system also allows for the transformer tank to be completely filled with oil and allows for
expansion to take place in the conservator tank, but with the addition of a bladder which completely
seals off the oil from atmospheric air and moisture and allowing the oil to expand freely.
Fig 3
Conservator With Bladder
Check the air drier desiccant color at least once per month and change as required.
The conservator Buchholz or gas relay should be tested & verified every 3 to 5 years.
On newer transformers, a bladder failure relay may be found on or near the highest point of the
transformer. Its purpose is to alarm if the bladder fails and admits air bubbles into the oil.
This device should be tested every 3 to 5 years using the manufacturer’s procedure.
The conservator inspection port should be opened every 3 to 5 years to check for oil inside the
bladder, if oil is found a leak has developed and a new bladder should be ordered. The transformer
can still be operated for a reasonable time without ill effect until the bladder can be replaced.
If dissolved gas analysis tests show a significant increase in atmospheric gasses (oxygen, nitrogen
& carbon dioxide), this is a good indication that the bladder is leaking.
Check the manufacturer’s recommendation for bladder replacement, 15 to 30 years is not unusual.
Information Sources
ABB Service Handbook for Transformers

Doble 2007 Life of a Transformer Conference
Doble Engineering company,(RBILG) – 391 Reference Book on Insulating Liquids & Gases
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Transformer Oil Analysis Interpretation (Mineral Oil Only)
Oil screening & dissolved gas analysis tests are an extremely important diagnostic method for determining the
condition of a transformer, early detection of a pending problem through oil tests is the key to avoiding failure.
Combustible gasses are generated by heat and absorbed by the transformer oil during the progression of an internal
fault, different gasses, levels & ratios of gas are detected as the fault progresses toward failure, careful interpretation
of the DGA test results is important to ensure that any pending problem is identified and help to investigate the
problem from the manufacturer or industry experts is sought.
The three key internal components of a transformer subject to deterioration over time are the paper used for the
conductor insulation, the pressboard materials used for winding & conductor support, & the oil.
Oxygen, moisture & heat cause the cellulose based materials (paper & pressboard) to age rapidly, seriously
reducing the service life of the transformer and reducing the dielectric strength of the insulation system.
It is important to perform the Identified oil screening tests periodically to ensure maximum life of the asset.
DGA (Dissolved gas analysis) Perform every 6 months – 12 month maximum

IEEE Standard C57.104 has been used as a guide to categorize & assess the severity of the DGA test results
Four condition categories are used:
Condition 1 Normal
Condition 2 Modest Concern
Condition 3 Major Concern
Condition 4 Imminent Risk of Failure
The following chart should be compared to the DGA report & used as a guide to determine the need for a course of action to avoid failure
Dissolved Gas Concentration Limits In PPM
Analysis Hydrogen Methane Acetylene Ethylene Ethane Carbon Monoxide Carbon Dioxide Total
H2 CH4 C2H2 C2H4 C2H6 CO CO2 TDCG

*
Condition 1 100 120 35 50 65 350 2500 720
*
Condition 2 101 – 700 121 – 400 36 – 50 51-100 66-100 351-570 2500 – 4000 721-1920
*
Condition 3 701 – 1800 401 – 1000 51 – 80 101-200 101-150 571-1400 4001-10000 1921- 4630
Condition 4 1800 + 1000 + 80 + 200 + 150 + 1400 + 10000 + 4630 +
Notes:
If a significant change of combustible gas level is detected, increase sample rate and monitor trend closely.
If Acetylene trend rate increases by more than 3 ppm– increase oil sample rate immediately and monitor closely.
For new transformers (up to 5 years in service) levels of 5 ppm should be monitored closely and investigated.
* The Acetylene limits are currently under review by IEEE working committee and will be subject to change.
CO2 is not a combustible gas so is therefore not included in the Total (TDCG).
These limits apply to mineral oil only
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Recommended Actions:
Condition 1 – No action required.
Condition 2 - Increase sample frequency to 6 months & investigate root cause of increased gas levels.
Condition 3 - Investigate by interpreting individual gas levels. Plan for outage, resample weekly. If TDCG gas generation rate averages 30ppm
or more per day the fault is active & serious consideration should be given to removing the transformer from service before failure.
Condition 4 – Remove transformer from service and investigate immediately.
Investigation
Approximate temperature of gas formation Probable cause Acceptable IEEE

Limit
Acetylene > 500 C Internal Arcing 35 ppm

Ethylene > 350 C Severe Localized Oil Overheating 50 ppm
Ethane > 250 C General Oil Overheating 65 ppm
Methane > 150 C Overheating or Corona Activity 120 ppm
Hydrogen > 150 C Corona or Partial Discharge Activity 100 ppm
Carbon Monoxide > 100 C Cellulose Overheating 350 ppm
The most important gas to note is acetylene. This gas requires arcing for its production and levels above 35 ppm should be investigated. Ethane
and ethylene are next in order of concern and indicate an intense hot spot. If an elevated level of carbon monoxide is also detected, paper
insulation is involved in the hot spot. Elevated levels of methane without correspondingly high values of ethylene and ethane indicate a hot spot
of less intensity. The presence of a high level of carbon monoxide would again indicate that paper insulation was involved. Hydrogen indicates
that corona is present in the oil. Corona results from the partial breakdown of oil when it is electrically stressed to a critical value. Hydrogen
theoretically should be a key gas in maintenance analysis but, in practice, the level of hydrogen varies so widely from test to test that its
usefulness is obscure.
Dielectric Strength Perform every 12 months along with DGA sample
ASTM Test Method D-877 or D-1816:

For transformers operating at 287.5 kV and higher minimum acceptable breakdown voltage is 30 kV. at 0.40” gap
For transformers operating at 287.5 kV and lower minimum acceptable breakdown voltage is 26 kV. at 0.100” gap
The dielectric strength is a measure of the oils ability to maintain satisfactory insulation levels between the transformer components.
If dielectric strength falls below these numbers, retest and confirm, then oil should be reclaimed or replaced.
IFT (Interfacial tension) Perform every 12 months along with DGA sample
ASTM D-791 Test
Clean oil will typically be between 40 to 50 dynes per centimeter
Low IFT is usually a good indicator of contamination of oil from oxidization products & other small particles which will lead to sludge build up.
It is recommended that the oil be reclaimed when the reading falls below 25 dynes per centimeter
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Acid Number Perform every 12 months along with DGA sample

ASTM D-644 Test
The acid number is the amount of potassium hydroxide (KOH) in milligrams (mg) required to neutralize the acid in 1 gram of oil,
the higher the acid number, the more acidic the oil.
High levels of acidity will attack cellulose insulation & accelerate insulation degradation.
It is recommended that the oil be reclaimed when the acid number reaches 0.20mg KOH/g.
PF (Power Factor) Perform every 12 months along with DGA sample
ASTM D-924 Test or Doble Method

Power factor indicates the dielectric loss (leakage current) of the oil.
A higher power factor indicates deterioration and contamination by products such as water, carbon or other conductive materials.
The Doble recommended in service limit is less than 0.50% at 25 deg C

If the power factor is greater than 1.0% at 25 deg C – the oil must be reclaimed or replaced, or failure may occur.
Water Content Perform every 12 months along with DGA sample

ASTM D-1533 Test
For transformers operating below 69 kV maximum acceptable level of moisture is 35 ppm
For transformers operating below 288 kV maximum acceptable level of moisture is 25 ppm
For transformers operating above 288 kV maximum acceptable level of moisture is 20 ppm
Increased moisture levels will significantly shorten the life of the transformer.
Furan Analysis Perform every 3 to 5 years along with DGA sample
ASTM D-5837 Test

Furanic compounds are generated by thermal decomposition of cellulose materials such as insulating paper, pressboard & wood,
These compounds dissolve in oil & serve as indicators of insulation degradation.
A ratio of CO2/CO below 7 may be an indication of cellulose degradation hence a furan analysis of the oil should be performed.
Transformers with furan levels greater than 250 ppb should be investigated
PCB Analysis Perform as required
ASTM D-4059 Test

Polychlorinated biphenyls (PCB) are a controlled hazardous substance found in transformer insulating fluids produced before the1980’s.
Each site should have a baseline test for PCB content of each oil filled transformer. Additional testing is required prior & following any
processing of the transformer fluid, this includes but is not limited to, reclamation, drying, degasification or refilling/topping with oil.
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Information Sources
IEEE Standard C57.104

ASTM Standard D-877 & D-1816
ASTM Standard D-791
ASTM Standard D-644
ASTM Standard D-924
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Exercising Of Oil Filled Transformer Off Load Tap Changer
Purpose
The off load tap change switches fitted to oil filled transformers can lead to failure if neglected or
overlooked during maintenance inspections, most GDF SUEZ GSU & station service
transformers are fitted with manually operated off load tap changers to adjust voltage ratios when
the need arises.
In many cases these switches are seldom used and the electrical contacts are prone to
oxidization from dissolved gasses in the transformer oil, the problem is more prevalent in heavily
loaded or older transformers.
To prevent this oxidization from accumulating the manually operated switch should be cycled
periodically. By design, most tap switch contacts use a wiping action which will remove surface
oxidization when cycled.
Before Cycling Tap Changer

Transformer must be off line & de-energized.
Note & record the selected tap position used before moving.
Cycling the Off Load Tap Changer

