Work Scope for Checkout on 2400V Motors & Starters RS-PH-ELC-GDL-410-4000

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RS-PH-ELC-GDL-410-4000

Title: Work Scope For 2400V Motorsand Starters and PM Check Shee

UNIT OR AREA: GENERAL GUIDELINE

Approval: James Demes Date: 09/08/2008 Re

Originator: Robert Huffnagle Date: 09/04/2003

Electrical

MaintenanceGuideline

Review every Five Years Date: 09/4//20131

MOC # Document Administrator: Steve Moore

Date

Created

Reviewers: Phil Criswell, Justin Lane , Eric Miller, TomBaney, Mike Adams, Stanly LeSueuer, D.

Mitchell, & M. Szymanski

SCENARIOS OF OPERATING AND MAINTAINING A FACILITY ARE COMPLEX AND HUMANLOGIC IS A REQUIREMENT. PROCEDURES ARE INTENDED TO ASSIST EMPLOYEES INPERFORMING THEIR DUTIES. ALTHOUGH MAINTENANCE PROCEDURES ARE A BEST

ATTEMPT AT DETERMINING EVENTS, THEY ARE NOT INTENDED TO REPLACE THOUGHTAND LOGIC. MAINTENANCE EMPLOYEES ARE EXPECTED TO SAFELY AND EFFICIENTLYMAINTAIN AREAS FOR WHICH THEY ARE QUALIFIED, EVEN IF A PROCEDURE DOES NOTEXIST. IT IS THE MAINTENANCE EMPLOYEES RESPONSIBILITY TO INFORM SUPERVISIONOF PROCEDURES NEEDED WHEN IDENTIFIED.

IF THERE IS A MODIFICATION REQUIRED TO THIS PROCEDURE NOTIFY THE AREASUPERINTENDENT IMMEDIATELY. AN MOC IS REQUIRED FOR ANY PROCEDURAL CHANGE

FOLLOW AREA SUPERVISION FOR ANY DEVIATION FROM THIS PROCEDURE.

Purpose: To have a ready scope of work and checklist for Preventative Maintenancwork on 2400 V motors and starters throughout the refinery. To be usedwhen the opportunity to do such work presents itself.

Validation Not Validated - Use Caution With All Procedures and Guidelines

EnvironmentalPrecautions:

None

ReferencesAnd Standards:

Use the latest EDMS drawings

Use testing equipment per manufactures guidelines.

Engineering Standards 0100 Electrical sections 1 to 13http://sunhome/ses/es/esclass0100frames.htm

ElectricalTechguidlineshttp://sunhome/ses/Ebp/Electrical/ebpelectricaltitleames.htm EPM2, EPM7, & EPM8

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT TIME OF PRINTING. THE CONTROLLEDVERSION OF THIS DOCUMENT CAN BE FOUND ON THE SUNOCO INTRANET

RS-PH-ELC-GDL-410-4000 Page 1 OF 9 Print Date9/10/2008
http://sunhome/ses/es/esclass0100frames.htmhttp://sunhome/ses/es/esclass0100frames.htmhttp://sunhome/ses/Ebp/Electrical/ebpelectricaltitleframes.htmhttp://sunhome/ses/Ebp/Electrical/ebpelectricaltitleframes.htmhttp://sunhome/ses/Ebp/Electrical/ebpelectricaltitleframes.htmhttp://sunhome/ses/Ebp/Electrical/ebpelectricaltitleframes.htmhttp://sunhome/ses/es/esclass0100frames.htm



Title: Work Scope For 2400V Motors and starters and PM Check Sheet


RS-PH-ELC-GDL-410-4000 Page 2 OF 9 Print Date 9/10/2008

Prerequisites: Work Order

Work permit

Electrical JSA Card

SafetyPrecautions:

Procedures are located in each control room on the computer, andfound on Sunoco @ Work along with all SSs standards.http://sunocoatwork/sites/RS-HSS/RS-HS-

NER/Procedures/Forms/AllItems.aspx SS-36

SS-10

SS-59

Have Knowledge of the Equipment and the Safe usage of it.

