4perform Maintenance of Electrical Equipment

AKSUM TECHNICAL COLLEGE
BUILDING ELECTRICAL
INSTALLATION LEVEL III
Unit of Competence : Perform Maintenance of

ElectricalEquipment
Module Title : Performing Maintenance of

ElectricalEquipment
LG Code :CON BEI3 MO4 0202
TTLM Code :CON BEI3 TTLM 1212V1
LO1. Plan and prepare for maintenance of electrical equipment

LO2. Maintain electrical equipment and associated circuits
LO3. Notify completion and document results of maintenance of
electrical equipment
Training, Teaching Learning Module Building Electrical Installation Level III
Instruction Sheet LEARNING GUIDE 4
This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics;
 Maintenance of electrical equipment
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
 Repair electrical equipment
Learning Activities
1. Read the specific objectives of this Learning Guide.
2. Read the information written in the “Information Sheets 1- 3”
3. Accomplish the “Self-check” in pages 22, 33, and 45.
4. If you earned a satisfactory evaluation proceed to “Operation Sheet 1”. However, if

your rating is unsatisfactory, see your teacher for further instructions or go back to
Learning Activity #1.
5. Submit your accomplished Self-check. This will form part of your training portfolio.
6. Read the “Operation Sheet” from page 48 to page 64 and try to understand the
procedures discussed.
7. You are provided with a CD containing lessons on how to prepare reports. Before
you open the CD read the information written in the “Information Sheets 1-3” in
pages 4, 25, and 36. You will be also provided with additional reference reading
materials.
8. Request a desktop computer or laptop from your instructor. Make sure the unit is
plugged to a power source before turning on the power ON. Then insert the CD in
the CD drive located in your computer. Access the information as described in the
Operation Sheet in pages 48 - 64.
TTLM:CON BEI3 TTLM 0213V1 TVET Program: Building Electrical Installation Level III
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Revision:Version 1 Author:BEI
9. Read all the contents of the CD and try to understand the procedures discussed.
Additional readings are provided in Operation Sheet in pages 48 – 64.
10. Request access to the materials described in the CD. Practice the steps or
procedures as illustrated in your CD. Go to your teacher if you need clarification or
you want answers to your questions or you need assistance in understanding a
particular step or procedure.
11. Do the “Job Sheet” in pages 71 - 81 (if you are ready) and show your output to your
teacher. Your teacher will evaluate your output either satisfactory or unsatisfactory. If
unsatisfactory, your teacher shall advice you on additional work. But if satisfactory
you can proceed to Learning Guide 5.
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Information Sheet-1 Preparing for Maintenance of Electrical Equipment
Definitions
1. Maintenance
A combination of any actions carried out to retain an item in, or restore it to, conditions
in which it is ableto meet the requirements of the relevant specifications and perform its
required functions.
2. Inspection
An action comprising careful scrutiny of an item carried out with or without dismantling
as required, supplementedby means such as measurement, in order to arrive at a
reliable conclusion as to the condition ofthis item.
3. Qualification of personnel
-The maintenance and inspection of installations should be carried out by personnel
whose training hasincluded instruction on the various types of installation practices,
relevant rules and regulations and onpersonnel safety.Qualified personnel responsible
for inspection and maintenance works should be appointed by owners andbuilders, in
accordance with the applicable rules and regulations.
Table 1 - Maintenance and inspection actions
Actions Every Year Every Five Year

1 Electrical switchboards and section X X
boards are to be visually
examined to assess the good
operation and maintenance.
2 Electric equipment is to be examined X X
for cleanliness. Where
deemed necessary, cleaning of
electrical equipment.
(dust suction, wiping up oil water
deposits)
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3 It is to be checked that:
3.1 Cables or other electric equipment X X
are still in the original
position. Any modification should be to
the satisfactionof the Society.
3.2 Cable penetration devices are still X X

in good condition (e.g. with
appropriate compound).
3.3 No evidence of overheating, X X

burning or tracking
3.4 Measuring equipment is in order. X X
3.5 Mechanical ventilation, if fitted, X X

operates as required
3.6 Where a protection device has X X

been replaced, its rating and,
where applicable, settings are to be
verified.
4 Contacts and arc screens, if any, of all X
concerned devices are to be checked
and reconditioned or replaced if
necessary in
accordance with manufacturers
recommendation. Movable parts of the
said devices are to be tested.
5 Tightening of connections and X
assemblies which may slacken
is to be checked and tightened, if
required, according to the
manufacturer’s recommendations.
Thermograph aids may be considered
to detect hot spots.
6 Where accumulator batteries may be X X
stored, the condition of
connections (salt deposits ...), the
fastenings, the ventilation
and the tray tightness are to be
checked.
7 Where fitted, computer based X
systems are to be tested. Their
original functions are to be
unchanged.
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8 An insulation measurement of any X

circuit in doubt is to be carried out.
Any large decrease in values is to be
investigated and corrected.
9 All circuits are to be subject to X
insulation measurements for
comparison with the insulation
recordings previously established.
Corrective actions are to be carried
out if the values obtained are under
1k½ per volt.
10 Circuit interlocks, if any, are to be X
tested.
11 Protective devices are to be tested. X
The electronic protective devices for
generators and large consumers are
to be tested according to Rec. 49.
12 The operation of all emergency X X
sources of power is to be tested,
including their automatic devices if
any.
13 X X
All automatic sequences, e.g. for
synchronization, connection,
This learning guide outlines eight simple steps that should be at the heart of an
electricalpreventive maintenance. These key steps are plan, inspect, clean, tighten,
lubricate, test, record, andevaluate. The following paragraphs briefly describe each step
and illustrate the part that they play in agood preventive maintenance program.
STEP 1– PLAN
Before working on anything, take time to think about what you are going to do and how
you aregoing to do it. A few minutes of thought before the job is started results in a safer
and more efficient job.This step is especially important when you are performing
emergency repair work.Start by identifying the specific task or tasks that you intend to
perform. In this initial stage youdo not need to go into too much detail, rather,
concentrate on the broad goals that you to accomplish.List each goal, the equipment
that you will need and the amount of timethat will be required.Be certain that you obtain
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and use the proper instruction manuals and design drawings beforeyou start. The joke
of "getting the manual after smoke is present" has too much basis in fact to be
veryfunny for experienced electricians. Trouble shooting without accurate and correct
schematics andwiring diagrams is close to impossible in all but the simplest circuits.
STEP 2 – INSPECT
Periodic inspections should be set up on a routine basis. Inspection can be done with
the sensesthat nature gave us, called unaided inspection, or with instruments such as
infrared viewers, ultra soundtransducers, etc.
Unaided Inspection
Your eyes are your most important inspection tools. They can detect dirt, note current
readings,determine levels, discover discolored, overheated insulation, determine the
presence of insects androdents, and find a whole host of other problems. The more
experienced you become, the moreinformation your eyes can provide; however, even
the most inexperienced electrician can detect spiderwebs in a circuit breaker operating
mechanism. Always observe what you are working on and look forany abnormalities
that can give you an idea of anything that can cause these problems.Your ears can also
be useful inspection tools. Overloaded transformers are normally noisier thanlightly
loaded ones, corona has a distinctive hissing sound, and motors with unbalanced
voltages or badbearings vibrate. Any change in sound should be investigated.Nothing in
electrical systems is more distinctive than the odor of overheated or burning
insulation.Your nose can detect such problems long before your other senses. Again,
the most usefulindicator of problems is a change in odor.Touch may also be employed
to inspect electrical equipment. Feeling for excessive vibration orheating is a time tested
technique. Of course, you should be extremely cautious before touching anypiece of
equipment. If the equipment is not de-energized, contact should be made only when
wearingappropriate insulating PPE such as rubber gloves.
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Inspection with Tools or Instruments