Every year the manual of load tap change switch should be cycled 4 to 6 times through the entire
tap range, be sure to return the switch to its original setting and ensure that the switch is properly
and securely seated in position.
Always lock the manual operating switch where provisions are made to do so.
Cautionary Note: For aged transformers with off line tap change mechanisms that have not been
manipulated for a long period of time, it is advisable to perform a TTR test (turn to turn ratio) at
each tap position before returning to service.
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Oil Filled Transformer Detailed Visual Inspection
Purpose
A thorough detailed visual inspection should be conducted every one to two years preferably prior
to a major outage so that any identified defects can be corrected promptly.
A checklist serves as a good reminder to ensure that all areas have been covered.
This information should be used as a guide only. Refer to the equipment manufacturers
recommended maintenance for detailed inspection instructions.
Preliminary Work
Perform thermal imaging survey of current carrying components prior to shut down. Refer to
guideline HVTHMG-01 for thermal imaging of electrical equipment.
Perform DGA & oil screening tests prior to outage to identify possible defects before shutdown.
Refer to guideline HVTRAN-02 for transformer oil analysis interpretation.
Before Inspection
Transformer must be off line & de-energized.
A tail board meeting should be held prior to inspection to discuss the inspection task
A proper work permit & grounds must be in place & issued prior to any inspection of HV
components, fall arrest equipment should be used where required.
Conducting the inspection
Control Cabinet & Wiring

Check all CT connections where accessible, control wiring terminations, power supply breakers
for any signs of looseness, corrosion, damage or overheating, ensure heaters are functioning.
Oil preservation system

For conservator type systems, look for oil leaks at sealing surfaces, check condition of dryer &
dryer desiccant for saturation or corrosion.
Check oil level on the indicator gage, compare the indicated temperature on the conservator level
gage is reading the same as the top oil temperature gage, if not one of the gages is incorrect.
For nitrogen systems, check to see proper grade of nitrogen is being used, inspect flexible lines
for cracks, leaks or UV damage, ensure regulator set values are within manufacturer
recommended operable range and that the pressure gage is functioning.
Refer to guideline HVTRAN-01 for more detail on oil preservation system.
Lubrication
Lubricate cooling fans & circulating pumps per manufacturers instructions.
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Bushings
If the bushings are fitted with sight glasses or level gages, confirm that level is within correct
range. Clean & visually inspect bushings for external damage or tracking.
Tracking develops in the form of streamers on the surface of the insulator that has an appearance
similar to tree branches, if the tracking can not be cleaned off without damage to the insulator
then consult with the manufacturer.
Inspect bushing termination connector for looseness and signs of overheating, if bushing
termination has been disconnected for maintenance purposes then torque values must be
checked when re-connecting, this is extremely important where aluminum, brass or bronze
hardware are used.
Lightning & Surge Arrestors

Visually check for cleanliness, signs of overheating, cracks or chips in the porcelain that will allow
moisture to enter,
Transformer Tank & Cooling Radiators

Check for excessive corrosion and oil leaks, pay close attention to all flanges, gaskets threaded
fittings and valve packing. Corrosion must be thoroughly cleaned, primed & painted, substantial
leaks should be assessed & rectified promptly.
Ensure that all radiator isolating valves are fully open.
Check frame grounding connectors for tightness & integrity.
Cooling Fans
Inspect fans to ensure that blades are clean
Manually test operate fans and ensure smooth operation & correct rotation.
Ensure fans are left in auto operation mode when the transformer is returned to operation.
Winding & Oil Temperature Indications

Check & record the winding & oil temperature drag hand indications, then reset.
The maximum acceptable winding operating temperatures are as follows:
IEEE C57.12.00 (RISE)

Max. Average Winding = 55*/65* °C (*-refer to manufacturers nameplate value)
Max. Winding Hot Spot = 80 °C (when fitted)
IEEE C57.91 (TEMPERATURE)

Max. Average Winding = 105 °C
Max. Winding Hot Spot = 120 °C (when fitted)
If temperatures exceed these levels the cooling system must be investigated further.
The relationship between the measured top-oil temperature and the average winding temperature
varies somewhat from design to design but usually the top oil-temperature will be 5 to 10 deg C
lower than the average winding temperature.
The winding temperature indicator, if one is provided, will usually read the winding's hottest spot
temperature, which is from 5 to10 deg. C higher than the average winding temperature.
Remember that all measured temperatures must have the ambient temperature subtracted to
come up with the temperature rises referred to on the nameplate and in the standards.
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If temperatures under similar load conditions are showing an increase when ambient
temperatures are subtracted, there may be thermal problems developing in the transformer and
further investigation, including winding resistance measurements and dissolved gas analysis,
should be performed and compared with prior tests.
Prolonged operation at over-temperature results in accelerated deterioration of the oil and
insulation, the reduction in life expectancy of the transformer will be proportional to the over
temperature condition. For every 6-8°C rise in temperature above design value, the life
expectancy of the insulation may be reduced by as much as 50%.
Pressure Relief Device & Sudden Pressure Relay

The sudden pressure relay is very sensitive to internal pressure changes, and is an important
protective device. To functionally test the sudden pressure relay, slowly close the isolating valve,
leave it closed for a few seconds then reopen the valve quickly this should activate the alarm.
Inspect the pressure relief device if the transformer has a conservator type oil preservation
system & oil is present around the relief device then either the gasket or the device itself is
probably leaking & should be replaced.
Verify the alarm & trip circuit by manually operating the switch. Check the transformer
manufacturer’s manual for specific information on the pressure devices.
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Power Factor Testing Of Transformer Windings & Condenser Bushings
Purpose
Power factor testing is a non destructive AC test which measures capacitive & resistive current
flow through the transformer winding insulation system, oil, & bushings.
The test is used to assess the dielectric condition of the transformer components and is a very
reliable method for determining dryness and integrity of the insulation system.
The most common equipment used for this testing is manufactured and developed by Doble
Engineering hence the term “Doble testing”.
Transformer (Overall tests)

Power factor testing is typically broken down into three groups:
CH measures the dielectric between the high voltage winding & ground.
CL measures the dielectric between the low voltage winding & ground.
CHL measures the dielectric between the high & low voltage windings.
The test results should be compared to factory test data, or commissioning data to ensure
stability and consistency in test readings.
The power factor of a healthy mineral oil filled transformer should not exceed 0.5% pf at 20ْ C.
A change in capacitance value of +/- 5% from the factory or commissioning data would indicate a
developing problem, further testing and investigation will be necessary. A change of +/- 10%
would warrant removal from service and immediate investigation.
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Bushings Tests
A large number of high voltage bushing failures are attributed to moisture ingress, so periodic
testing is of great importance. Most HV bushings used at GDF SUEZ facilities are oil filled
condenser type bushings and are fitted with capacitance test taps.
A capacitance measurement to determine bushing losses is made from the top of the bushing to
the test tap, this is referred to as the C1 measurement, a second measurement referred to as C2
is made from the test tap to ground.
All condenser bushings are supplied with factory test data, if this is not available refer to table 1,
or preferably, contact the bushing manufacturer for maximum allowable power factor values.
Investigate any bushing that has a capacitance deviation of 10% or more from nameplate or
manufacturers published values.
For bushings not fitted with test taps a hot collar test measuring watt loss may be used as an
alternative, refer to manufacturers published information for maximum allowable values.
For detection of partial discharge or corona, a power factor tip up test is used, the tip up test is
the percentage difference in power factor when compared at minimum & maximum test voltage.
Typical Oil Filled HV Bushing Construction
1. Cork or nitrile gasket.
2. Oil sight glass.
3. Porcelain insulator body.
4. Nameplate data (will have C1 & C2 values).
5. Power factor test tap.
6. Mounting flange & ground sleeve assembly.
7. Paper foil capacitor core.
8. Flange core potting compound.
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Before Testing
Obtain factory test data or commissioning test data as a reference base line.
Verify the test set is calibrated and functioning properly.
Verify the test set-up is correct.
Be sure all test grounds are securely connected
Do not test spare bushings while in the crate.
Recommended action to take if power factor tests results are abnormal
It is not uncommon for the test results in the field to differ slightly from the manufacturer
nameplate values, this may be due in part to differences in the test equipment used, a significant
difference may indicate an issue with the bushing, if differences of more than 10% of the
nameplate values are found then contact the bushing manufacturer for further guidance.
For higher or lower than nameplate C1 values, check the following:

 Ensure the bushing porcelain surface is clean and dry
 Check condition of transformer oil for contamination & moisture
 Consult bushing manufacturer for further guidance & plan to change bushing.
For bushings equipped with C2 test taps
If you experience significantly higher C2 values than manufacturer nameplate value while bushing
is tested in the transformer, try the following:
 Clean & dry the bushing porcelain surface.

 Clean & dry the bushing voltage tap area.
 Check condition of transformer oil for contamination & moisture.
 Isolate the bushing flange from transformer tank, if reading is still high, consult bushing
manufacturer & prepare to replace bushing.
If you experience significantly lower or negative C2 values:
 Check condition of transformer oil for contamination & moisture.

 Clean & dry the bushing porcelain surfaces. (& inside the tank if problem still exists)
 Consult bushing manufacturer if low reading persists
Note: Always be sure to replace C2 test tap grounding covers after testing, neglecting to do so
may lead to bushing failure.
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The following table gives an example of typical and questionable power factor values for bushings
from several different manufacturers and of various types.
Table 1. Typical Bushing Power Factors
Manufacturer Type Description Typical PF % Questionable PF % Comment

Through
GE A 3% 5% Type S no form letter
Porcelain
GE A High Current 1% 2%
Flex cable
GE B 5% 12% Type S form F, DF & EF
compound filled
Oil-filled upper
GE D 1.0% 2.0%
portion, sealed
GE F Oil-filled, sealed 0.7% 1.5%
Oil-filled upper
GE L 1.5% 3%
portion, sealed
Oil-filled upper
GE LC 0.8% 2.0%
portion
Oil-filled
GE OF expansion 0.8% 2.0%
chamber
Force C & CG
GE S rigid core, 1.5% 6%
compound filled
See special instructions for
GE U
type U
Epoxy Resin
LAPP ERC Core, plastic or 0.8% 1.5%
oil-filled
Typical C2 PF for older
PRC, Paper Resin PRC design range from 4-
LAPP 0.8% 1.5%
PRC-A Condenser Core 15% due to injected
compound
ODOF,
Change of 22% of
Ohio Brass class G 1.0% – 5.0%
nameplate value
&L
Ohio Brass S,OS,FS 0.8% 2.0%
Westinghouse RJ Solid Porcelain 1.0% 2.0%
Westinghouse D Semi Condenser 1.5% 3.0%
Bushings on OCB &
Westinghouse 1.5% 3.0% Instrument transformers
92kV to 139kV
Bushings on power &
distribution transformers of
Westinghouse 1.0% 2.0%
all ratings except O, O-A1 &
O+C
Modern
Condenser 0.25 – 0.5% 0.5 – 1.0% (e.g. ABB type A, O+C)
Bushings
Information Sources
Doble Testing Power Apparatus Bushings, 2004 International Conference.

