KALINGANAGAR

TITLE:

STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

STANDARD MAINTENANCE PROSEDURE FOR H.T SYSTEM

PURPOSE: THE PURPOSE OF THIS STANDARD MAINTENANCE PROCEDURE IS FOR

MAINTENANCE OF HT SYSTEM IN F/C - 1 & 2 WHICH INCLUDES
(A)
(B)
(C)
(D)

HT CABLE
HT VCB
HT STAR/DELTA SWITCH
HT TRANSFORMER

VSL/FCP/SMP/7.5.1/15(A)
VSL/FCP/SMP/7.5.1/15(B)
VSL/FCP/SMP/7.5.1/15(C)
VSL/FCP/SMP/7.5.1/15(D)

SAFETY PRECAUTIONS
Before doing any maintenance work on H.T. Equipments following safety precautions must be
followed up.
1.
2.
3.
4.
5.
6.

H.T. maintenance works must be carried out under an authorised supervisor.

Ensure that the load and power supply is cut off.
Isolators at both the ends of the equipment under maintenance must be kept open.
"MEN AT WORK sign board to be hanged at the supply end switch.
All the conductors must be discharged through earth discharge rod and same to be kept
connected at the input end of the equipment under maintenance.
While closing/opening isolators HT hand gloves must be used.

A)

H.T.CABLE.
This instruction is valid for XLPE Cable 11KV (E) and PILC Cable 33 KV (E) and also
XLPE cable 33 KV (E).

1.

INSULATION RESISTANCE
The H.T.Cables are to be meggered with 5 KV H.T. megger as per appendix -A.
Insulation value of phase to phase and phase to earth of each individual cable are to be
recorded.

ISSUE DATE
16.08.2009

PREPARED BY

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2.

STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

GENERAL CLEANING
The H.T.Cables end termination are to be maintained by cleaning of the accumulated
dust.

B)
1

H.T. VCB
GENERAL CLEANING

Visually check the breaker. Clean the outer insulating part with a soft cloth.
2.

DRIVING UNIT

The Driving unit is first thoroughly cleaned. All the moving parts/Springs are greased. Spring
charging motor carbon brushes checked and if found worn out, is replaced. Foundation bolts
are checked for tightness. The entire micro switch, auxiliary switches operation is checked.
Driving rod/plate from driving unit to breaker pole is to be checked thoroughly for any
Cracks/worn out.
HT Transformer Breaker is checked for closing from the Control Panel. Its tripping
operation is checked for all the protective relays of the transformer as listed below, by
activating all the trip circuits externally.
a)
b)
c)
d)
e)
C)

O/c Trip
E/f Trip.
Under voltage trip.
Buchholz Trip.
Oil surge relay trip.

f)
g)
h)
i)
j)

Tap changer motor O/c trip.

Oil Pump trip.
Water circulation trip.
Winding Temp Trip.
Oil level Trip.

HT TRANSFORMER.
This standard maintenance procedure valid for all H.T transformers used.

1.

OIL RENEWAL & MAINTENANCE (DIVERTER SWITCH).

Oil is renewed or changed once in year/ 50000 operations which ever comes first.
Note the BDV value of transformer oil used for diverter switch maintenance.
ISSUE DATE
16.08.2009

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STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

(BDV value of oil should not be less than 30 KV at 2.5 mm gap) Switch off and
lock furnace breaker and furnace isolator.
Earth temporarily to discharge at the out going side of the furnace breaker.
Switch off power and control supply of OLTC panel and record tap position no.
De-couple driving mechanism shaft.Drain out contaminated transformer oil from
diverter switch along with OLTC conservator tank.Take out diverter switch after
removing all fixing bolts and nuts and mark the position of lower coupling.
Thoroughly clean conservator tank, diverter switch tank and diverter
switch.Inspect diverter switch for the followings:
a) Contact erosion (replace if found worn-out)
b) Flexible strips (replace if found cut)
c) Tightness of all pocket fixing screws.
d) Tightness of all connecting leads.
e) Measure transition resistance value (compare values as per name plate)
f) Test resistance-in-circuit test by operating the switch externally and connecting an
analog multi meter across both fixed main contacts of a shell in ohms mode. During
switching takes place a kick of the needle of meter should be marked enabling transition
resistors comes to the circuit just before main contacts are closed. During operation any
other abnormalities in the switch should be closely observed. Clean diverter switch with
fresh oil again. Insert diverter switch in the tank after confirming lower coupling position
and as per manufacturers marking on tank and diverter switch.
Note: Other than the above marked positions, diverter switch cannot be inserted fully, and
do not put pressure to insert fully.Tighten all bolts and nuts.Put and tighten the cover
and couple the driving shaft.Fill fresh transformer oil via conservator tank keeping the
vent plug of diverter switch chamber open. (As soon as oil comes out through vent
plug close the same) Manually operate diverter switch and record total no. of rotations
to complete one cycle & no.of rotations for operation of selector switch (which can be
known by closely hearing two click sounds to come from inside of transformer tank
near selector switch area, during rotating the OLTC operating handle
manually).Operate diverter switch and observe tap selector and diverter switch sound
by restoring OLTC control supply. Carry out no-break and ratio test. If above tests are
found ok then measure transformer insulation resistance by 5 kv meager between
Primary winding to body and record values : 15 secs , 60 secs & 10 mins.Vent air
again from the OLTC chamber. Disconnect temporary earthlings wherever
connected. Give clearance for operation.
ISSUE DATE
16.08.2009

PREPARED BY

APPROVED BY

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2.