Except for your own senses, infrared viewers are the most cost effective maintenance
tool inexistence. Annual infrared scans of your power system invariably discover
problems which, if allowedto continue, could result in severe problems. Whether this
service is done "in house" or contracted to anoutside service, you should perform an
annual (minimum) infrared scan of your system.Ultra sound transducers are normally
used on major overhauls to evaluate the condition ofmetals which are subjected to
constant vibration.Many other such tools and instruments are available to help in the
performance of maintenancetasks. Such tools should be used as required by qualified
personnel trained in their proper and safe use.
STEP 3 – CLEAN
Dirt and electricity don't mix. After you have completed the inspection of your electrical
equipment, the next step is to clean all components.The first step is general cleanliness.
Dust, dirt, and foreign material must be cleaned frommotors, switchgear, transformers,
and other such electrical equipment. For such cleaning werecommend the use of high
suction, insulated hose shop vacuum, clean, lint free wiping cloth, and
general purpose solvents. A citrus based, general purpose solvent is effective and
biodegradable.Each insulator or conductor has its own way to be cleaned. Porcelain, for
example, can becleaned with soap, water and appropriate cleaning brushes or pads.
Plastic insulation, on the other hand,cannot take any abrasion. Always refer to the
manufacturer's recommendations for specific techniques.Also, always avoid using steel
wool or other conductive abrasives in any area where contact withenergized conductors
is possible.
Conductor connecting surfaces need special attention. Contact surfaces of copper

conductorsshould be cleaned to a bright finish where they are connected together.
Aluminum must not only becleaned to a bright finish so that the protective oxide coating
is not damaged. Refer to the manufacturer's instruction books sometimes specify the
cleaning material to be usedfor their equipment. Be sure to consult this literature before
attempting to clean electrical components.
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STEP 4 – TIGHTEN
Tightening fasteners on electrical equipment takes special care and should be done to
the torquerecommended by the equipment manufacturer. Electrical connections are
especially critical.Recommendations for recommended torque values can be found in
the maintenance and acceptancetesting specifications published by the International
Electrical Testing Association. Be certain to torqueconnections per this table and/or
manufacturer's recommendations.
STEP 5 – LUBRICATE
Lubrication of electrical system components is an often overlooked or improperly
performedprocedure. Too much lubricant can be worse than no lubricant at all. This is
especially true of devicessuch as protective relays and circuit breakers which may go
for years without operating. Be especiallycareful of conductive lubricants to make sure
they do not cause a short circuit. Always use thelubricants recommended by the
equipment manufacturer or one that has the same characteristics.Lubrication falls into
two important areas:
1. Non-conductors
Non-conductive joints or moving members should be lubricated using an
appropriate material.In some cases grease, oil, or some synthetic lubricant may
be recommended. Motor bearings,mechanism pivots, and other such
equipment fall into this category. Remember that some piecesof equipment,
such as protective relays, do not require any lubricant at all.
2. Conductors
Most manufacturers make and/or recommend a lubricant to be used on
conductors, stabs, andother such equipment. The ubiquitous "black grease"
has been and continues to be a goodlubricant when used properly. The correct
approach to lubrication of electrical conductors is toapply a small amount and
then wipe the contact surface clean with a clean, lint free cloth. Donot scrub the
surface however. You wish to leave a fine film of lubricant in place.
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REMEMBER
Use the proper lubricants in the proper amounts.
STEP 6 - TEST
Electrical equipment should be tested periodically. Insulation resistance should be
measured,breaker trip times should be checked, relays should be calibrated, and a
variety of other proceduresshould be performed. The only exercise that many protective
devices get is during thetest interval.A detailed review of all procedures is beyond the
scope of this course; however, the recommendationsmade by the InterNational
Electrical Testing Association (NETA) in their publicationentitled Maintenance Testing
Specifications should be reviewed an applied as appropriate.
STEP 7– RECORD
Doing work without keeping records is almost useless. Recording test and other data
can helpset maintenance intervals, isolate troublesome equipment (or manufacturers),
and provide a baseline thathelps to know when insulation or other components are
starting to fail. Besides test results recordsshould always include the date, equipment
identification, and all pertinent data on any problemsdiscovered. System conditions like
load current, voltage, temperature and, other such information canhelp determine how
close components are to being overloaded.Test and record forms should be developed
and tailored to your company's specific needs.Examples of such forms may be found in
the back of the NFPA 70B Electrical Equipment Maintenance,Review that document for
ideas and examples.
STEP 8 – EVALUATE
Evaluation of the test results is, possibly, the single most important step in the entire
process.Since 1990, significant progress has been made in the statistical analysis of
small population data suchas that gathered during maintenance intervals. Whether the
analysis is done using sophisticatedmathematical techniques or simple field rules of
thumb, no program is complete without it. Analysis ifrecords will allow the company to
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determine what, if any, additional maintenance needs to be performedand to pinpoint

problems which might otherwise go un-observed.
FREQUENCY OF MAINTENANCE
How often should a power system be maintained? Unfortunately there is no simple
answer tothis question. The following should help in determining frequency of
maintenance in a power system.The steps listed in this procedure are valid for all of the
testing and maintenance information given inthis text.
DETERMINING TESTING INTERVALS

1. Start initially with a once per year test program. Continue this procedure forthe
first two (2) times.
2. Review the test records from your maintenance intervals.
3. If frequent and/or severe problems are evident, decrease the
maintenanceintervals.
4. If no major or frequent problems are evident, increase the maintenanceintervals.
5. Repeat steps 2 through 5 throughout the life of your maintenance program.
The average maintenance interval in industrial systems is about two years. This means
thatevery two years, most industrial plants completely maintain their electrical system.
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Self – Check 1 WRITTEN TEST
Name: _____________________________ Date: ___________________________
Time started: _______________________ Time finished: ____________________
Test I – Multiple Choice
Instruction:Read carefully the statement and select the best answer from the given
alternatives. Write your answer on the separate answer sheet and write
only the letter of corresponding alternatives
1. Evaluation of the test results is the most important step in the entire maintenance
process.
a. Step 5 c. Step 6
b. Step 7 d. Step 8
2. Periodic inspections should be set up on a routine basis.
a. Step3 c. Step 4
b. Step 2 d. Step 5
3. Which of the steps that starts in identifying the specific task or tasks that you
intend to perform.
a. Step 1 c. Step 4
b. Step 2 d. Step 5
4. Cleaning of all components in electrical equipment.
a. Step 3 c. Step 4
b. Step 5 d. Step 6
5. Tightening fasteners on electrical equipment takes special care and should be
done to the torquerecommended by the equipment manufacturer.
a. Step 4 c. Step 5
b. Step 6 d. Step 7
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6. Step 5 Which step you apply a conductive lubricants to a conductor.

a. Step 5 c. Step 6
b. Step 7 d. Step 8
7. Electrical equipment should be tested periodically.
a. c. Step 6
b. Step 7 d. Step 8
8. Which step which recording of evaluationor test can helpset maintenance
intervals, isolate troublesome equipment.
a. Step 5 c. Step 6
b. Step 7 d. Step 8
Test II. Discussion: (12 points)
Differentiate briefly the difference between Maintenance of equipment and Repair

of electrical equipment.
Note:Excellent - 20 points Retake - below 10 points

You can ask you teacher for the copy of the correct answers.
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Maintenance Practices for Electrical

Information Sheet 2
Distribution System Equipment
Recommended Maintenance Practices for Electrical Distribution System

Equipment
The purpose of this standard is to provide the insured with recommended practices and
frequencies that would form the core of a regularly scheduled electrical preventive
maintenance program. All work associated with electric power systems and equipment
should be performed in accordance with accepted industry safety standards and work
practices.
1. Frequency of EPM
In general, Hartford Steam Boiler recommends a frequency of once every three years
for conducting regular preventive maintenance on electrical equipment. Where
applicable, this standard will note components that require a more frequent EPM
program to help ensure reliability and operation.
It is recognized that individual locations may require more frequent maintenance due to
the physical environment or operational nature of the equipment. For example, harsh
environments where excessive moisture or dust may be present should have a more
frequent EPM program. Similarly, equipment that is used intermittently or equipment
critical to a key process should be considered for a more frequent program. Sound
engineering judgment should be used in determining if more frequent maintenance is
appropriate.
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2. Recommended Maintenance Practices
The following sections are segmented by equipment type. For each component, a
recommended minimum practice for preventive maintenance is provided. Where
applicable, additional suggested practices are presented for a more thorough EPM
program.
1. Switchgear
1.1. Enclosures
Ensure that all enclosure panels, doors, and structures are well-maintained in
accordance with the manufacturer’s specifications. During deenergized
maintenance, enclosures are to be vacuum cleaned of all loose dirt and
debris — use of compressed air is not recommended since this may cause
foreign particles to become embedded in the insulation or damage insulators.
Any buildup of dirt or other contaminates that will not come off with
vacuuming should be cleaned with lint free rags using cleaning solvents
recommended by the manufacturer.
All vents and fan grills are to be cleaned of all dust and/or dirt accumulations.
Ensure that ventilation openings are not obstructed. Where seals and/or
gaskets are installed, these should be examined and repaired or replaced as
necessary. All doors and access panels should be properly secured during
operation. Where heater elements are installed, these should be cleaned,
examined for damage and/or deterioration, and tested. Repair or replace
heater elements as necessary.
In environments where there is an extreme exposure to adverse conditions,