LAPP (PCORE).
ABB Service Handbook for Transformers.
Doble 2007 Life of a Transformer Conference.
FM Global
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Transformer Instrumentation & Gauge Calibration
Purpose
Transformer instrumentation & gauge calibration should be performed every 3 to 5 years to

ensure that level, temperature and pressure indications and alarms are accurate and that cooling
fan set values are functioning as designed.
There are many types & styles of transformer instrumentation available, this document will cover
only the most commonly used transformer instrumentation types.
Top Oil Thermometers
These are typically sealed spiral bourdon tube dial indicators with liquid-filled bulb sensors. The
bulb is usually fitted inside a thermo well, which penetrates the tank wall into oil near the top of
the tank. As oil temperature increases, the bulb, liquid expands, which expands the spiral tube.
The tube is attached to a pointer that indicates temperature. The instruments have multiple
electrical contacts at pre-set temperatures to trigger alarms, start cooling fans and also trip the
transformer if necessary on temperature rise. These devices should be calibrated by following the
manufacturer’s instructions every 3 to 5 years, cooling system operating, alarm and trip points
should be checked and recorded at this time.
Oil & Winding Gauges (Ennis GSU)
Winding Temperature Thermometer
These devices are intended to indicate hottest spot in the winding based on the manufacturer’s
heat run tests. At best, this device is only accurate at full rated load and then only if it is not out of
calibration. They are only simulated measurements, there is no temperature sensor imbedded in
the winding hot spot. The winding temperature thermometer well is usually located near the top of
the tank. Most winding temperature thermometers are load compensated by a current driven
heater coil either inserted into or wrapped around the thermo well. The compensating current is
proportional to load & warms the thermo well to provide an approximation of winding temperature.
These devices should be calibrated by following the manufacturer’s instructions every 3 to 5
years, and if used for cooling system operation, verify the operation & alarm points.
The winding & oil temperature instruments should be checked with an accurate oil bath or thermal
calibration oven. Pay particular attention to the upper temperature range at which the transformer
normally operates (50 °C to 80 °C). If the measurement error is greater than 5°C
Then calibrate or replace the instrument.
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Hydran Monitors
These devices are used to monitor dissolved gas levels within the transformer, they are not
capable of discerning between the types of gasses generated by an overheating transformer,
but they do provide a composite gas value which will alert the operator to an abnormal condition
and prompt an investigation, they are highly reliable intelligent devices with built in internal
diagnostics that reduce the need for maintenance.
Calibration can be checked once per year by taking a dissolved gas analysis sample directly from
the hydran sampling port & comparing against the composite ppm value.
Alarm functions and analog output can be checked once per year by using the hydran host
software to enter test values.
Hydran 201Ti
Level Indication Gauges
These devices should be periodically checked to ensure they are functioning properly & can
easily be verified against a thermal image while the transformer is still in service to ensure the
proper oil level is maintained. If fitted with a low level trip function, this should be tested off line.
Qualitrol level gauge
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Sudden pressure relay
These devices are usually used on sealed transformers and are designed to protect the
transformer from further damage during a fault condition by reacting to a sudden increase in
internal pressure and tripping the protection to isolate the transformer from the energy source
within milliseconds.
The relay is usually a very sensitive bellows operated device that can be tested by using a small
squeeze type bulb to verify the alarm and trip points, (Qualitrol manufacture a field calibration kit
013-01 for this purpose) review the manufacturer’s manual for calibration procedure and details.
this check should be performed every 3 to 5 years.
Qualitrol rapid pressure rise relay
Buchholz Relay
This relay is only used on transformers with conservators, it is fitted on the interconnecting piping
between the conservator and transformer. It is designed to operate & trip the transformer if a
sudden high speed surge of gas & oil occurs such as during rapid expansion during a fault
condition, the relay also serves as a low oil level trip if the conservator is drained.
Buchholz gas/oil relay
The Buchholz relay should be tested every 3 to 5 years following the manufacturer’s procedure.
Ensure alarm points and trip functions are correctly verified.
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Pressure Switches.
Nitrogen blanketed transformers are usually fitted with low pressure switches to activate an alarm
if the nitrogen pressure drops below the recommended minimum, these switches should be
checked for calibration every 3 to 5 years.
Pressure gauges
Pressure gauges fitted to sealed transformers should be checked every 3 to 5 years, the gauge is
used to ensure that a positive pressure is maintained in the tank to prevent moisture from being
drawn in, if the pressure does not vary with temperature swings, this is a good indicator that it is
not working.
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High Voltage Electrical Maintenance Guidelines HVTHMG-01
Thermal Imaging of Electrical Equipment
Recommended thermal image scans of substation equipment.
Periodic scanning of the current carrying components can reveal potential problems long before
failure, each substation should be inspected at least once per year for defects.
New equipment should be monitored during commissioning and a follow up inspection 3 months
later.
Before Testing
Caution: Review arc-flash safety procedures before removing any covers and observe safe limits
of approach, a safety person should be present where required to ensure that proper procedures
are adhered to.
Thermal imaging is best performed outdoors when the weather is overcast or dark.
The equipment should preferably be at full operating load, but no less than 40% as heating is
typically related to the square of the current.
Record loading and ambient conditions for future reference.
Carefully observe the temperature differences between components of each phase and record
any potential problems for follow up.
Typical problem areas to observe are bolted bus and cable connections, gang operated air break
Isolator switches, transformer bushing connectors, Circuit breaker bushing connectors, and any
other current carrying components.
Refer to the following table produced by the National Electrical Testing Association as a guide to
determine a course of action.
Thermographic Survey
Suggested Actions Based on Temperature Rise
Temperature difference (T) Temperature difference (T)
based on comparisons between based upon comparisons
similar components under between component and ambient
similar loading. air temperatures. Recommended Action
Possible deficiency; warrants
1ºC - 3ºC 1ºC - 10ºC
investigation
Indicates probable deficiency; repair
4ºC - 15ºC 11ºC - 20ºC
as time permits
Monitor until corrective measures can
-- -- -- 21ºC - 40ºC
be accomplished
>15ºC >40ºC Major discrepancy; repair immediately
This table is intended as a guide only and each situation will need to be carefully assessed before
arriving at a conclusion.
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The following examples are from actual GDF SUEZ facilities equipment and demonstrate the
importance of thermal imaging.
*>119.5°F
115.0
110.0
105.0
100.0
95.0
90.0
Spot 1 Diff. 1 Spot 2
85.0 119.6 34.0 85.6
80.0
75.0
70.0
65.0
60.0
*<55.5°F
Fig 1
Fig 1 is a classic example of indirect heating found on an oil filled pad mounted transformer
Notice the source of heat is not from the bushing external connection, but from within the
transformer tank, the internal bushing lead was loose and conducting heat externally.
Left undetected this problem would likely result in catastrophic failure.
*>149.0°F
Defective Bushing
140.0
130.0
120.0
110.0
100.0
90.0
80.0
70.0
60.0
50.0
*<45.1°F
Fig 2
Fig 2 is an example of a GSU failing high voltage oil filled condenser bushing an outage was
scheduled and problem was rectified before failure due to early detection by thermal imaging.
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>248.0°F
240.0
220.0
200.0
180.0
160.0
140.0
120.0
100.0
80.0
60.0
40.0
20.0
0.0
<-4.0°F
Fig 3
Fig 3 shows a seriously overheated connection at the point of failure on a small distribution
transformer used to supply critical auxiliary control systems.
Maintenance recommendations
Thermal imaging should be conducted prior to and following substation routine maintenance
outages for any heating problems.
Scan all post insulators, surge arrestors, bolted hardware, breaker & transformer bushings,
Transformer tanks & bus ducts, air break switches, cable terminations, instrument transformers.
Unusually high external temperatures or unusual thermal patterns of transformer tanks indicate
potential problems inside the transformer such as low oil level, circulating stray currents, blocked
cooling, loose shields, tap changer problems, etc. if any anomalies are noted seek additional help
to analyze the problem.
Information Sources
NETA Maintenance Testing Specifications for Electric Power Distribution Equipment & Systems.
ANSI/NFPA 70B Section 18-16 (Infrared Inspection)
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High Voltage Electrical Maintenance Guidelines HVPROT-01
Protection Relay Testing
Purpose
The purpose of the protection relay system is to prevent or limit thermal, mechanical or electrical
overstressing damage to the electrical equipment that can be caused by grid faults, generator
internal faults, incorrect operating faults, or other equipment failures.
Protections when properly designed and maintained, should be coordinated to quickly isolate the
faulted area or equipment while preventing nuisance tripping or mis-operations.
Any mis-operation of a protection relay should be properly documented and investigated.
Mandatory NERC Standards