SS-17

Several motors in the refinery have multiple sources of power; Secureall power sources before proceeding with the PM.

Some control circuits have multiple power sources; ensure all voltageare dead before proceeding.

Some contacts mounted on the starter could also have power on

them from different sources All Equipment tested must have warning Signs posted.

Check all Testing Equipment for proper calibration.

Materials &Equipment:

Hand Tools

Computerized Baker Surge Tester (will do all needed testing for both 480& 2400V Motors)

5KV Megger (Only if baker is not available )

500v to 1000V Megger for control systems

Micro-ohm meter (Only if baker is not available )

DVM EDMS Prints for complex circuits

**Detailed Guideline Starts Next Page**
http://sunocoatwork/sites/RS-HSS/RS-HS-NER/Procedures/Forms/AllItems.aspxhttp://sunocoatwork/sites/RS-HSS/RS-HS-NER/Procedures/Forms/AllItems.aspxhttp://sunocoatwork/sites/RS-HSS/RS-HS-NER/Procedures/Forms/AllItems.aspxhttp://sunocoatwork/sites/RS-HSS/RS-HS-NER/Procedures/Forms/AllItems.aspxhttp://sunocoatwork/sites/RS-HSS/RS-HS-NER/Procedures/Forms/AllItems.aspx




Preventative Maintenance for 2400V Motors

Scope of Work

Verify with Operations that the motor can be worked on.

Caution: Ensure all power has been removed, the starter has been locked out and tagged o

and the starter aux. contacts are de-energized before proceeding.

Starter visual inspection: Make a thorough visual inspection of the starter and all its components.everything looks alright, mark yes on the form. If you notice something is wrong, and you can fix iteasily, do so. Make note of your repairs in the comments section. If there is a major problem thatcant be fixed easily mark no on the form and write the problem down in the comments section forlater repair. Record the overload number in the appropriate spot on the inspection form.

Oil filled starters and start/ stop stations: Check the oil level, to ensue there are no leaks. Drain

and refill the reservoirs. Follow the procedure for disposal of waste oil (PH-442-MP-1001).

Air Fi lter: Inspect the air filter for cleanliness, if there is one. Clean or replace as needed.Main Contacts Inspection: Open the compartment that houses the main contacts. Inspect thecontacts for pitting, burning, & charring. Rate the contacts, Good:being very little damage to thecontact, Fair: being some damage is present but the contact is still serviceable, Poor: The contactsneed replacement as soon as possible.

Before Using Test Equipment on Energized parts, you must fi ll ou t Test Equipment CalibratiSheet.

Check Connections: Caution: the line side of the breaker is hot! All other connection pointsshould be checked to verify they are dead!! Using a torque wrench as required in tighteningconnections. Mark Yes on the inspection form if all connections are tight, and mark No if you hadto re-torque any connections. In the comments section mark how many connections you had to re-torque.

Testing Electrical Equipment: A danger high voltage testing placard sign must beon the ElectricEquipment under testing.Sample of sign posting








Baker Surge Tester: We now use the new computerized baker surge tester, which performs all thnecessary testing for both the 2400V and 480V motors. All you need to do is enter the properinformation, and follow instructions. If baker surge tester is not available use a 5000V, Megger on t2400V motors. If there is a surge arrestor connected to the motor it must be disconnected beforetesting, to prevent false readings to ground.

Megger Motor:Perform a 1 minute (or long enough for the reading to stabilize) Megger reading ofthe motor windings to ground, which should be done from the starter, the baker dose this

automatically, or you can use a 5000V Megger. Record the reading in the appropriate space on thePM sheet. Readings below five Megs are unacceptable. A reading should also be taken to ensurthe windings are closed in the A/B, B/C, C/A phasing format. You should also use the MICRO-OHMmeter to compare phase to phase resistances if you are not using the computerized baker surgetester, which must be done from the motor connection box.