the frequency of maintenance for enclosures should be increased as
conditions warrant.
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Electrical equipment rooms or vaults should be kept cleaned of dirt and/or

dust accumulations on a regular basis. Doors and windows should be
maintained in proper working order and kept closed during routine operation.
Access doors should be clearly marked to alert personnel that live electrical
equipment is in use. Where ventilation and/or air conditioning is used, all fan
motors should be cleaned and examined for signs of wear and deterioration.
Fan blades should be cleaned of dirt and dust and bearings should be
properly lubricated. Vent openings should be cleaned of all dust and dirt
accumulations. Filters should be cleaned and/or changed as recommended
by the manufacturer, or more often if conditions warrant. Electrical equipment
rooms should never be used as storage areas.
Electrical equipment rooms or vaults should be examined for evidence of

water seepage. The tops of electrical equipment enclosures should be
examined for evidence of water since this is a common entryway that often
goes undetected until a failure occurs. The source of the water should be
immediately identified and corrective measures taken to permanently correct
the condition.
1.2. Insulators, Supports, and Connectors
Inspect insulators and conductor supports for signs of cracking, broken

pieces, and other physical damage or deterioration. Clean all loose dirt with
lint free rags. For contaminates that will not remove easily, solvents approved
by the manufacturer may be used. Examine for evidence of moisture that may
lead to tracking or flashover while in operation. Examine surrounding areas
for signs of tracking, arcing, or overheating. Repair or replace damaged
insulators and supports as necessary.
Examine all bolts and connecting devices for signs of deterioration, corrosion,
or overheating. Ensure that bolts and connecting devices are tight, according
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to manufacturer’s specifications. Be careful not to overtorque bolts and

connecting devices since insulators are easy to damage and difficult to
replace. Where copper and aluminum conductors and/or connectors are used
together, examine connections for signs of galvanic action. Ensure that the
connectors are properly used and installed in accordance with manufacturer’s
specifications. Apply an antioxidant compound to all aluminum-to copper
connections.
1.3. Conductors
Examine insulation for signs of deterioration, cracking, flaking, or overheating.
Examine all connections for signs of overheating, cracked or broken
connectors, and signs of tracking or arcing. Ensure that conductors are clean
and dry. Examine and clean all connections, and torque to manufacturer’s
recommendations.
2. Air Circuit Breakers
2.1. Insulation
Remove and clean interphase barriers. Clean all insulating materials with
vacuum and/or clean lint free rags. If it is necessary to use cleaning solvents,
use only solvents recommended by the manufacturer. Inspect for signs of
corona, tracking, arcing, or thermal or physical damage. Ensure that
insulation is left clean and dry.
2.2. Contacts
Ensure that all contacts are clean, smooth, and in proper alignment. Ensure
that spring pressures are maintained according to manufacturer’s
specifications. On silver contacts, discoloration is not usually harmful unless
caused by insulating deposits. Clean silver contacts with alcohol or silver
cleaner using non-abrasive cloths.
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Manually close breaker to check for proper wipe, contact pressure, contact
alignment, and to ensure that all contacts make at approximately the same
time. If possible, a contact resistance test should be performed to determine
the quality of the contacts.
Older breakers equipped with carbon contactors generally require very little
maintenance. Examine for proper pressure, deterioration, or excessive
dressing which may interfere with their proper operation.
Draw-out contacts on the circuit breaker and the stationary contacts in the
cubicle should be cleaned and inspected for overheating, alignment, and
broken or weak springs. Coat contact surfaces with contact lubricant to ease
mating (see manufacturer’s recommendations).
2.3. Arc Interrupters

Clean all ceramic materials of loose dirt and examine for signs of moisture,
make sure the assemblies are clean and dry. Examine for cracked or broken
pieces. Dirt and arcing deposits may be removed by light sanding — do not
use emery cloth or wire brushes which may leave conductive residue behind.
Repair or replace as necessary.
Examine arc chutes for dirt and/or dust accumulations and clean as
necessary. Dielectric testing of arc shields may be recommended by the
manufacturer. Check air puffer for proper operation.
2.4. Operating Mechanism

Inspect for loose, broken, worn, or missing parts (consult manufacturer’s
schematics for required parts). Examine for excessive wear of moving parts.
Observe that operating mechanisms function properly without binding,
hanging, or without delayed action. Ensure any lubrication is done according
to the manufacturer’s specifications. Ensure mechanisms are clean, properly
lubricated, and all bolts and screws are properly secured. Repair or replace
as necessary.
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2.5. Auxiliary Devices

Inspect operating devices for proper operation and general condition. Ensure
all indicating devices are fully functional and properly set. Protective relays
and circuit breaker trip devices should be inspected and tested according to
manufacturers’ specifications and applicable industry standards such as
those issued by the Institute of Electrical and Electronics Engineers (IEEE)
and the National Fire Protection Association (NFPA).
3. Vacuum Circuit Breakers

All maintenance is similar to that performed on air circuit breakers. As always,
it is recommended that the manufacturer be consulted for specific
maintenance and testing procedures.
The integrity of the vacuum chamber is often tested by applying a test voltage
across the open contacts of the breaker. However, this can be a destructive
test and is therefore not recommended by Hartford Steam Boiler.
Caution: This procedure can produce X ray emissions, so personnel should

maintain a safe distance from the breaker if this test is performed. It is
important to closely follow manufacturer’s recommended procedures if
conducting this test in order to ensure that proper results are obtained. The
breaker vapor shield can accumulate an electrostatic charge during this test.
Ensure that it is discharged immediately following the test.
4. Air Disconnect Switches

Inspect and clean insulators and conductors as with circuit breakers. Tighten
connections in accordance with manufacturer’s specifications. Do not
overtighten as this may result in damage to connectors. If cleaning solvents
are used, ensure that they are as recommended by the manufacturer. Where
abnormal environmental conditions exist, more frequent inspection and
cleaning may be required.
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Check the operation of the arc blades, if applicable, and ensure proper wipe
of the main contacts. Interphase linkages and operating rods should be
inspected to make sure that the linkage has not been bent or distorted and
that all fastenings are secure. The position of the toggle latch to the switch
operating linkage should be observed on all closed switches to verify the
switch is mechanically locked in a closed position. Operate switch manually
several times to ensure proper operation, and then by motor if power-
operated. Ensure that all moving parts are properly secured and lubricated as
specified by the manufacturer.
Contact resistance testing of each phase contact should be performed. The

results should be recorded and analyzed to ensure proper contact is being
made. If the contact resistance of the switch exceeds recommended
minimums, repair or replace the switch immediately.
5. Oil Circuit Breakers
5.1. External
Inspect the enclosure for signs of oil leakage. Clean external bushings
assemblies and examine for signs of deterioration, tracking, and loose or
broken parts. Observe oil gauge to ensure device is operating properly and
measuring the oil level accurately.
5.2. Insulating Oil Test

Conduct a dielectric screen test of the insulating fluid. Based on the results of
this test, filter or replace oil as required. Heavy carbon content can indicate
potential contact wear and should be investigated further.
5.3. Internal
Since the contacts for oil circuit breakers are not readily accessible for
inspection, the contact resistance should be tested as a minimum.
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More extensive maintenance on the contacts might be require draining the oil
and dropping the tank, and is therefore performed less frequently. Follow
manufacturer’s recommended schedule for examination of internal
components such as contact inspections. Open breaker and examine
contacts for wear and/or excessive deterioration. Examine linkages for loose,
broken, or missing parts; repair or replace as necessary.
5.4. Auxiliary Devices

Operating mechanisms should be maintained as with air circuit breakers.
Where applicable, examine oil level indicators, sight glasses, oil lines,
gaskets, and tank lifters for proper conditions. Repair or replace as necessary
and in accordance with manufacturer’s recommendations.
Examine arc-quenching assemblies for carbon deposits or other

contaminates. Follow manufacturer’s recommendations for cleaning.
6. Molded-Case Circuit Breakers