All NERC registered GDF SUEZ generating facilities in the US & Canada are obligated to comply
with North American Electricity Reliability Council (NERC) Reliability Standards.
NERC has 10 individual regional reliability councils, each reliability council has its own
geographical area of control, as identified on the map below, and has its own set of reliability
standards that mandate the policy and requirements for protection relay testing.
The standards vary from area to area and are readily available from the individual reliability
organization web sites. The applicable standards should be carefully studied to ensure that all
testing and relay settings comply with the standard requirements.
Failure to comply could result in financial penalties.
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Current NERC Standard PRC-005-1
Transmission & Generation Protection Systems Maintenance & Testing

This standard has been in effect since May 1st 2006 and is very vague and states the following:
R1. Each Transmission Owner and any Distribution Provider that owns a transmission Protection
System and each Generator Owner that owns a generation Protection System shall have a
Protection System maintenance and testing program for Protection Systems that affect the
reliability of the BES. (Bulk Electrical System) The program shall include:
R1.1. Maintenance and testing intervals and their basis.
R1.2. Summary of maintenance and testing procedures.
The following Suez created procedure can be tailored by each facility to meet the requirements of
NERC Standard PRC-00501.
Maintenance & Testing Intervals & Their Basis
Protection relays can be broken down into three categories,
Electromechanical
This type of relay has moving mechanical elements that can bind wear or fail over time therefore
requires more frequent calibration and function checks.
For critical or network system protections these relays should be calibrated every two years.
Electronic
Has solid state components that can fail undetected or drift from calibrated values over time
These relays are typically more reliable than electromechanical types.
For critical or network system protections these relays should be calibrated every three years.
Microprocessor Based
These relays use digital electronics and typically have continuous self checking and diagnostic
capabilities along with redundancy and are therefore highly reliable
For critical or network system protections these relays should be calibrated every 5 years
Relays that are operating in harsh environments, aging, subject to severe or frequent fault
operations, should be carefully reviewed and the testing frequency should be shortened.
Specific calibration schedules may also be required by your local utility. The utility connection
agreement should be reviewed and compared with the CEMG 071007 and the more stringent
schedule should be followed.
Electromechanical & Electronic generator under frequency relays must be calibrated every 2
years to meet regional reliability standards.
If the relay manufacturers recommended calibration interval is shorter than stated above then you
must follow the shorter schedule.
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Maintenance Testing Procedures
Safety and arc flash procedures should be strictly observed, as the potential for injury & damage
is present, relay testing should be performed by experienced and trained personnel only.
Before calibration, the relay setting data must be reviewed and compared to the official relay
setting documentation to ensure that the correct and most up to date information is used.
Previous testing results should also be reviewed to reveal any possible errors.
The relay test set and any test equipment used must have a valid certification of calibration, this
is very important as all calibrations will be out of tolerance if the test equipment used is not
accurate.
It is preferable to perform testing with the equipment out of service & off line, a log should be kept
of any disconnections made or blocking switches opened for the purpose of testing, and the log
should be reviewed and signed off following completion of the work to ensure that all wiring &
blocking switches have been returned to the pre-test condition.
In all cases, the manufacturers recommended testing procedure for each protection function
should be followed and each relay function tested individually to ensure that the tripping or
blocking function follows through to the isolating device accordingly.
Review the one line protection, and DC control drawings to determine the exact function of each
trip and if any trips to other zones exist. To avoid unnecessary tripping of utility breakers outside
the GDF SUEZ facility or activating breaker fail schemes, the trip circuits should be blocked
accordingly.
When testing the tripping functions be sure to check that every contact from every relay in the
circuit will trip the breaker and prime mover as intended. Check that all targets, seal in circuits,
reset circuits and alarms function as designed.
Testing of pilot wire or remote operated tripping schemes should be coordinated with your local
utility or controlling authority every two years in order to ensure that the remote tripping functions
are properly tested from both the GDF SUEZ facility and the remote protection point.
An accurate record of each relay function & calibration should be kept & should include the serial
numbers of any test instruments used for the calibration, as found & left values & observations or
comments that may be of future use.
Information Sources
IEEE 242 Recommended practice for protection & coordination of industrial power systems
NETA Maintenance testing specifications for electric power distribution equipment & systems
IEE Power Series 24 Power System Commissioning & Maintenance Practice
NPCC A-4 Maintenance Criteria for Bulk Power System Protection
3 of 4
Critical elements to ensuring compliance with NERC PRC-005
Protection Systems Maintenance & Testing
1. The protections must be treated & tested as a system.

All DC circuitry must be checked, this includes but is not limited to; verifying the integrity and
continuity of all DC battery supply voltages, auxiliary relays, tripping relays (94), lockout
relays (86).
Each control path circuit that provides a trip must be operated to prove they perform as
designed.
Each breaker trip coil must be test operated at least once to prove functionality.
2. All relay functions must be tested, this includes all IEEE designated device functions (50, 51,
81, 87, 27, etc.) Breaker failure schemes, pilot wire schemes, & transfer trip functions should
also be tested and may require co-ordination with your transmission service provider in
advance.
All enabled tripping functions of a multi function microprocessor based relay must be checked
and documented as individual functions.
3. Battery systems must be load tested within the prescribed period.

(Refer to the GDF SUEZ HV Maintenance Guidelines for detailed information).
4. Documentation should be complete & accurate, it must include the relay identifier, IEEE
device function, the setting values, & as found values of each relay, date tested, date of last
calibration, and the equipment protected. The documentation should also include any noted
observations, deviations or deficiencies. The relay test equipment Identifier should be
recorded on the form along with the relay accuracy acceptance criteria.
4 of 4
High Voltage Electrical Maintenance Guidelines HVCB-01
HV & MV Circuit Breakers
Purpose
Periodic maintenance of the facility high voltage circuit breakers is an important task. The breaker
is a fault clearing device and is designed to interrupt high levels of current and safely isolate the
plant equipment when required to do so during fault conditions. In order to ensure reliable
performance there are key maintenance items that need to be addressed. There are many
different breaker designs and types, this document will cover the most commonly used at GDF
SUEZ facilities. Each facility should review its own procedures to ensure that all utility connection
agreement maintenance requirements are met. In some cases, more extensive maintenance may
be required. In all cases, the manufacturer’s maintenance recommendations should be followed
within reason and adhered to. Site specific procedures will need to be created for each style of
breaker to be worked on.
Safety
Extreme care and caution should be exercised when working with any high voltage or stored
energy breaker, the potential for injury and damage can be very high if the manufacturer’s
instructions and recommendations are not followed when working on these breakers.
Personnel working on this type of equipment must be fully knowledgeable of the hazards
associated with these breakers. The presence of mechanical stored energy, high & low voltage, &
high pressure air, oil & sulfur hexafluoride gas are just a few of many hazards to consider before
proceeding to work on these circuit breakers. A job safety analysis should be conducted to
ensure that no potential back feed from control or power sources exist and all aspects of safety
have been covered. Proper lock out tag out and grounding procedures should be established.
Types of HV Circuit Breakers
Voltage classifications
Low voltage: Less than 600 Volts

Medium Voltage: 600 to 15,000 Volts
High Voltage: 15,000 to 230,000 Volts
Extra High Voltage: Greater than 230,000 Volts
The most common HV breaker type found at the Suez facilities is the SF6 (sulfur hexafluoride)
gas insulated breaker. Other HV breaker types are Bulk Oil, Air Blast & Vacuum.
Vacuum breakers are typically only used for applications less than 40 kV.
Breaker operating mechanisms are usually one of three types, spring operated, hydraulically
operated, or pneumatically operated. The mechanism is comprised of the electrical & mechanical
components required to charge the closing springs with sufficient energy to close the breaker and
store opening energy for tripping the breaker.
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SF6 Circuit Breakers
SF6 gas has excellent dielectric and arc quenching properties and has rapidly become the
preferred choice for high voltage breaker applications over the last few decades.
Areva 145 kV 2000 A rated 3 pole SF6 dead tank breaker (Windsor)
SF6 Circuit Breaker Maintenance
3 Monthly – Conduct a visual inspection of the breaker while in operation. Listen for unusual
electrical noises, (corona). Check that SF6 gas pressure gage is within the manufacturers
recommended operable range, in cold weather ensure tank heaters where fitted are functioning.
Visually check the operating mechanism & control cabinets for loose or damaged hardware,
water ingress or corrosion damage, check oil level of damping devices.
For hydraulic operated stored energy breakers check for oil leaks & record the number of pump
cycle operations. Excessive pump cycling may be caused by internal bypassing of the hydraulic
oil system & should be rectified as soon as possible.
ABB 500 kV Hydraulic Operated SF6 Breakers (Hot Spring)
2 of 11
ABB HCB-8 Hydraulic Operating Mechanism (Choctaw)
Yearly – Thermal imaging survey of breaker & connections (see guideline HVTHMG-01).
Visual mechanical inspection of operator mechanism, frame hardware, grounding connections,
control cabinets & wiring.
Cycle the breaker open & closed while observing the operation, pay close attention to the tripping
mechanism latches and operating coil assemblies, any wear or friction may result in delayed or
failed tripping. Listen for any unusual noises from the charging and operating mechanism.
Check & verify oil levels on hydraulic operated or dampened breaker mechanisms.
Two Years - Operation of the breaker trip, block & close functions should be tested through from
the protection tripping relays.
This is a NERC reliability standard requirement for HV & EVH systems.
Lubricate the operating mechanism and inter-phase linkages (where used) with approved
lubricants as directed by the manufacturer.
Five Years – A thorough inspection of the operating mechanism should be conducted.