Megger Control Wiring: Caution: some control devices are sensitive to voltages higher than120V ensure none of these devices are in the control circuit before proceeding!In most casethe groundside of the control transformer must be lifted for accurate readings. Perform a 1 minute long enough for the reading to stabilize) Megger reading of the control circuit to ground. This shouldbe done with a 500V Megger, from the starter. Record the reading in the appropriate space on the

PM sheet. Readings below one Meg are unacceptable.

Nameplate Data: Record the nameplate data on the check sheet where indicated.

Motor Connection Box Visual Inspection:Open the Motor Connection Box Inspect the box andconnections for signs of water / oil damage. Repair as necessary. Inspect the connections fortightness, insulation damage, & wear from vibration, on the taped or booted connection.

Control Station Visual Inspection: Open the control station and inspect for damage, repair orreplace as necessary. Indicate findings in the section provided on the PM sheet.

**End of Guideline**

Megger Reading guidelines

2- Meg per each 1,000Volts standard (for each 1,000volts a max of 2-megs is allowed forleakage)

Voltage Rating ofEquipment

Minimum Megger ReadingValue

Voltage used to MeggerEquipment

115/230V 1-Meg 250Vdc480V 2-Meg 1,000Vdc2400V 4.5 to 5-Meg 2500Vdc13,200 26.4 Meg See Engineer13,800 27.6 Meg See engineer




PM Data Sheet for 2400V Motors

Starter Visual

Inspection

Starter visual inspection OK? _____Yes _____NoOverload Number:______________ Mfg.:__________________Overload CT Ratio: __________________Oil Level:______________ Oil Cleanliness______________Comments:

______________________________________________________________________________________________________________________

_________

Main Contacts

Inspection

Contact Condition

Good ________ Fair ________ Poor ________

Comments:_____________________________________________________________________________________________________________ _________

Starter

Connections

Are all connections tight? ______Yes _______No

Comments:________________________________________________________________________________________________________________________________________________________________________ _________

Note:If you are using the Baker Motor Tester skip the Meggering of themotor portion only of this checklist. You still must Megger the control wiring

as indicated in this procedure, and enter data below.

Baker Motor

Tester

Test ResultsPass_______________ Fail_______________

Megger Motor Megger reading Phase to Ground: ______________@ 5000VMegger reading Phase to Phase: ______________@ 5000VComments:__________________________________________________ _________

Megger Control

Wiring

Megger Reading: ______________@ 500VComments:__________________________________________________ _________

Nameplate Data Motor Tag #____________ HP__________ SF________Motor Frame Type____________ Serial #________________ _________

Ai r Fi lter Filter Condition: _________ Cleaned: ___ Replaced: __

Connection Box

Inspection

Connection box condition good? ________Yes ________NoComments:__________________________________________________

_______________________________________________________________________________________________________ _________

Control Station

Inspection

Control station condition good? ________Yes ________NoOil Level:_________________ Oil Cleanliness:_________Comments:__________________________________________________

____________________________________________________________________

Check this box if this motor needs further attention.






ELECTRICAL CONNECTION

INSTRUCTIONS

Table 2.1-1 Bolted Joints

Recommended Hardware Materials (Quantity per Bolt)Materials Being Joined: Bolt Nut Flat Lock Belleville Reference

Washer Types Figure(1) (2) (1) (1) 2.1-1

Copper to Copper *** SB SB SB SB NR (a)SS SS SS SS NR (a)

Copper to Aluminum SB* SB* SB* NR SS (b)

SS SS SS NR SS (b)Aluminum to Aluminum AL AL AL AL NR (a)

SS SS SS NR SS** (b)Copper to Steel *** SB SB SB SB SS** (a) or (b)

SS SS SS SS NR (a)Aluminum to Steel SB* SB* SB* NR SS (b)

SS SS SS NR SS (b)Key:NR : Not Required * Tin PlatedSB : Silicon Bronze ** Alternate recommendation in place of lock washer.