Molded-case circuit breakers should be kept clean for proper ventilation of the
breakers. These types of breakers are usually tripped by a thermal element
that senses an increase in temperature due to excessive current draw.
However, if dirt accumulates on the surrounding of the breaker, the heat
build-up may not be permitted to dissipate properly and result in nuisance
tripping.
Clean the breaker housing and inspect it for cracks or signs of overheating.
Tighten all connections. Exercise the breaker several times to ensure the
mechanism has freedom of movement and to allow contact wiping.
In addition, larger duty circuit breakers (225 amps or above) should be

electrically trip tested to ensure proper operation of the trip elements and trip
linkages. Refer to the latest edition of the National Electrical Manufacturer’s
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Association (NEMA) Standard AB4, Procedures for Verifying Field

Inspections and Performance Verification of Molded-Case Circuit Breakers. If
possible, test contact resistance to ensure quality of breaker contacts.
All molded-case circuit breaker panels should be cleaned of all dirt, dust, and
debris using a vacuum.
7. Battery Stations / Chargers
7.1. Batteries
Thoroughly clean all battery surfaces of dust and/or dirt accumulations. Clean
and tighten all terminal connections. Remove any corrosion on battery
terminals with bicarbonate of soda.Clean battery studs and cable ends. On
stranded cable, if ends are corroded, cut off ends or separate strands and
clean internally. Check electrolyte levels and specific gravity. Variations of
more than fifty (50) points between cells may indicate a bad cell.
7.2. Charger
Clean all dust and/or dirt accumulations from charger. Clean all vent openings
and ensure that they are free from obstructions. Check terminals and
connections for tightness. Check all relays, lights, and other indicating
devices for proper operation. If all cells consistently read low, check charger
for proper operation. If electrolyte levels are low, check charger rate settings
against the manufacturer’s specifications. Consistently low levels may
indicate the charge rate is too fast.
7.3. Safety
While charging, batteries emit explosive gases. Allow no open flames or
sparks permitted near charging batteries. Battery rooms should be well
ventilated and smoking should not be permitted.
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8. Cables and Bus
De-energize cables if they are to be touched or moved during maintenance.
8.1. Cables in Manholes
Caution: Check for dangerous gases using a properly calibrated test meter
before entering any confined space such as a manhole.
Inspect for sharp bends, physical damage, excessive tension, oil leaks, pits,
cable movement, soft spots, cracked jackets, damaged fireproofing, poor
ground connections, deteriorated and corroded or weakened cable supports.
Inspect for wear at entrance point and at supports. Inspect manhole for
spalled concrete, proper ventilation and excessive moisture. Inspect potheads
for oil or compound leakage and for cracked / chipped porcelain.
Examine the manhole and cable grounding system to ensure its integrity. If
cathodic protection has been installed in the manhole, it too should be
evaluated. Corrective action should be taken as appropriate to maintain the
integrity of these systems.
8.2. Aerial Cables

Check supports for excessive wear or deterioration, check cables for wear at
support points, inspect for mechanical damage from vibration. At dead-ends,
check cable for worn insulation, sharp bends, or cracks.
8.3. Raceways
Check raceways for proper mechanical support of raceway and cables as well
as check insulation for abrasion or cracks at support points. Examine raceway
joints for clean and tight connections.
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8.4. Bus Duct

Bus duct joint covers should be removed to allow access for a thermographic
survey of the energized bus under load. After de-energizing and grounding
the bus duct, connections should be checked for proper tightness as well as
evidence of overheating, corrosion, arcing, or other forms of deterioration. All
loose or dirty connections should be cleaned and properly torqued — be
careful not to overtorque the bolts. Consult the manufacturer for
recommended maintenance practices and torque values. The tops of the bus
duct enclosure should be inspected for evidence of water or other foreign
matter that may contaminate the bus duct.
8.5. Testing
Suggested cable or bus tests include insulation resistance testing and
polarization index testing. These tests should be recorded to track trends that
may indicate a deterioration of the cable’s insulation.
9. Transformers
Transformer data (such as, voltage, current, and temperature readings)

should be recorded on a regular basis in order to determine operating
conditions of the transformer. Peak, or redline, indicators should be recorded
and reset. Readings taken on a weekly basis can provide important
information about the loading of the transformer that is needed before
additional loads can be added to the transformer.
9.1. Dry Type Transformers

After de-energizing and grounding the transformer, clean all coils,
connections, and insulators of loose dust or dirt deposits with a vacuum
cleaner. Examine the transformer for signs of overheating, deterioration,
arcing, loose or broken parts, or other abnormal conditions. Ensure all
Page 24
connections are tightened according to manufacturer’s specifications. Clean

enclosure of any dust and dirt accumulations and ensure that vent openings
are free from obstruction. If cooling fans are installed, examine for proper
operations and lubricate as necessary.
Additional suggested testing includes an insulation resistance test, a dielectric

absorption test, and a power factor test. These are non-destructive tests
which can be performed to track the condition of the insulation over time.
Detailed records should be maintained and analyzed to identify undesirable
trends that may indicate the onset of an insulation failure.
9.2. Liquid-Filled Transformer

Insulating liquid samples should be taken annually and screen tested for
dielectric breakdown, acidity, color, power factor, and interfacial tension. A
Fault gas analysis or a Dissolved-Gas-in-Oil (DGA) test conducted by a
qualified testing laboratory should be performed annually. The results should
be trended to track conditions and schedule maintenance as necessary.
Examine the transformer tank and bushings for evidence of leakage. Inspect
the bushings, insulators, and surge arrestors for broken or damaged parts,
signs of overheating or arcing, or tracking. Clean all bushings, insulators, and
surge arrestors of any dirt or dust accumulation. Tighten all conductor
connections in accordance with manufacturer’s recommendations. If
applicable, perform a ground resistance test to ensure a value of 25 ohms or
less.
10. Surge Arrestors

Clean and inspect porcelain for signs of damage or deterioration. Repair or
replace as necessary.
Examine arrestor leads for damage and/or deterioration.
Page 25
Other suggested tests are 60 cycle spark over and hold tests, watts-loss and
leakage current tests, insulation resistance tests, and grounding electrode
circuit resistance tests. These should be conducted according to
manufacturer’s recommendations.
11. Protective Relays

Inspection, maintenance and testing of protective relays should be done on
an annual basis in order to ensure proper and reliable operation. All
necessary precautions should be taken while working with protective devices
to ensure personnel safety and to avoid any unplanned interruption of service.
In particular, when working on control circuits, all current transformer (CT)
secondaries should be shorted to ground and never left open-circuited in
order to avoid serious injury to maintenance personnel.
11.1. Visual and Mechanical Inspection

Inspect relays for physical damage and deterioration. Inspect gaskets and
covers for damage and/or excessive wear, and repair or replace as
necessary. Examine and clean the relay and enclosure of foreign materials,
such as dust, dirt, and moisturecontamination. Examine the condition of the
spiral spring, disc clearances, contacts, and case shorting contacts (if
present). Check mechanism for freedom of movement, proper travel and
alignment, and tightness of mounting hardware and plugs.
11.2. Electrical Testing

Using an appropriate testing instrument, suitable for the relays being tested,
conduct electrical testing of the relays in accordance with manufacturer’s
recommendations and IEEE testing standards. For overcurrent relays, test
the following functions of the relay at the established settings specified by the
system engineer or manufacturer:
Page 26
• Pickup contacts should close when a current equal to the relay tap setting is
applied to the induction coil. Adjust the spring as needed to allow for proper
operation.
• Timing tests should be performed corresponding to two (2) or more points

on the relay’s timecurrent curves. One of the tests should be done at the
specified time dial setting.
• Instantaneous pickup test should be performed for the specified

instantaneous setting, if applicable.
• Seal-in units should be tested to ensure that the contacts hold closed with
the minimum specified current applied.
• Relay target should indicate when the relay has operated.
• If possible, the relays should be tested to ensure that operation of the relay
will in fact cause a tripping action of the respective circuit breaker. Relays that
do not test satisfactorily or are found to be defective should be replaced
immediately to maintain the integrity of the protection systems.
12. UPS Systems