Inspect all moving assemblies closely for looseness, friction, bent, broken or worn parts, missing
nuts, bolts, pins or retainers. Inspect DC charging motor or pump motor brushes for wear.
For hydraulic operating mechanisms, observe the condition, color & level of the hydraulic oil.
Record the pump up time of the pressurizing pump from initiation to auto shut down, compare to
manufacturers data, if time is excessive the pump may be worn or strainer restricted, or the
hydraulic circuit may be bypassing internally.
The low fluid pressure alarms & trip/close blocking functions should be tested and confirmed to
ensure the breaker cannot be operated. This will prevent the breaker from only partially opening/
closing or operating at low velocity leading to failure.
Breaker contact erosion and resistance measurements should be checked on each pole. Higher
than normal contact resistance may be an indication of excessive contact erosion, contamination,
loose connections or defective bushing connections, any of which will lead to excessive heat
generation under load. Refer to the commissioning documentation and manufacturers instructions
for comparison and maximum allowable tolerances.
Power factor testing of the bushings and & Insulation resistance of each phase to ground should
be performed and results recorded with the breaker in both the open & closed positions.
The power factor readings should be within 10% of the factory test or nameplate data.
Insulation resistance should be measured for one minute using Table 1 to determine test voltage
and minimum acceptable insulation resistance values phase to phase and ground.
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Breaker Nominal Rating DC Test Voltage Minimum Resistance

15 kV 2.5 kV 5,000 MΩ
25 kV 5.0 kV 20,000 MΩ
35 kV 15 kV 100,000 MΩ
46 kV 15 kV 100,000 MΩ
69 kV and higher 15 kV 100,000 MΩ
Table 1. Minimum Acceptable Insulation Resistance
Breaker timing tests should be conducted using a motion analyzer to ensure opening & closing
times are within design tolerances. The timing tests will reveal defects such as weakened
operating springs, sluggish operating mechanism, defective dashpot or damping mechanism &
contact bounce. Ensuring that the timing & trip functions are correct, will give confidence the
breaker will operate as designed to clear fault conditions.
All HV & EHV breakers should be fitted with two independent trip coils, each coil should be tested
for minimum pick up voltage, and the results compared to manufacturers test data, any significant
increase in voltage required to trip the breaker as compared to factory testing, would suggest a
problem, such as excessive friction of the trip operating mechanism or shorted turns in the
tripping coil, these conditions should be investigated.
Verification and confirmation of the SF6 density meter alarms and open/close blocking functions
should be confirmed. The breaker should not be permitted to operate open or closed when the
Sf6 density has dropped below the safe operation level; the breaker fail protection scheme should
operate the surrounding breakers to isolate the defective breaker.
Insulator bushings should be inspected & cleaned as necessary, more frequent cleaning will be
required when operating in harsh or dusty environments.
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Bulk Oil Circuit Breaker (OCB) Maintenance
3 Monthly –Perform a general visual inspection of the breaker and control mechanism cabinet.
Inspect the operating mechanism & control cabinets for loose or damaged hardware, water
ingress or corrosion damage.
Look for signs of oil leaks, listen for unusual electrical noises, (corona). Check oil level gages &
sight glass indications in both tank and bushings (where fitted) for correct level.
40 kV rated OCB
And control cabinets.
mechanism latches and operating coil assemblies.
Two Years – Perform the following oil screening tests: Dielectric moisture & clarity.
Dielectric should be minimum 26 kV using ASTM D877 standard
Moisture should be not more than 50 ppm using ASTM 1533 standard
Clarity should be clear & bright with no signs of carbon or sludge using ASTM 1500 standard
If the oil does not meet the test requirements it must be reclaimed or replaced.
Operation of the breaker trip, block & close functions should be tested through from the protection
tripping relays. This is a NERC reliability standard requirement for HV & EVH systems.
Test each trip coil for minimum pick up voltage, and compare results to manufacturers test data,
any significant increase in voltage required to trip the breaker as compared to factory testing,
would suggest a problem, such as excessive friction of the trip operating mechanism or shorted
turns in the tripping coil, these conditions should be investigated.
Inspect insulator bushings & clean as necessary
Three Years – A thorough inspection of the operating mechanism should be conducted.
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Lower oil tanks for visual internal inspection, check contacts for erosion or pitting. Contact
pressures and alignment should also be checked. Inspect all bolted connections and contact
springs for looseness, ensure tanks are free from sludge & carbon contamination.
Arc quenching assemblies should be inspected for carbon deposits or other surface
contamination. If cleaning is necessary, refer to manufacturers instructions.
contact bounce.
Insulation resistance should be measured for one minute using table 1 to determine test voltage
and minimum acceptable insulation resistance values phase to phase and ground.
Measure the contact resistance across each pole, refer to manufacturers manual to obtain
maximum recommended value, if not specified use the corresponding value from Table 2.
Breaker Rated Voltage Breaker Rated Current Microhms Maximum

7.2 to 15 kV 600 Amp 300
1200 150
2000 75
4000 40
23 to 24 kV All 500
46 kV All 700
69 kV 600 500
1200 500
2000 100
115 to 230 kV All 800
Table 2. Maximum Recommended Contact Resistance For OCB’s
Special note for OCB’s –Following a heavy fault interruption, it is worth the effort to obtain an oil
screening sample from each phase for analysis to ensure oil is not contaminated from fault.
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Air Blast Circuit Breaker Maintenance
3 Monthly – Visually Inspect insulators, bus connections & hardware, make a general visual
inspection of the operating mechanism & control cabinets for loose or damaged hardware, water
ingress or corrosion damage. Check that air pressures are within operable range, listen for air
leaks or unusual electrical noises (corona).
500 kV Rated Air Blast Circuit Breaker
Measure the moisture content of the air for dryness, acceptable value should be 20 ppm by
volume or less (confirm with manufacturer). Cycle the breaker open & closed while observing the
operation, pay close attention to the tripping mechanism latches and operating coil assemblies.
the protection tripping relays. (NERC reliability standard requirement for HV & EVH systems.)

Inspect the pressure reducing valves (re-filling valves), check the operation of the refill timers &
alarm functions (if fitted). Check calibration of all air pressure switches.
Lubricate the tripping system impulse & isolator control blocks as required by manufacturer’s
schedule (only use recommended lubricant). Inspect air compressor and air dryer.
Verify operation of safety pressure relief devices.
Manually slow close & open the breaker through one operating cycle to check for binding, friction
or misalignment.
Check air consumption by closing the main supply valve and operating the breaker through one
complete open – closed –open cycle record & compare the results with manufacturer’s data.
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Breaker contact erosion and resistance measurements should be checked on each pole. Refer to
the commissioning documentation and manufacturers instructions for comparison and maximum
allowable tolerances.
times are within design tolerances.
Test each trip coil for minimum pick up voltage, and compare results to manufacturers test data,
any significant increase in voltage required to trip the breaker as compared to factory testing
would suggest a problem, such as excessive friction of the trip operating mechanism or shorted
turns in the tripping coil, these conditions should be investigated.
Clean and inspect insulators & bushings where necessary.
Vacuum Circuit Breaker Maintenance
3 Monthly –Perform a general visual inspection of the breaker and control mechanism cabinet.
Inspect the operating mechanism & control cabinets for loose or damaged hardware, water
ingress or corrosion damage.
13.8 kV 2000 A Rated Siemens Vacuum Breaker (Windsor)
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mechanism latches and operating coil assemblies.
the protection tripping relays. (NERC reliability standard requirement for HV & EVH systems.)

contact bounce.
Dielectric over-potential (hi–pot) testing of the vacuum bottles should be performed to determine
vacuum integrity, refer to manufacturers recommendations for test voltage & acceptance criteria.
Tests should be conducted with the breaker in both the open & closed positions.
Follow the manufacturer’s recommendations for vacuum assembly replacement frequency.
Measure the contact resistance across each pole. Refer to manufacturers manual to obtain
maximum recommended acceptance value.
Contact erosion should be checked by measurement of travel stroke, or by indicator (if provided).
Test each trip coil for minimum pick up voltage, and compare results to manufacturers test data.
Clean insulators & breaker housing as necessary.
Information Sources:
NFPA 70B 2006 Recommended Practice for Electrical Equipment Maintenance Annex H
FM Global Property Loss Prevention Data Sheets 5-19
IEE Power Series Power System Commissioning and Maintenance Practice
9 of 11
Recommended Maintenance Intervals by Breaker Type
Breaker Type: SF6

Maintenance Task
3 Monthly Every 1 Year Every 2 Years Every 5 Years
Open/Close Check X
Full Trip & Close Function Testing X
Thermography Inspection X
Pole Timing Tests X
Trip Coil Voltage Test X
Power Factor Testing X
Dielectric Testing X
Hi Potential Testing Per Manufacturer
Minor Visual Inspection X
Detailed Inspection X
Lubrication of Actuator X
Contact Resistance & Erosion Test X
Densimeter Alarm & Blocking Test X
Damping Device Oil Level Checks X
Hydraulic Oil Quality Checks X
Tank Heater Checks (Winter Only) X
Gas Pressure Check X
Breaker Type: Air Blast

Maintenance Task
Open/Close Check X
Pole Timing Tests X
Power Factor Testing X
Air Moisture Checks X
Desiccant or Air Drier Check X
Low Air Pressure Blocking Function X
Compressor inspection X
*Items in Red Require Breaker to Be Removed From Service
10 of 11
Recommended Maintenance Intervals by Breaker Type
Breaker Type: Bulk Oil

Maintenance Task
Open/Close Check X
Pole Timing Tests X
Power Factor / Tank Loss Index Tests X
Oil Screening Checks X
Oil Level Checks X
Breaker Type: Vacuum