STANDARD MAINTENANCE
PROCEDURE

MECHANICAL OPERATION

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

(DIVERTER SWITCH)

The motor drive mechanism is inspected once in a year. The oil level is checked in
the gear box. The operation of cam operated micro switch is checked manually. All
its mechanism is thoroughly checked and lubricated.
3.

CLEANING (Oil Flow Water Cooler)

Once in a year it is cleaned. The top cover and the cleaning cover at the connection
water box is removed. All the tubes through which water flows is cleaned with soft
nylon brush till it is cleared up from rusting, scale formation. Finally it is washed with
clean water. On no account any hard or pointed tools is used as this may damaged
the tubes. The dirt removed from the tube is extracted from the bottom water box.
When the above two cover is fitted, ensure that it is sealed properly.

4.

REGENERATION OF SILICA GEL

Once in a year the silica gel is reactivated / replaced as noted below.

REGENERATION OF SILICA GEL.

1) Remove the silica gel from the container and remove the dust particle with the help
of a cloth.
2) Keep a thin layer of silica gel over a flat pot.
3) Heat the pot uniformly and stir the silica gel till the colour of silica gel will change to
blue colour from pink and white colour.
4) Cool the silica gels and check its colour. If it has got its original blue colour then pack
it in container, unless repeat the no.3 process till getting the original colour.
5) If silica gels do not get the original blue colour after repeating above procedure 2 to 3
times, new silica gels are to be replaced.
5. AIR VENTING
Open the Air venting plug of Transformer tank, Buchholz Relay & HT Bushing for the
release of the air. After that when all the air comes out , slight oil will come out through the
plug without air bubbles. Then tighten the air release plug fully.
ISSUE DATE
16.08.2009

PREPARED BY

APPROVED BY

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STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

6. CONDITION OF OIL
Once in a year, the oil should be tested for dielectric strength . For dielectric
strength it is tested . If the value is less than 40 Kv with 2.5 mm electrode gap, oil
filtration is done.
a) OIL RENEWAL
Check the oil level. Replace with new oil up to the level. The oil should have a breakdown
value of at least 40 KV with 2.5mm electrode gap which is to be tested as per procedure
given below.
b) OIL TESTING PROCEDURE.
Before collecting oil into a bottle, the bottle shall be agitated with oil several times and turn
over several times. Then the oil is collected and allowed to reach the room temperature
without being exposed to atmospheric air about 700 ml. is required for a test.
The test cell shall be rinsed and turnover several times. Then the oil sample is poured slowly
through a glass rod to avoid air bubbles. It is allowed to rest for 10 minutes.
Then it is subjected to voltage at the rate not exceeding 2 to 3 KV/sec. till brake down
occurs. A series of six breakdown tests at interval of 1 to 2 min. shall be performed on the
same cell filling. Average value is taken finally.
7.

INSULATION RESISTANCE

It is taken once in a year. It is taken with motorised 5 KV megger as given below. Minimum
value should 100 M- -. in between phase to body in HV side.
MEGGER TEST WITH (5KV) POWER MEGGER(WACO)
Never make any connections to live electrical circuit.
Apply 230V AC/DC input at the plug pin socket with the help of provided cord.
By applying input supply, if the pointer does not go to the infinity, use the infinity
adjuster provided to bring it to infinity.
Connect the line terminal to the `circuit' and earth terminal to the `Ground' while
measuring insulation between circuit and earth. But for insulation test for two conductor
ISSUE DATE
16.08.2009

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STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

connect one conductor to the `line terminal' and other to the `earth terminal', so that
both the leads should be separated and line terminal lead should not touch the
ground.
Make the motor switch `ON'
Read the insulation value from the indicator at 15 Sec. and 60 Sec. respectively.
8.

TIGHTNESS (SECONDARY BUS TUBE)

All the jointing points of the secondary Bus Bars/Tubes will be checked by the
appropriate tools.

9.

OPERATION OF PROTECTIVE DEVICE

Once in a year all the protection and alarm is checked as given below.
i)

BUCHHOLZ RELAY
The tripping and alarm function is checked by shorting the alarm and trip
contact at the buchholz relay terminal box. Whenever possible this to be
checked by draining oil or giving surge through the relay by artificial means. A
hand pump with a non return valve used to pump air to the relay through the air
release valve and see when alarm and trip occurs.

ii)

DIVERTER SWITCH OIL SURGE RELAY

It is tested as above ie. clause (i).

iii)

WATER CIRCULATION FAILURE.

The water flow is stopped by stopping the inlet water valve and check if trip and alarm
function is OK or not.

iv)

LOW OIL LEVEL.

Its alarm and trip (if any) is checked by shorting the contact at the terminal box of this
relay. Wherever possible it should be checked by draining oil up to this level.

ISSUE DATE
16.08.2009

PREPARED BY

APPROVED BY

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v)

STANDARD MAINTENANCE
PROCEDURE

FERRO CHROME PLANT

DOCUMENT NO
VSL/FCP/SMP/7.5.1/15
REVISION NO. 0/0

OVER TEMPERATURE OF OIL AND WINDING.

Its alarm and trip function is checked by decreasing the setting level gradually less
than the actual temperature of the oil and winding and see if alarm and then tripping
occur.

DISTRIBUTION
CONTROL COPY NO
1
2
3
4

ISSUE DATE
16.08.2009

COPY HOLDER
M.R. QMS (VSL)
HOD FCP
I/C ELECTRICAL
I/C SHIFT (ELECT)

PREPARED BY

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