This section provides general recommended maintenance guidelines for
Uninterruptible Power Supply (UPS) systems. Since there is a wide variety of
systems and equipment available, the manufacturer’s instructions and
recommendations should be consulted for more complete and detailed
maintenance requirements.
UPS systems are categorized in two basic ways: static and rotary. For the
purposes of this standard, only static systems will be addressed.
Page 27
When performing any maintenance and/or testing of UPS systems, follow all
recommended safety procedures as indicated by the manufacturer and
required by OSHA. Only fully trained and qualified persons with proper test
equipment should perform UPS maintenance.
Clean interior and exterior of cabinets and enclosures, ensuring that any
areas of corrosion and/or deterioration are repaired as necessary. Clean all
vent and air circulation openings and ensure freedom from obstructions. If
installed, clean cooling fan blades and motor housings. Ensure that motor
bearings are properly lubricated and that fan blades are properly secured to
drive shafts. Examine for signs of moisture contamination and correct if
necessary.
Clean and examine all electrical connections for signs of corrosion or

deterioration, repair or replace as necessary. Ensure all connections are
tightened according to manufacturer’s specifications. As applicable, clean and
test all breakers, disconnects, and relays as prescribed elsewhere in these
standards and as specified by the manufacturer. Check all system alarms and
indicating lights for proper operation.
Check inverters for fluid leaks from wave-forming capacitors. Check

capacitors for signs of bulging or discoloration. Examine transformers and
heat sinks for signs of overheating. Maintain batteries as prescribed in section
3.7 of this standard and as specified by the manufacturer.
Page 28
Name: _____________________________ Date: ___________________________
1. Switchgear
a.
b.
c.
2. Cables and Bus
a.
b.
c.
d.
e.
3. Battery Stations / Chargers
a.
b.
c.
4. Oil Circuit Breakers
a.
b.
c.
d.
Page 29
5. Protective Relays
a.
b.
6. Transformers
a.
b.
Test II. Discussion: (10 points each)
1. Discuss briefly the safety procedures in maintaining Vacuum Circuit

Breakers.
2. Discuss briefly the safety procedures in maintaining Cables and
Buses..
3. Discuss briefly the procedures in testing relays.
Note:Excellent - 50 points Retake - below 18 points

Page 30
Electrical Safety in Electrical

Information Sheet-3
Equipment Maintenance
Electrical safety in motor maintenance and testing carries the same requirements as
anyother work that involves working on or near exposed energized and deenergize
parts ofelectrical equipment operating at 50 volts to ground or more. This iformation
sheet will address the hazards associated with working on or nearelectrical circuits and
equipment, as well as the personal protective equipment (PPE) andsafe work practices
that must be used to protect workers from the hazards.
Electrical Hazards
We must first understand the hazards of electricity. All of the studies reviewed
haverevealed three major hazards of electricity, which are: 1) electrical shock, 2)
electrical arc flash and 3) electrical arc-blast. Each of these hazards will be addressed
as to thebmphysiological effect on the human body and the analysis needed to
determine the extent ofthe hazard.
Electrical shock
It takes a very low value of current, flowing through the human body, to cause death or
serious physical harm. Many studies have been performed in this area with different
values of current that causes each effect. The following chart shows average values of
current and the effects as taken from the published studies:
Current Effect
1 mA Barely perceptible
1 – 3 mA Perception threshold (most cases)
3 – 9 mA Painful sensations
9 – 25 mA Muscular contractions (can’t let go)
25 – 60 mA Respiratory paralysis (may be fatal)
60 mA or more Ventricular fibrillation (probably fatal)
Page 31
4 A or more Heart paralysis (fatal)

5 A or more Tissue burning (fatal if vital organ)
Physiological Effects of AC Current on the Body
Electrical arc-flash
There are two different issues with this hazard, the arc temperature and the
incidentenergy. The main concern with the arc temperature is the flash flame and
ignition ofclothing. At approximately 2030F (960C) for one-tenth of a second (6 cycles),
the skin isrendered incurable or in other words a third-degree burn. With only 1.2
cal/cm2 of incidentenergy, we have the onset of a second-degree burn. It does not take
a very hightemperature or very much energy to cause extreme pain and discomfort to
the worker.
Electrical arc-blast
The pressures developed by an electrical arc can be extremely high. One study noted
thatcopper, when vaporized, expands at a factor of 67,000 times, which one expert
estimatedwas the same expansion as that produced by dynamite. Doors or covers must
besecurely latched before operating a switch or circuit breaker. Technicians or
operatorsmust place their body in the safest position possible before operating the
equipment.
Page 32
Shock Hazard Analysis
Each year several hundred workers are killed due to inadvertent contact with energized
conductors. Because of this, the 2004 edition of NFPA 70E established a
newrequirement for conducting a “Shock Hazard Analysis” in order to determine the
voltage
that a person would be exposed to, establish shock protection boundaries, and
determinethe proper personal protective equipment.
Recent investigations into the causes of these fatalities point to three principle factors:
 Failure to properly or completely de-energize systems prior to

maintenance or repair work;
 Intentionally working on energized equipment; and
 Improper or inadequate grounding of electrical system components.
These three factors form the basis for hazard analysis of the electrical shock hazard.To
appropriately assess the electrical shock hazard associated with any type
ofmaintenance or repair work, it is necessary to evaluate the procedures or work
practices
that will be involved. These practices should be evaluated against regulations
andconsensus standards requirements as well as recognized good practice within
theindustry. These principles are summarized below.
OSHA Regulatory Requirements
 All equipment must be placed in a deenergized state prior to any maintenance or

repair work. (Limited exceptions exist).
 The deenergized state must be verified prior to any work.
 The deenergized state must be maintained through the consistent use of locks
andtags, and in some cases, grounding.
Page 33
 When energized work is performed, it must be performed in accordance with

writtenprocedures.
NFPA 70E-2004 Standard Requirements

· The Shock Hazard Analysis must establish the:
1. Limited Approach Boundary
2. Restricted Approach Boundary
3. Prohibited Approach Boundary
 This applies to all exposed live parts operating at 50 volts or more
 Only qualified persons are permitted within these boundaries.
 Unqualified persons may not enter these boundaries unless the conductors and
equipment have been placed in an electrically safe work condition.
Industry Recognized Good Practices

 Plan every job.
 Anticipate unexpected results and the required action for these results.
 Use procedures as tools.
 Identify the hazards. Keep unqualified workers away from these hazards.
 Assess employee’s abilities. Remember, there is a difference between ten years
ofexperience, and one year of experience repeated ten times.
In addition to the assessment of work practices, the shock hazard analysis must include
an assessment of the physical condition of the electrical system. The assessment must
also identify the proper PPE for shock protection, which would include, but not be
limitedto, rubber insulating gloves with leather protectors, rubber blankets and mats,
insulatedhand tools, and properly rated test equipment.
Page 34
Insulated Tools and Rubber Insulating Gloves
Of equal importance is to insure that equipment covers and guards are in place;
thataccess to exposed conductors is limited to electrically qualified personnel; and
overcurrentprotective devices are operable and of appropriate interrupting rating. Even
the safestprocedures, when performed on poorly constructed or maintained equipment
represent arisk to employees.
Flash Hazard Analysis
An estimated 75% to 80% of all serious electrical injures are related to electrical
arcscreated during short circuits and switching procedures. In recognition of this
Page 35
fact,standards organizations such as the National Fire Protection Association (NFPA)

have
provided the industry with better techniques to evaluate both the magnitude of
theelectrical arc hazard and appropriate protective clothing and equipment.An electrical
arc is basically an electrical current passing through ionized air. This currentflow
releases a tremendous amount of energy as both radiated light and convected heat.The
amount of liberated energy is obviously dependent upon the system configuration,
butthe principle factors used in the determination of the hazard to personnel are as
follows:
1. Available short circuit current at the arc location.
2. Duration of the electrical arc (protective device clearing time).
3. Distance from the arc to personnel.
4. The arc gap.
5. Environmental conditions and surroundings at the arc location.
To accurately assess the arc hazard, and make appropriate decisions regarding
personalprotective clothing, it is necessary to fully understand the operation of the
system underfault conditions. This requires both a short circuit analysis, in all likelihood
down to thepanel board level, and a protective devices coordination study. It is a
commonmisconception that arc hazards are an effect of only high voltage. The actual
arc hazard isbased on available energy, not available voltage. In certain conditions, a
low voltage arc’sduration is longer than a high voltage arc. With this information
available, the magnitudeof the arc hazard at each work location can be assessed using
several techniques. Thesetechniques include:
· NFPA 70E-2004 Equations and Tables.
· IEEE Std. 1584-2002.
· SKM, E-Tap, EDSA, EasyPower, and other similar engineering software.
Each of these techniques requires an understanding of anticipated fault conditions, and