Maintenance Task
Open/Close Check X
Pole Timing Tests X
Power Factor / Tank Loss Index Tests X
Hi Potential Testing (Vacuum Integrity) Per Manufacturer
Oil Screening Checks X
*Items in Red Require Breaker to Be Removed From Service
11 of 11
High Voltage Electrical Maintenance Guidelines HVGOAB-01
Gang Operated Air Break Switches
Recommended Maintenance
Annually
While off line, the air break switches should be visually inspected and exercised open and closed,
observe alignment of moving switch blades and ensure they seat properly in stationary contacts.
If fitted with a motorized operator, check the action and condition of the operator motor limit
switches, operators levers, shafts and cranks, ensure there is no looseness, binding or excessive
wear of components.
While air break switch is in service and under load check with thermal imaging camera for
localized heating or temperature differential between switch blades and contacts, also check all
flexible shunts, connections, terminations and splices for any possible abnormalities.
Every 3 to 5 Years
With switch out of service and isolated, a detailed mechanical inspection should be conducted.
Where fitted, inspect high voltage cable termination stress cones for cleanliness and signs of
tracking. Check insulators and insulating rods for cleanliness and any signs of damage.
Inspect the main switch blades and contacts for spring pressure, wear and alignment, badly worn
or pitted contact assemblies should be replaced.
Observe the operation of the inter-phase linkages and that the switch blades operate in unison.
Ensure mechanical stops or locking mechanisms are correctly adjusted.
Clean and lightly lubricate contact surfaces as per manufacturer’s recommendation using proper
contact lubricant.
Inspect arcing horns for wear and damage and replace if necessary.
Check contact resistance across contacts using a micro-ohm meter and compare against the
manufacturer’s test data. The resistance should be maintained as low as possible, values will
vary by switch type and current rating, but as a rule of thumb the resistance should not deviate
more than 25% from pole to pole or from similar equipment values.
Lubricate the moving components and linkages according to the manufacturer’s recommendation.
If fitted with a motorized operator, cycle the operator to verify the limit switches allow full range of
switch operation. Electrical interlock circuits should be tested for function and proper operation.
Check lubrication level and condition of gear reducers.
1 of 2
High Voltage Electrical Maintenance Guidelines HVGOAB-01
For manually operated switches, ensure that operating handle grounding mechanism is
functioning properly, slip rings and brushes or braided shunt are securely connected, any
component showing signs of wear or corrosion should be replaced.
Ensure all station grounding and bonding leads are securely attached and in place.
Finally, perform an insulation resistance test for one minute to ground on each pole, use
manufacturer’s recommended test voltage and minimum resistance values.
Joslyn R2-F Air Break Switch
NFPA70B Recommended Practice For Electrical Equipment Maintenance 2006

International Electrical Testing Association Maintenance Testing Specifications 1997
Cleaveland Price Operating and Maintenance Instructions
Joslyn R2-F Instruction Manual
2 of 2
High Voltage Electrical Maintenance Guidelines STNBAT-01
Substation Battery Maintenance
Purpose
Substation batteries are a critical component and ensure that there is sufficient operating control
voltage available to operate breakers and protection systems during both fault, and normal
operating conditions. If a breaker cannot be opened during a fault condition due to lack of battery
operating voltage then the results could be catastrophic, so periodic maintenance and testing of
the battery systems should be routinely performed.
Safety
Only experienced personnel with knowledge of the hazards associated with large storage
batteries should be permitted to work on these systems.
Use extreme care when working around substation batteries, all lead acid batteries produce an
explosive mixture of hydrogen & oxygen while charging. Ensure the battery rooms are well
ventilated and that no sparks, flame or other source of ignition are permitted within the room.
Arc flash safety procedures should be observed and followed, Insulated spark free tools should
be used within the battery room and when performing major maintenance the cell links should be
separated to reduce the shock hazard. Do not use mercury filled thermometers for cell
temperature monitoring. Electrolyte is highly corrosive, always use proper chemical PPE when
opening cell vents for hydrometer readings or topping off cells.
Types of Batteries
The Suez facilities use a number of different types of storage batteries, each type will require
different maintenance procedures, the two most common types are discussed in this document.
In all cases carefully follow the manufacturers recommended practice to ensure maximum battery
life and availability.
Lead Acid Flooded Cells

Also known as vented batteries, are probably the most common and reliable type used for
substation purposes, this style of battery usually has a transparent case, so you can clearly see
the electrolyte level & lead plates within the cell. The electrolyte used is sulfuric acid.
Valve Regulated Lead Acid

Also known as VRLA or gel cells, this style of battery design immobilizes the electrolyte using an
absorbent material or silica compound to form a gel, the sealed cell is fitted with a pressure relief
device to vent internal pressure, this type of battery is intended to be maintenance free and
conventional lead acid maintenance techniques cannot be used to service these batteries.
The gel cells have a shorter life expectancy than a flooded cell & are extremely sensitive &
vulnerable to deviation in charging voltage and ambient temperature & will deteriorate at a rapid
pace if these parameters are not properly maintained.
1 of 14
Recommended Lead Acid Flooded Cell Battery Maintenance
Monthly: Float & equalize voltage checks

Electrolyte specific gravity checks & visual
Pilot cell voltage readings
Yearly: Voltage measurement across all cells & re-selection of pilot cells
Three Years: Charger & monitoring alarm inspections

Clean & torque cell interconnections*
*Micro ohm connection resistance may be used as a substitute for torque
Five Years: Capacity load testing *
*If testing reveals battery capacity is less than 90%, then frequency of testing should be reduced
to 1 year intervals, end of life is considered to be when battery cannot meet 80% of design rating.
A copy of the manufacturer’s capacity testing or commissioning testing report should be used as
a base line comparison.
Float & Equalize Voltage Checks
Float Charge
The float charge is a voltage that is just slightly higher than the battery design open terminal
voltage. It maintains the battery at design voltage by compensating for any internal losses.
It is extremely important to maintain the float voltage on both types of battery within the
manufacturers recommended range, overcharging or undercharging will result in rapid
deterioration of the cells.
The float & equalize voltages will vary slightly for different types of cells depending on the
materials used, lead antimony, lead calcium, lead selenium, etc. so therefore always refer to the
OEM manual for correct float voltage range.
The following is an example only.
A typical float voltage for a large lead acid battery is 2.25 to 2.27 volts per cell. If a combination of
60 cells were used then the overall float voltage would be as follows:
60 x 2.25 = 135 volts minimum
60 x 2.27 = 136.2 volts maximum
The float voltage should be kept within this range at all times except when equalizing.
2 of 14
Measurement of Float Voltage

Tested monthly, the float voltage should be measured with the charger in service.
Using an accurate DC voltmeter with a resolution of at least 0.01 volt, the overall voltage should
be measured at the battery positive & negative connections, record the float voltage on the
battery record sheet (see appendix A for example).
If the float voltage is out of tolerance then adjustment of the charger will be necessary, refer to
charger manufacturers manual for specific detail on adjustment.
Equalize Charge
The purpose of the equalize charge is to bring the battery cells back to a full charge condition
after any of the following scenarios:
 After completion of load testing.

 Following any significant discharge event.
 If multiple or any single cell should drop below the minimum fill level requiring addition of
large amounts of de-mineralized water.
 If the corrected specific gravity drops more than 0.010 below the full charge value while
on float.
 The individual voltage of any cell falls below 0.04 volts of the cell average while on float.
Frequent equalizing of the cells should not be necessary (once every 3 months only if needed)
If the above conditions persist then investigate the cause.
Before equalizing the cells make sure that the electrolyte levels are topped up to the high level
mark & make sure that the equalize voltage and timer is set to the manufacturers recommended
value, failure to do so could result in damage to the cells.
Using an accurate DC voltmeter with a resolution of at least 0.01 volt, the equalize voltage should
be measured at the battery positive & negative connections, while operating the charger in the
equalize mode.
For example only: Always refer to the OEM manual for correct equalize voltage range.
Typical equalize voltage range of 2.35 to 2.40 volts per cell for 24 to 48 hours is not uncommon.
For a combination of 60 cells the equalize voltage range would be as follows:

60 x 2.35 = 141.0 volts minimum
60 x 2.40 = 144.0 volts maximum
If the equalize voltage does not fall within the recommended range then the charger must be
adjusted accordingly before proceeding.
Pilot Cell Voltage Readings
Each year a complete set of cell voltage readings and specific gravity readings should be taken to
determine the overall condition of the batteries & establish which cells will be used as pilot cells.
Example for a 60-cell battery bank:

Pilot cell selection should be based on finding 6 average cells at varying locations in the bank that
are representative of the entire battery’s individual cell voltage and specific gravity readings. The
temperature difference between the selected cells should not be greater than 5 deg C
3 of 14
The purpose of this is to select and monitor 10% of cells as a representation of the overall battery
charge and condition a more frequent basis. The selected cells & voltage readings should be
recorded on the battery record sheet once per month (see appendix A for example).
Electrolyte Specific Gravity Checks & Visual Inspection
Specific Gravity Checks

Pilot cell electrolyte specific gravity and temperature should be measured and recorded on the
battery sheet monthly. (See appendix A for example).
When taking hydrometer readings from cells, be sure to hold the hydrometer syringe vertically
and make sure the float is floating freely with no pressure applied to the bulb.
The batteries must be at steady state float charge for at least 72 hours and the electrolyte level at
mid point on the min/max indication, do not record gravity readings immediately after topping off
cells with water, it may take as long as several weeks for the water to thoroughly mix
Specific gravity readings provided by the manufacturer for any flooded lead acid cell is always
specified at 77 degrees Fahrenheit. Therefore any hydrometer readings must be temperature
corrected by measuring the electrolyte temperature and using the following factor:
Add 0.001 point of Specific gravity for every 3 deg above 77 F

Subtract 0.001 point of Specific gravity for every 3 deg below 77 F
After recording the pilot cell voltages & specific gravities, the information should be reviewed and
if any cell voltage is 0.04 volts less than the cell average or the specific gravity is 0.10 points less
than the cell rated full charge Sp. Gr. corrected to 77 F, then an equalize charge is necessary.
Visual Inspection
Monthly check should be made to ensure that the battery room ventilation systems are
functioning and that the room temperature is maintained below 77 deg F, a sustained increase of
15 deg F in room temperature can mean a reduction in battery life of up to 50%.
The recommended operable range for storage batteries is min 60 deg F. & max 90 deg F.
Check electrolyte levels in all cells and correct if necessary.