AL ; Aluminum *** Zinc plated hardware may be substituted for SB.

SS : Stainless SteelFigure 2.1-1 Bolted Joints

Notes; Use largest bolt size that fits hole diameter.Bolt length: 2 threads min to max passed nut after tightened.

All washers used to be properly sized to match bolt.Flat washers used with Belleville washers should have an outside diameter greater than the flatteneBellevilles such that no overhang results. Select a flat washer that is twice as thick as the Belleville








for strength. (If not available, stack two or three thinner washer to achieve the same effect.) Tightenthe nut on to the bolt until a sudden, noticeable increase in torque is required to continue. TheBelleville washer is now flat. It is not necessary to back off the nut after tightening to this point.Remove all corrosion and surface oxides along contact areas.Coat contact surfaces with an appropriate oxide inhibiting compound. Such as; Penetrox A or similafor AL-AL or AL-CU (verify voltage limits if any) Not recommended for rubber or polyethyleneinsulated conductors.

Use Penetrox E or similar for CU-CU connections all voltages.Plated surfaces should not be wired brushed. Use an appropriate cleaning solvent or similarcompound that does not disturb the integrity of the plating.

Table 2.1-2 Recommended Tightening Torque

Torque (in-lb)DURIUM (silicon bronze)

Zinc PlattedBolt Size* Stainless steel Aluminum1/4 20 80 -------------5/16 - 18 180 ------------3/8 16 240 1681/2 - 13 480 3005/8 - 11 660 4803/4 - 10 960 650Note: All bolts and nuts to be lubricated with Penetrox or similar lubricant.You convert in-lb to ft-lb by dividing by 12.Example: 480in-lb / 12 = 40 ft-lb

Buss Connection: Follow manufactures Installation Instructions.

Motor Terminations600V and Below1 hole compression lugs with proper # of crimpsProper size Bolt for lugsHardware per Table 2.1-1 Bolted Joints and Figure 2.1-1Torque per Table 2.1-2Motor Lead Pigtail Splice Kit (3M 5300 series or similar)

orVulko Wrap tape: 1- 1/2 lap layer next to lugs130C rubber tape: sufficient quantity to soften hard edgesBlack Tape: 88, 33, and 33 plus or similar: 2 1/2 lap

Note: Sealant filled wire nuts are acceptable on #10awg wire and smaller.

Motor Terminations2,300 volts and aboveUse compression lug, to match motor leads, and proper # of crimpsUse Proper size Bolt for lugsHardware per Table 2.1-1 Bolted Joints and Figure 2.1-1Torque per Table 2.1-2






Termination Kit for proper voltage / conductor size

OrVulko Wrap tape: 2-1/2 laps130 C Rubber tape: 3-1/2 LapsBlack Tape: 88, 33, and 33 plus or similar: 3-1/2 lap

Cable Termination to Buss Connections

5 KV and BelowCompression lug properly size for conductor: proper # of crimpsProper size Bolt for lugsHardware per Table 2.1-1 Bolted Joints and Figure 2.1-1Torque per Table 2.1-2Preformed Booting preferred

OrVulko Wrap tape: 2-1/2 laps130 C Rubber tape: 3-1/2 LapsBlack Tape: 88, 33, and 33 plus or similar: 3-1/2 lap

Above 5 KVTermination Kit for proper voltage / conductor sizeProper size Bolt for lugsHardware per Table 2.1-1 Bolted Joints and Figure 2.1-1Torque per Table 2.1-2Preformed Booting preferred

OrHigh Voltage Putty: Fill voidsVulko Wrap tape: 2-1/2 laps130 C Rubber tape: 3-1/2 LapsBlack Tape: 88, 33, and 33 plus or similar: 3-1/2 lap




Test Equipment, Make , Model, Calibration Date

Sunoco, Inc.

Philadelphia Refinery

Test Equipment

Type Make Model / Serial Number Calibration Date



Work Scope for Checkout on 2400V Motors & Starters RS-PH-ELC-GDL-410-4000

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