the limitation of the calculation method, both of which are beyond the scope of this
paper.The results of the arc hazard assessment are most useful when they are
Page 36
expressed interms of the incident energy received by exposed personnel. Incident

energy is commonlyexpressed in terms of calories per cm2 (cal/cm2). Arc protective
clothing is rated in termsof its Average Thermal Performance Value (ATPV), also
expressed in terms of cal/cm2.In addition to flame-resistant (FR) clothing and PPE,
there are some safe work practicesthat can be adopted to minimize or eliminate the
hazards. These practices includeclothing, body positioning, insulated tools, and other
factors that must be carefullyscrutinized to insure that the risk to employees is
minimized. The first choice should be tominimize or eliminate the hazard; however when
this is not possible FR rated clothing andPPE must be utilized.
The 2005 NEC Section 110.16 states, “Switchboards, panel-boards, industrial

controlpanels, and motor control centers that are in other than dwelling occupancies
and arelikely to require examination, adjustment, servicing, or maintenance while
energized shallbe field-marked to warn qualified persons of potential electrical arc-flash
hazards. Themarking shall be clearly visible to qualified persons before examination,
adjustment,
servicing or maintenance of the equipment.”Section 80.9(B) sets forth the provision for
the Authority Having Jurisdiction to require allexisting equipment to be marked if it is
determined that non-conformity would present aneminent danger condition to occupants
or qualified workers. Because of the NEC 2002requirements, we can conclude the
following:
1. The 2002 NEC requires equipment to be field-marked to warn of potential
flashhazards.
2. The energy level will have to be determined from Short Circuit and
Protective DeviceCoordination Studies.
4. The Authority Having Jurisdiction may require all facilities to be marked.
Page 37
Recommended Warning Label
As with the electrical shock hazard, the easiest and most effective way to mitigate the
archazard is to completely de-energize the system for any type of maintenance activity.
Blast Hazard Analysis

An electrical blast, or explosion, as it is often termed, is the result of the heating effects
ofelectrical current and the ensuing arc. This phenomenon occurs in nature as the
thunderthat accompanies lightning, a natural form of an electrical arc.During an
electrical arc, both the conducting material and the surrounding air are heated
Page 38
toextremely high temperatures. The resulting expansion of the air and vaporized
conductivematerial creates a concussive wave surrounding the arc. The pressures in
this wave mayreach several hundred lbs/ft2, destroying equipment enclosures and
throwing debris greatdistances. Pressures as low as 50 lbs/ft2 have knocked down
cinderblock walls severalfeet away. The pressure created during an electrical explosion
is directly proportional tothe available short circuit at the arc location. With an up-to-date
short circuit studyavailable, the anticipated blast pressure can be estimated from tables
or charts.
Unfortunately, little can be done to mitigate the blast hazard, at least in terms of
personalprotective clothing or equipment. Blast pressure calculations can be used to
determinewhether enclosures will withstand an internal fault if sufficient manufacturer’s
data isavailable. Again, it may be more important to merely recognize the magnitude of
thehazard so that appropriate safety practices, such as correct body positioning can be
incorporated into work procedures. If the blast hazard is high, or if it is in a limited
space,the blast can severely injure or kill a person. If these conditions are present,
seriousconsideration should be given to not allowing personnel in the area during
specificequipment operations.
Page 39
Selection of Electrical Protective Equipment

Most employers, operators, and electricians are knowledgeable in the selection
andinspection requirements for electrical PPE used for the prevention of electrical
shockhazards, as well as head, eye, hand, and foot protective equipment. These
requirementsare readily found in OSHA 29CFR1910, Subpart I, “Personal Protective
Equipment” with1910.137 covering “Electrical Protective Equipment” which also
provides requirements forthe in-service care and use of electrical protective equipment.
Unfortunately, most havelimited knowledge or experience with the arc and blast hazards
that may be associatedwith the maintenance, testing, and operation of energized
electrical equipment and thenecessary protective clothing and equipment that would be
required.
The OSHA requirements for the hazard analysis and selection of protective clothing are
found in 29CFR1910.132, “General Requirements for Personal Protective Equipment”,
paragraph (d) states “The employer shall assess the workplace to determine if hazards
arepresent, or are likely to be present, which necessitates the use of Personal
ProtectiveEquipment (PPE). If such hazards are present, or likely to be present, the
employer shall:“Select, and have each employee use, the type of PPE that will protect
the affectedemployee from the hazards identified in the hazard assessment.”1910.132
(f) – Training (1) states: “The employer shall provide training to each employee who is
required by this section to use PPE. Each such employee shall be trained to knowat
least the following:”
 When PPE is necessary;
 What PPE is necessary;
 How to properly don, doff, adjust, and wear PPE;
 The limitations of the PPE; and
 The proper care, maintenance, useful life, and disposal of PPE.
Included in this hazard assessment should be the three electrical hazards; shock, arc,
andblast. 1910.137 identifies the selection, inspection, and use requirements for
Page 40
electricalPPE. OSHA does not identify specific clothing that should be worn to protect
theemployee from the arc-flash hazards but OSHA does specify what type of clothing is
prohibited. OSHA states “Clothing made from the following types of fabrics, either alone
or in blends, is prohibited…, unless the employer can demonstrate that the fabric has
beentreated to withstand the conditions that may be encountered or that the clothing is
worn insuch a manner as to eliminate the hazard involved: acetate, nylon, polyester,
rayon.”
OSHA also requires protection from the hazards of electricity in 1910.335(a)(2)(ii) which
states: “Protective shields, protective barriers, or insulating materials shall be used to
protecteach employee from shock, burns, or other electrically related injuries while that
employee isworking near exposed energized parts which might be accidentally
contacted or wheredangerous electric heating or arcing might occur.”If, during the
operation, insertion, or removal of a circuit breaker, a fault occurs, the workermay be
exposed to an electric arc with temperatures up to 35,000ºF. Unprotected
workersexposed to an increase in skin temperature of 203ºF for 0.1 second or 1.2
cal/cm2 ofenergy may suffer second or third degree burns and ignition of clothing.
Protectiveclothing, including a complete multi-layered flash suit with hood and face
shield, may be
required for these activities.
Once it has been determined that protective clothing and/or equipment is necessary
toperform the specific task, it must be purchased and the employees trained to wear
itproperly. Having the properly sized and rated clothing will provide protection of
theemployee when performing the task. The required PPE may be uncomfortable to
wear,especially in hot climates but it is better to suffer ten minutes in an
uncomfortableenvironment then ten months, or longer, in a burn center.
Page 41
Name: _____________________________ Date: ___________________________
Page 42
Note: Satisfactory rating - 7 points Unsatisfactory - below 4 points

Information Sheet-4 Electric Motor Care and Maintenance
Electric Motors
A maintenance program for electric motors should utilize proven and well understood
testing and inspecting methods performed by qualified knowledgeable personnel to
identify and evaluate conditions.
Page 43
Recommended Maintenance Practices and Frequencies