Ensure that the batteries are kept clean, dry & free of residue.
Observe the cell connections for corrosion or discoloring.
Ensure that battery chargers are functioning and no ground indications are present.
Observe the condition of the plates & grid through the jar, a battery that receives insufficient
charge will develop sulfate buildup and buckling of the plates, and if left untreated will suffer
irreversible damage, the lead sulfate is light in color, hard & dense contact the manufacturer or
refer to the OEM manual for further guidance.
Sedimentation on the bottom of the cell jar is normal, a perfectly charged battery should have
only fine brown sediment, layers of fine dark gray sediment could suggest that there have been
long periods of overcharging, and layers of white would suggest undercharging.
4 of 14
Adding Water
Water consumed by a battery is proportional to the amount of overcharge it receives. A small
amount of loss from evaporation and oxygen diffusion is normal.
Lead-antimony batteries will use increasingly more water as they age, up to ten times the original
as they approach the end of their useful life, lead-calcium cells of the same size use about one-
tenth of the quantity of lead-antimony & usage should be constant throughout the life of the cell.
Monitor the quantities of water consumed by the cells, if usage is excessive review the float
voltage values and lower if necessary (see appendix B for water consumption chart).
The cells should be topped off prior to performing an equalize charge and filled to the upper fill
line, use only distilled or de-mineralized water.
Charger & Monitoring Alarm Inspections
Every three years the charging system should be inspected and tested to ensure reliability and
safe operation, refer to the manufacturer’s manual for details of recommended procedures.
Lock out tag out procedures should be used when cleaning & inspecting the chargers, care
should be exercised at all times to ensure that circuits are properly isolated & de-energized
before any work proceeds. Arc flash procedures should be followed when charger is powered.
Visually inspect charger components & heat sinks for dust & signs of overheating
Test and confirm voltage & current limits, grounding & trouble alarm functions.
Verify the panel voltage and current meters for accuracy.
Measure charger output voltage for AC component, if present then consult the manufacturer.
If dual load sharing chargers are used check the load sharing currents & adjust accordingly.
Test & record the float & equalize voltage regulation of each charger independently by powering
the opposite charger down and measuring the active one.
Clean & Torque Cell Interconnections
Every three years the cell interconnections should be checked to ensure the battery terminals
remain clean and free from corrosion that will lead to high resistance between the contacting
surfaces causing heating and wasted capacity.
If the cell terminals and posts are corroded, they will need to be disconnected and cleaned using
a fiber bristled brush and a solution of 1 pound baking soda to 1 gallon of water and then rinsed
off with de-mineralized and dried with clean rags, never use solvents or a wire brush of any kind.
Connections should be lightly coated with NO-OX grease following cleaning.
If the cells terminals & posts are clean, bright and free of discoloration then a contact resistance
check across each cell connection will be sufficient, readings should be typically less than 100
micro-ohms between each connection point, if the value is higher the connections will need to be
separated cleaned and re-torque. Check manufacturers recommended values for contact
resistance & torque values.
5 of 14
Capacity Load Testing
Every five years the batteries should be load tested to ensure adequate capacity, the batteries
are considered to have reached the end of their useful life when the capacity has fallen below
80% of the rated value.
The batteries are rated on their ability to deliver a specified amount of current to the connected
load for a specific amount of time before the battery voltage drops to a final cutoff value at which
time the test is concluded, the performance of the batteries will vary with a number of factors,
State of charge
The individual cell voltages and specific gravity must be closely matched between cells, if not an
equalize charge will be required first, then allow batteries to stabilize on float for at least 72 hours,
this is extremely important following an equalize charge to allow time for the gasses to clear the
surface of the plates,
Age & condition of cells

The cell performance will diminish over time, but if properly cared for they will provide many years
of reliable service. When the ability of a battery to produce 80% of its rated capacity occurs, the
aging process accelerates rapidly, so if performance cannot be restored then the batteries should
be replaced.
Integrity of connections
Corrosion and high resistance connections lead to generation of heat and wasted capacity. Be
sure connections are clean & tight before load testing.
The capacity test should be conducted using manufacturer approved load test method, for
flooded LA cells IEEE STD-450-2002 has a detailed description of the test procedure and criteria.
This test should only be conducted by experienced personnel. The risk of permanently damaging
the cells is high if the test is not halted at the correct cutoff voltage.
The batteries must be isolated from the charging system and plant load, and then connected to a
constant current DC load bank to simulate the load. Typically a data logging monitoring
instrument is used to record the test, one channel of the monitoring instrument is connected
across the total battery voltage output, and additional channels are used to monitor each
individual cell voltage for the duration of the test. The load should match the rated capacity of the
battery bank, for example if the battery is rated 100 AH for an 8 hour load then the batteries
should be able to deliver a constant 100 A load for 8 full hours before reaching the cell minimum
cutoff voltage. Always consult the manufacturer to determine the safe cutoff voltage and the test
should be halted as soon as any cell reaches this value.
Calculation for % rated capacity @ 77 deg. F. to specified end point voltage:
Actual Discharge Time

% Capacity = -------------------------------- x 100%
Specified Discharge Time
If battery overall load test result drops to 90% of rated, or if one or more cells fail the test, then the
test should be conducted yearly.
Note: For VRLA battery load testing refer to IEEE STD 1188.
6 of 14
Recommended Valve Regulated Lead Acid Cell Battery Maintenance
Monthly: Float voltage & current checks.

Pilot cell voltage readings.
Visual inspection.
Yearly: Voltage measurement across all cells & re-selection of pilot cells.
Internal resistance check of all cells.
Thermal imaging & record of cell temperatures.
Monitor charger for AC ripple.
Capacity load testing.
Two Years: Charger & monitoring alarm inspections.

Clean & torque cell interconnections.*
*Micro ohm connection resistance may be used as a substitute for torque.
Float & Equalize Voltage Checks
Float Charge
Float voltage setting is extremely important with VRLA batteries, check the OEM manual to be
sure that the float voltage per cell (vpc) meets the recommended requirement, the float voltage
should be corrected for the average ambient temperature of the battery room.
Overcharging of VRLA batteries can lead to thermal runaway and possible fire, any overcharge
energy results in heat generation, if the rate of heat generated is greater than the ventilation is
capable of dissipating, then the battery temperature will rise & more charging current will be
required to maintain float voltage, causing more heat to be generated and destruction of the cells.
Float voltage & current should be measured and recorded monthly, measure voltage across the
overall positive & negative connection using a digital volt meter with a resolution of 0.01 volts DC,
if the float voltage is out of tolerance then adjust the charger output accordingly.
Equalize Charge
Equalize charge is not normally used on VRLA batteries in instances where the cells have been
undercharged or rapid charging is required check the OEM manual or consult with the
manufacturer before proceeding, never exceed the maximum recommended charge voltage.
Pilot cell voltage and temperature readings
Each year a complete set of cell voltage readings and cell temperature readings should be taken
to determine the overall condition of the batteries & establish which cells will be used as pilot cells
for future monitoring, the temperature of the cells should be measured at the negative terminal
using the most accurate means available (thermal image is the best method), charging current
increases with electrolyte temperature increase, therefore lower cell voltages can be found with
warmer cells. Keep a record of the annual temperature & voltage trends.
Check and record the pilot cell voltage & temperature values monthly and record on the battery
record (see appendix C for example).
7 of 14
Visual inspection
Monthly check should be made to ensure that the battery room heating & ventilation systems are
functioning and that the room is maintained as close as possible to 77 deg F.
Check that the batteries and racks are kept clean, dry & free of residue or corrosion.
Observe the cell connections & posts for corrosion or discoloring.
Ensure that battery chargers are functioning properly and no ground indications are present.
Check the cell cases for signs of leaks or swelling.
Internal Resistance Check Of All Cells
There are a number of commercially available portable test instruments such as the Hioki 3551
that will enable quick and easy testing of the VRLA battery cell internal resistance, and can also
log the cell voltages & temperatures simultaneously. Internal resistance testing should be
performed once per year on each cell and the readings compared with the manufacturers design
values, changes of internal resistance of more than 20% should be considered significant and the
manufacturer should be consulted for guidance. (see appendix D for example record)
Thermal Imaging & Record Of Cell Temperatures
A thermal imaging camera is a quick and easy method of collecting an accurate record of cell
temperatures and can also reveal other potential thermal problems, such as high resistance
connections or overheated cells, this should be performed once per year.
Monitor for AC ripple
Most charging systems are powered by AC current & rectified to produce DC charging current,
If the charger is not functioning properly the possibility of producing an AC component on the
charger output exists, VRLA batteries are very sensitive to AC ripple, as it will generate additional
heat and gassing & severely shorten the life of the cells.
The AC ripple should never exceed 0.5% of the float voltage, this should be measured once per
year using an AC voltmeter or oscilloscope. The charger filtering capacitors should be
investigated if excess ripple is found, if in doubt contact the charger manufacturer.
Charger & Monitoring Alarm Inspections
Every Two years the charging system should be inspected and tested to ensure reliability and
safe operation, Lock out tag out procedures should be used when cleaning & inspecting the
chargers, care should be exercised at all times to ensure that circuits are properly isolated & de-
energized before any work proceeds. Arc flash procedures should be followed when charger is
powered.
Refer to the manufacturer’s manual for details of recommended maintenance procedures.

Visually inspect charger components & heat sinks for dust & signs of overheating
Test and confirm voltage & current limits, grounding & trouble alarm functions.
Verify the panel voltage and current meters for accuracy.
Measure charger output voltage for AC component, if present then consult the manufacturer.
Never use a charger designed for flooded cells to charge VLRA batteries, VRLA chargers have
additional protection built in to help protect against thermal runaway.
8 of 14
Clean & Torque Cell Interconnections
Every two years the cell interconnections should be checked to ensure the battery terminals
remain clean and free from corrosion that will lead to high resistance between the contacting
surfaces causing heating and wasted capacity.
If the cell terminals and posts are corroded, they will need to be disconnected and cleaned using
a fiber bristled brush and a solution of 1 pound baking soda to 1 gallon of water and then rinsed
off with de-mineralized and dried with clean rags, never use solvents or a wire brush of any kind.
Connections should be lightly coated with NO-OX grease following cleaning.
If the cells terminals & posts are clean, bright and free of discoloration then a contact resistance
check across each cell connection will be sufficient, readings should be typically less than 100
micro-ohms between each connection point, if the value is higher the connections will need to be
separated cleaned and re-torqued. Check manufacturers recommended values for contact
resistance & torque values.
Capacity Load Testing
Every two years a capacity test should be conducted using manufacturer approved load test
method, for VRLA cells, IEEE STD-1188 has a detailed description of the test procedure and
criteria. This testing should only be conducted by experienced personnel, the risk of permanently
damaging the cells is high if the test is not halted at the correct cutoff voltage.
The batteries must be isolated from the charging system and plant load and then connected to a
constant current DC load bank to simulate the load. Typically a data logging monitoring
instrument is used to record the test, one channel of the monitoring instrument is connected
across the total battery voltage output, and additional channels are used to monitor each
individual cell voltage for the duration of the test. The load should match the rated capacity of the
battery bank, for example if the battery is rated 100 AH for an 8 hour load then the batteries
should be able to deliver a constant 100 A load for 8 full hours before reaching the cell minimum
cutoff voltage. Always consult the manufacturer to determine the safe cutoff voltage and the test
should be halted as soon as any cell reaches this value.
Calculation for % rated capacity @ 77 deg. F. to specified end point voltage:
Actual Discharge Time

% Capacity = -------------------------------- x 100%
Specified Discharge Time
Before the test is conducted the cell interconnection resistances or torque should be checked,
And the cells should be at steady state float voltage for at least 72 hours prior.
If battery load test result drops to 90% of rated then the test should be conducted yearly.
At 80% capacity the cells should be replaced as deterioration beyond 80% will be rapid.
9 of 14
Information Sources
IEEE 450 Recommended practice for maintenance, testing & replacement of vented lead acid
batteries for stationary applications.
IEEE 1188 Recommended practice for maintenance, testing & replacement of VRLA batteries
C&D Technologies Effects of AC ripple on VRLA batteries
NFPA 70B Recommended practice for electrical equipment maintenance
US Department of the Interior Bureau of Reclamation F.I.S.T. Volume 3-6
FM Global Property Loss Prevention Data Sheets 5-20
10 of 14
Appendix A
Example Battery Record for Flooded Lead Acid Cells

(From NFPA 70B Recommended Practices)
11 of 14
Appendix B
Flooded Cell Water Consumption
12 of 14
Appendix C
Example Battery Record For VRLA Cells
(From US Department of the Interior Bureau of Reclamation F.I.S.T. Vol 3-6)
13 of 14
Appendix D
Internal Resistance Check Record
Valve Regulated Battery Connection & Internal Resistance Report
Date:______________ Location:__________________ Battery Type:___________________
Note: For contact resistance, take the first reading between the connector (lug) & cell post, then
take readings between adjacent opposite polarity cell posts (Caution: not across the cell). Take
the last reading between the last post and the connector lug. For internal resistance use the left-
most number as the cell number.
Measured As Found As Left Internal Measured As Found As Left Internal

Between: µ Ohms µ Ohms Resistance Between: µ Ohms µ Ohms Resistance
Lug to post1 30-31
1-2 31-32
2-3 32-33
3-4 33-34
4-5 34-35
5-6 35-36
6-7 36-37
7-8 37-38
8-9 38-39
9-10 39-40
10-11 40-41
11-12 41-42
12-13 42-43
13-14 43-44
14-15 44-45
15-16 45-46
16-17 46-47
17-18 47-48
18-19 48-49
19-20 49-50
20-21 50-51
21-22 51-52
22-23 52-53
23-24 53-54
24-25 54-55
25-26 55-56
26-27 56-57
27-28 57-58
28-29 58-59
29-30 59-60
Tested By:__________________________
14 of 14
High Voltage Electrical Maintenance Guidelines HVINST-01
Substation Instrument Transformers
Recommended Inspection and Testing
This guideline is intended to cover potential transformers (PT’s) and current transformers (CT’s)
used for the purposes of protection, control & metering of the station high voltage equipment.
Every Three Years
General off Line Inspection

Visually inspect instrument transformer enclosures.
Inspect PT primary fuse holders and fuses. Look for any evidence of overheating, corrosion,
loose or damaged wiring or any other signs of degradation. For instrument enclosures with draw
out compartments, make sure that anti condensation heaters are functioning and that the
enclosures are free of moisture.
Capacitive Voltage Transformers

Capacitor voltage transformers (CVT’s) and coupling capacitors (used for relaying &
communication over the transmission lines) should be doble tested every three years, and the
capacitance and power factor test results compared to the factory supplied data.
Inspect for leaks, check the oil level in the bushing and base tank. If oil level in base is high this
could be an indication that the bushing may be leaking internally and should be investigated.
Ensure HV bushing is clean and damage free.
Check secondary connections to ensure they are clean, tight, corrosion and damage free.
Trench 115 kV CVT’s (Windsor)
1 of 2
High Voltage Electrical Maintenance Guidelines HVINST-01
Current transformers
General off line inspection

Loose wiring will lead to CT failure and presence of extremely hazardous voltages.
Where accessible all CT wiring connections should be inspected for tightness and integrity, check
all tightness of all shorting links used on spare CT connections.
Oil filled CT’s should be doble tested every three years, and the test results compared to the
factory test values. The oil level should be checked and bushing insulator cleaned.
Cut away view of an HV oil filled current transformer
Every 5 Years
Ratio check of the PT’s and CT’s should be conducted (IEEE C57.13.1), and total burden
measurement should be made and compared to the nameplate rating of the transformer.
PT insulation test should be conducted from winding to winding, and winding to ground.
Trench Electric Capacitive Voltage Transformer Bulletin IM300-05

ABB Instrument Transformer Application Guide 1HSE 9543 40-00en
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High Voltage Equipment Maintenance Guidelines

Page No. Document ID

Maintenance Testing Intervals of HV Substation Equipment HVSUB-01

Oil Filled Transformers…………………………………… 1

Transformer Oil Preservation System Inspection HVTRAN-01

Sealed Gas Pressure Systems………………………….. 1

Transformer Oil Analysis Interpretation HVTRAN-02

Exercising of Oil Filled Transformer Off Load Tap Changer HVTRAN-03

Oil Filled Transformer Detailed Visual Inspection HVTRAN-04

Transformer Bushing & Winding Power Factor Testing HVTRAN-05

Transformer Instrument & Gage Calibration HVTRAN-06

Buchholz & Sudden Pressure Relay Testing HVTRAN-06

Thermal Imaging of Electrical Equipment HVTHMG-01

Page No. Document ID

Protective Relay Testing HVPROT-01

Mandatory NERC Standards…………………………….. 1

HV & MV Circuit Breakers HVCB-01

SF6 Circuit Breakers…………………………………….. 2

Gang Operated Air Break Switches HVGAOB-01

Substation Battery Maintenance STNBAT-01

Substation Instrument Transformers HVINST-01

Recommended Maintenance Testing Intervals of HV Substation Equipment

Loading: Heavily loaded equipment may be more prone to premature failure.

Fault trips: Cause stress on the operating equipment.

Criticality of Equipment: Potential for serious financial impact as a result of failure.

Oil Filled Transformers

Inspection Type Equipment Operating Condition

Inspection Type Equipment Operating Condition

HV Circuit Breakers SF6, Bulk Oil, Air Blast, Vacuum

Inspection Type Equipment Operating Condition

Gang Operated Air Break Switches

Inspection Type Equipment Operating Condition

Substation Instrument Potential Transformers

Inspection Type Equipment Operating Condition

Substation Instrument Current Transformers

Inspection Type Equipment Operating Condition

Isolated Phase Bus Duct

Inspection Type Equipment Operating Condition

Inspection Type Equipment Operating Condition

Overhead Structures & Transmission Lines

Inspection Type Equipment Operating Condition

Substation Battery Maintenance

Inspection Type Equipment Operating Condition

Substation Grounding & Fencing

Inspection Type Equipment Operating Condition

Transformer Oil Preservation System Inspection

Guidelines for inspection and maintenance of oil preservation system

Sealed Gas Pressure System (Fig 1)

Sealed Transformer Without Conservation System

Free Breathing Conservator (Fig 2)

Conservator With Bladder (Fig 3)

ABB Service Handbook for Transformers

Transformer Oil Analysis Interpretation (Mineral Oil Only)

DGA (Dissolved gas analysis) Perform every 6 months – 12 month maximum

Four condition categories are used:

Dissolved Gas Concentration Limits In PPM

H2 CH4 C2H2 C2H4 C2H6 CO CO2 TDCG

Condition 4 1800 + 1000 + 80 + 200 + 150 + 1400 + 10000 + 4630 +

Condition 1 – No action required.

Condition 4 – Remove transformer from service and investigate immediately.

Approximate temperature of gas formation Probable cause Acceptable IEEE

Acetylene > 500 C Internal Arcing 35 ppm

Dielectric Strength Perform every 12 months along with DGA sample