Installed and running – Actions typically performed with the motor installed and coupled
to the driven load.
Installed and offline – Actions which require the motor to be electrically disconnected
but can be performed with the motor installed and coupled.
Overhaul – Actions typically completed during a routine overhaul. Additional testing /
activities may be required based on the individual situation.
Post Overhaul – After completion of maintenance, the insured should review work
report, ensure all parts sent with the motor(i.e. terminal box,
couplings) were returned and perform basic testing of the motor
before placing it in the stock system.
Maintenance Location Performance characteristics Frequency

activity
Visual Installed Inspection should look for: 6 MONTHS
Inspection and running Evidence of damage caused by dirt, loose
parts, or foreign objects.
Verification that air inlets are not blocked
Evidence of moisture and/or dirt build-up
Unusual noises, leaking oil seals, or high
vibration
Oil level gages (if present) should be
checked
Evidence of degradation of foundation, bed
plates, anchor bolts
Evidence of oil rings turning (if applicable)
Evidence of leaking oil and water piping
and connections
Temperature Installed If motor is not equipped with installed 6 Months
monitoring of and running sensors:
bearings and record bearing temperatures and stator
windings temperature using thermographic imaging.
This data should be trended. The
monitoring should be completed at similar
motor loading and ambient temperature to
allow for accurate trending.
Vibration Installed Record and trend vibration levels. 6 months
and running This should be done by a trained and
Page 44
experienced technician, preferably a

qualified level II technician.
Oil analysis Installed Sample and analyze. Look at overall 12 Months
conditions and check for foreign matter,
additive depletion, varnish precursors and
metallic elements.
Motor should be shut down when taking
sample.
Running Installed Record and trend all three phase currents 12 Months
current and running and verify the currents are balanced and
do not exceed nameplate rating.
Each phase should be within +/- 5% of the
average of all three phases
Insulation Installed Perform IR check between motor leads 12 months
resistance(IR) and off line and ground. This determines condition of for > 600
the ground insulation. Record, temperature Volt motors
correct and trend 24 months
Motor Test Acceptable for < 600
voltage voltage(Vdc) reading Volt motors
< 1000 500 > 5 megohm
1000 -2500 1000 > 100 megohm
2501-5000 2500 > 100 megohm
> 5000 5000 > 100 megohm
Polarization Installed Ratio of the 10 minute IR to the 1 minute 12 months
index (PI) and off line IR. for > 600
(10 min IR / 1 min IR) Volt motors
Determines condition of ground insulation 24 months
Test voltages similar to the IR test voltages for < 600
Acceptance criteria ratio > 2 Volt motors
Winding Installed A comparison of the line to line resistances 12 months
resistance and off line of the motor’s winding. This test should be for > 600
done at the motor terminals using a meter Volt motors
capable of measuring low resistance 24 months
(milliohms). A typical ohm meter does not for < 600
have adequate accuracy. Record, Volt motors
temperate correct and trend.
Each phase should be within +/- (3% - 5%)
of the average of all three phases
Bearing overhaul Completed similar to other IR (megger) 60 months
insulation test. Used to verify condition of insulation
resistance on a bearing.
check (if Test voltage: 500 Vdc
applicable) Acceptance criteria: 1 megohm
Shaft total overhaul Measure the trueness of the shaft 60 months
indicated run extension. A high value can cause
out (TIR) vibration issues.
Page 45
Acceptance criteria: 3600 rpm max .001 in

< 3600 rpm max .003 in
Inspection and overhaul Diameters of the fits should be measured 60 months
measurements and compared to bearing industry
of bearing standards.
journals and Brg journals and housing bores should be
housing fits visually inspected for finish, pitting, rubbing
and corrosion.
Stator visual overhaul Inspection should look for: 60 months
Inspection coil movement
plugged vent holes
soft or degraded insulation
coil bracing adequate and intact
lamination damage
partial discharge activity
tightness of wedges
Rotor / Shaft overhaul Inspection should look for: 60 months
visual cracks in rotor bars
Inspection balance weights properly secured
signs of bar movement
signs of rotor/stator rub or lamination
damage
cooling ducts clear
rubbing marks on shaft
keyway distortion
Clean*, bake overhaul All parts should be cleaned and baked dry 60 months
dry and to remove all dirt and contamination. The
varnish (as windings should be reinsulated as
needed) appropriate.
Insulation overhaul Perform IR check between motor leads 60 months
resistance and post and ground. This determines condition of
overhaul the ground insulation. Record, temperature
correct and trend
Motor Test Acceptable
voltage voltage(Vdc) reading
< 1000 500 >5
1000 -2500 1000 >100 megohm
2501-5000 2500 >100 megohm
> 5000 5000 >100 megohm
Polarization overhaul Ratio of the 1 minute IR to the 10 minute 60 months
index (PI) and post IR. Determines condition of ground
overhaul insulation.
(10 min IR / 1 min IR)
Test voltages similar to the IR test voltages
Acceptance criteria ratio > 2
Winding overhaul A comparison of the line to line resistances 60 months
Page 46
resistance and post of the motor’s winding. This test should be

overhaul done at the motor terminals using a meter
capable of measuring low resistance
(milliohms). A typical ohm meter does not
have adequate accuracy. Record,
temperate correct and trend.
Each phase should be within +/- (3% - 5%)
of the average of all three phases.
Surge Test overhaul The test verifies the insulation condition 60 months
between the turns of a motor’s winding. It
can be a destructive test. This test should
only be done after the visual inspection,
the other electrical checks and the clean
and drying process. Test
voltage(overhaul): 2 x rated voltage + 1000
Acceptance criteria: steady and duplicate
patterns
Rotor balance overhaul Balance process minimizes the out of 60 months

balance of the rotor. Acceptable levels are
based on speed and application of the
machine.
Core loss overhaul This test is completed on both the rotor 60 months
and stator This test excites the core to
determine overall core loss levels and
locate any shorted laminations. Any
hotspots or high core loss found should be
investigated and corrected.
Broken rotor overhaul Methods to check for cracked rotor bars 60 months
bar checks include visual, audible, hot spot check,
growler, magnetic paper, single phase
rotation.
No load run overhaul This test is performed after all work has 60 months
test with been completed. Test should verify
vibration acceptable current balance, bearing
measurements temperatures, vibration levels and no
unusual rubbing or noises present.
There are several methods of acceptable cleaning. These include water spray, low
pressure steam cleaning and cryogenic (CO2 pellets) cleaning. The intent of cleaning is
to remove all dirt and contamination, including any grease or oil film on the windings.
Cleaning methods should not utilize high pressure flow or any abrasive methods that
could cause damage to the windings.
Page 47
An industry accepted test to verify the integrity of the turn to turn insulation in an electric
motor is a Surge or Impulse test. This test uses a charged capacitor to pulse a voltage
into two windings of a motor simultaneously. The voltage is set low to begin and raised
slowly while the operator watches the wave forms on an oscilloscope. The voltage pulse
is eventually raised to twice the operating voltage, plus 1000 volts. Since the windings
are supposed to be identical, the wave forms should be identical - a difference in wave
forms indicates a problem. A skilled operator can determine the exact type of fault (turn
to turn, phase to phase etc.) by studying the wave form patterns. This test can be
considered a potentially destructive test because marginal motors can fail under test.
This test should only be performed during an overhaul period, after the visual
inspection, the other electrical checks and the clean and drying process has been
completed.
Motor Current Signature Analysis is a relatively new test that can help detect rotor and
stator issues based on the current waveform of the motor. This test evaluates the
condition of the motor by analyzing the frequency spectrum of the line current. This test
is still considered in the developmental stage by HSB. Industry standards for test
procedures or acceptance criteria have not been established.
There are additional tests which can be completed on motors at voltage levels 4160
volts and higher. These tests include power factor (or dissipation factor), capacitance
and partial discharge test. These tests can be very beneficial but they are highly
specialized. They should be evaluated on a case by case basis to determine their
suitability.
4.0 Infrared Inspection
An infrared, or thermographic, inspection should be performed at least once every three

years on all switchgear, distribution panels, cable and bus connections, motor control
centers and starters, and other critical equipment. Infrared inspections are extremely
beneficial in reducing electrical failures by identifying potentially dangerous conditions;
such as, loose or dirty connections, overloaded or imbalanced circuits, or improperly
Page 48
installed equipment. By measuring the heat imbalance relative to the environment and
to surrounding equipment, abnormal or adverse conditions can be uncovered that if left
unattended would worsen to the point of failure.
Infrared (IR) surveys are very helpful in planning the work scope of an upcoming
scheduled outage. Prior to the planned maintenance, an IR survey should be conducted
to help identify areas that need specific and immediate attention. Resources can then
be allocated to address these specific problems during the de-energized period.
Infrared surveys are done on energized equipment and should be conducted during
peak demand periods if possible. This will reveal the most serious problems and those
that would otherwise go undetected. At a minimum, the loading should be at least 40%
of the rated load of the equipment being inspected.
Effective infrared surveys require specialized equipment and should be performed only
by qualified technicians. Experience and training is required to accurately identify
problem conditions and possible causes so that specific recommendations can be made
to correct the situation. It is imperative that these recommendations be implemented in
a timely manner to benefit from an infrared inspection. Knowing a problem exists does
not help avoid an electrical failure unless corrective actions are employed.
5.0 Record Keeping
The electrical preventive maintenance program should be well-documented as to scope

and frequency of maintenance. Record all routine maintenance activities and the results
of routine testing for trending purposes. Document all repair and/or replacement of
electrical components. When changes are made to the electrical distribution system,
update all applicable drawings and maintenance schedules to reflect the changes.
Ensure that spare parts inventories are updated for any new equipment added based on
the manufacturer’s recommendations.
Page 49
6.0 Standards
Any electrical preventive maintenance program should be performed in accordance with

accepted industry standards and work / safety practices. This includes, but is not limited
to, the latest releases of the following:
 National Fire Protection Association (NFPA) 70B, Recommended Practice

for Electrical Equipment Maintenance.
 National Fire Protection Association (NFPA) 70, National Electrical Code.
 National Electrical Manufacturer’s Association (NEMA) Standard AB4,
Procedures for Verifying Field Inspections and Performance Verification of
Molded-Case Circuit Breakers.
 International Electrical Testing Association (NETA), Maintenance Testing
Specifications for Electrical Power Distribution Equipment and Systems.
 IEEE Std P1415 Motor Maintenance and Failure Analysis (draft).
 National Electrical Manufacturer’s Association (NEMA) Standard MG1.
 OSHA Applicable Standards.
 IEEE STD 1415, IEEE Guide to Introduction Machinery Maintenance Testing
and Failure Analysis
 National Fire Protection Association (NFPA) 70B, Recommended Practice
for Electrical Equipment Maintenance
 Standard for an Electrical Preventive Maintenance Program #420 (rev 02/10)
www.hsb.com ©2010 The Hartford Steam Boiler Inspection and Insurance
Company. All rights reserved. Page 13 of 13
 EEE STD 43, IEEE Recommended Practice for Testing Insulations
Resistance of Rotating Machinery.
Page 50
Name: _____________________________ Date: ___________________________
1. Actions typically performed with the motor installed and coupled to the driven
load.
a. Installed and running
b. Installed and offline
c. Overhaul
d. Post Overhaul
2. Actions which require the motor to be electrically disconnected but can be
performed with the motor installed and coupled.

c. Overhaul
d. Post Overhaul
3. Actions typically completed during a routine overhaul. Additional testing /
activities may be required based on the individual situation.
c. Overhaul
d. Post Overhaul
Page 51
4. After completion of maintenance, the insured should review work report, ensure
all parts sent with the motor(i.e. terminal box, couplings) were returned and
perform basic testing of the motor before placing it in the stock system.

c. Overhaul
d. Post Overhaul
5. An instrument used once every three years for inspection of electrical equipment
such as switchgears, distribution panels, cable and bus connections, motor
control centers and starters, and other critical equipment.
a. infrared, or thermographic
b. Digital Multimeter
c. Tachometer
d. Megger
6. A system used in electrical preventive maintenance program in order to scope

the frequency of maintenance
a. Maintenance Chart
b. Maintenance Schedule
c. Record Keeping
d. Monitoring
7. What statement is the requirement on the maintenance of electrical equipment?
a. Maintenance should conform to Industry standard

b. Maintenance should be planned carefully
c. Always apply maintenance
d. All of the above
Note: Satisfactory rating - 7 points Unsatisfactory - below 4 points

Page 52
Operation Sheet 1 Maintenance of Electric Motor
I. TITLE: Maintenance of Electric Motor
II. PURPOSE: At the end of this practice activity, the trainee/students will be able to:
 Identify parts of electric motor
 Des-assemble and assemble electric motor
 Maintain electric motor
III. CONDITIONS/SITUATION:
You are given a task to des-assemble and assemble electric motor.
IV. TOOLS, MATERIALS AND EQUIPMENT NEEDED:

A. Equipment
Electric Motor
B. Tools
Set of Screw Drivers
Long Nose Pliers
Side Cutter Pliers
Digital Multimeter
Clamp Meter
Tachometer
Megger
C. Materials
Cleaning Materials
Page 53
V. PROCEDURE
VI. Precautions
 Be careful of making scratch on the winding of electric motor.
 Always make mark on the body of the electric motor as reference for
assembling the parts.
 Tightness of the screws and bolt should be observed.
VII. Quality Criteria

 Proper use of hand tools
 Proper use of multi-tester
 Cleaning of parts
 Tightness of the screws and bolts
Page 54
LAP TEST/
Maintenance of Electric Motor
JOB SHEET 1
I. READING:
 Ethiopian Electrical Code
 Care and Maintenance of Electric Motor
 Electrical Safety in Motor Maintenance and Testing
II. OBJECTIVES:
At the end of the activity the trainee will be able to:

 Maintain electric motor.
III. LABORATORY WORK

Equipment/Facilities, Tools and Materials
A. Equipment/Facilities
 Electrical Motor
B. Tools
 Long nose plier
 Diagonal Side cutter plier
 Electrician plier
 Set of Screw Driver
 Digital Multitester
A. Materials
 Cleaning Materials
Page 55
IV. Procedure
OBSERVATION
PROCEDURE
CHECK LIST
Steps YES NO
Your task is to install start-stop motor control

system using magnetic starter.
1 Use of PPE
Use of Hand Tools
2
Testing of Resistance
3
Testing of Voltage
4
Testing of Current
5
Angular Velocity Testing
6
Insulation Resistance testing
7
Page 56

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4perform Maintenance of Electrical Equipment

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AKSUM TECHNICAL COLLEGE

Unit of Competence : Perform Maintenance of

Module Title : Performing Maintenance of

TTLM Code :CON BEI3 TTLM 1212V1

LO1. Plan and prepare for maintenance of electrical equipment

Instruction Sheet LEARNING GUIDE 4

 Maintenance of electrical equipment

 Repair electrical equipment

1. Read the specific objectives of this Learning Guide.

2. Read the information written in the “Information Sheets 1- 3”

3. Accomplish the “Self-check” in pages 22, 33, and 45.

4. If you earned a satisfactory evaluation proceed to “Operation Sheet 1”. However, if

Information Sheet-1 Preparing for Maintenance of Electrical Equipment

Actions Every Year Every Five Year

3.2 Cable penetration devices are still X X

3.3 No evidence of overheating, X X

3.4 Measuring equipment is in order. X X

3.5 Mechanical ventilation, if fitted, X X

3.6 Where a protection device has X X

8 An insulation measurement of any X

Inspection with Tools or Instruments

Conductor connecting surfaces need special attention. Contact surfaces of copper

determine what, if any, additional maintenance needs to be performedand to pinpoint

DETERMINING TESTING INTERVALS

Self – Check 1 WRITTEN TEST

Name: _____________________________ Date: ___________________________

Time started: _______________________ Time finished: ____________________

Test I – Multiple Choice

6. Step 5 Which step you apply a conductive lubricants to a conductor.

Test II. Discussion: (12 points)

Differentiate briefly the difference between Maintenance of equipment and Repair

Note:Excellent - 20 points Retake - below 10 points

Maintenance Practices for Electrical

Recommended Maintenance Practices for Electrical Distribution System

2. Recommended Maintenance Practices

In environments where there is an extreme exposure to adverse conditions,

Electrical equipment rooms or vaults should be kept cleaned of dirt and/or

Electrical equipment rooms or vaults should be examined for evidence of

1.2. Insulators, Supports, and Connectors

Inspect insulators and conductor supports for signs of cracking, broken

to manufacturer’s specifications. Be careful not to overtorque bolts and

2. Air Circuit Breakers

2.3. Arc Interrupters

2.4. Operating Mechanism

2.5. Auxiliary Devices

3. Vacuum Circuit Breakers

Caution: This procedure can produce X ray emissions, so personnel should

4. Air Disconnect Switches

Contact resistance testing of each phase contact should be performed. The

5. Oil Circuit Breakers

5.2. Insulating Oil Test

5.4. Auxiliary Devices

Examine arc-quenching assemblies for carbon deposits or other

6. Molded-Case Circuit Breakers

In addition, larger duty circuit breakers (225 amps or above) should be

Association (NEMA) Standard AB4, Procedures for Verifying Field

7. Battery Stations / Chargers

8. Cables and Bus

De-energize cables if they are to be touched or moved during maintenance.

8.1. Cables in Manholes

8.2. Aerial Cables

8.4. Bus Duct

Transformer data (such as, voltage, current, and temperature readings)

Name: ___ Date: _

Time started: ___ Time finished:

Name: ___ Date: _

Time started: ___ Time finished:

Name: ___ Date: _

Time started: ___ Time finished:

Name: ___ Date: _

Time started: ___ Time finished: