THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-0815-00
GLOBAL 13-AUG-2007
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OFF-LINE MAINTENANCE PROCEDURE FOR LOW VOLTAGE DISTRIBUTION PANELS
(Lighting, Power, Instrument, UPS distribution, DC, etc.)
Scope This procedure is to be used by Electrical Skilled or Electrical Instructed persons for
Acceptance Testing (ACCTST) and off-line Predictive/ Preventive Maintenance
(OVHAUL) of Low Voltage Distribution Panels.

This procedure is intended to be used with Data Form G7M-0815-01.

Categories This is a routine operating procedure

and
attributes

Definitions LOW VOLTAGE DISTRIBUTION PANELS: These are typically single or three
phase, or DC power panels used to distribute low voltage (typically below 500V to
final stage devices (UPS power distribution, lighting branches, AC power to
receptacles, DC control power, instrument power,etc.).

MANDATORY TEST/INSPECTIONS ( ) – These test are considered mandatory

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

SUPPLEMENTAL TEST/INSPECTIONS ( ) – In general, all tests are used for

initial acceptance testing. Routine off-line PPM tests are not as stringent and
items marked as supplemental are only to be preformed when there is a
suspected problem with the equipment. For example: If routine infrared testing
indicates a problem within a power panel, then a torque (TORQUE) inspection will
be used to troubleshoot the problem. For this example case, an MOC is not
required for performing the supplemental tests. However, performing additional
tests just for the sake of testing or just because the tests have been traditionally
done at a particular site is not supported by the Electrical Discipline or Global
Maintenance Leadership. An approved MOC from the MCC TRL is required
before such supplemental testing is initiated.

Safety The requirements of 06.05.C.03 Electrical Safe Work Standard and associated
Electrical Work Practices (EWP) apply.

All applicable Corporate, site-specific safety and loss prevention practices and
procedures shall be rigidly applied in the execution of the work described in this
procedure. It is the responsibility of the lead person administering this Practice, Work
Planner, as well as the person using this practice to assure that such safety related
Practices/procedures are identified and followed.

Each facility has general and specific PPE requirements and must be used.

Hazards and Electrical Shock. Only Electrical Skilled or Electrical Instructed persons may penetrate
Precautions the Electrical Shock Hazard Distance (ESHD). Wear PPE, utilize insulating rubber
goods and/or use insulated tools as needed (see EWP-22 and EWP-30). Always test
for de-energization before touching any electrical conductor.

Electric Arc Flash. Wear arc flash PPE as needed (see EWP-21 and EWP-30). Only

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ELECTRICAL G7M-0815-00
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Electrical Skilled or Electrical Instructed persons may penetrate the Electrical Arc Flash
Hazard Distance (EAFHD). Evaluate the need for barriers or other methods to restrict
work area to only those involved with the task and implement as required.

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

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

Solvent Use. Non flammable spray cleaning solvent intended for use on electrical
equipment may be used on insulator and conductor parts. Review the cleaning solvents
MSDS sheets prior to use. Follow the manufactures recommendations and precautions
for use. Use in well ventilated areas. Use portable fans as needed to better ventilate
work area. Use chemical gloves as needed.

Tools and The tools and equipment listed below are needed to do this job:
Equipment
• Arc Flash PPE see EWP-21 and EWP-30

• Electrical Shock PPE see EWP-22 and EWP-30

• Safety Glasses.

• Approved Voltage tester per G7M-1210-00 and EWP-32.

• Hand tools. Torque wrench or screw driver.

• Work Gloves.

• Cleaning materials. Rags and approved electrical cleaners and solvents.

o Mild soap solutions (such as Fantastic) may be used to clean non-

electrical parts of the equipment i.e. the enclosure.

• Chemical Gloves for use with the cleaners used.

• Portable fans as needed for comfort and ventilation.

• Vacuum cleaner with nonconductive hose and nozzle to remove dust, dirt and
debris as needed. Do not use vacuum cleaner on energized parts.

Before You 1) Obtain a Safe Work Permit or other work authorization.

Begin
2) Perform a pre job hazard analysis (PJHA). Conduct a job briefing. Review

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PJHA with all crew members, boundaries of work, identify equipment to be
worked on, and work scope

3) Inspected your tools, equipment and PPE. All must be in good condition and
working order.

4) Review and understand equipment manufacturer’s manuals, instructions,

diagrams and safety precautions.

5) Review this procedure and agree it is appropriate for the task. Otherwise,
contact your Electrical DAS, the appropriate TRN leader or supervision to
address any concerns before proceeding.

6) Review the cleaning solvents MSDS sheets and follow manufactures directions
for use.

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

Step Service Action OVHAUL ACCTST

P/PM
offline

Plan and schedule the inspection as



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

2 PREP Review the AC/DC control schematic of

 

the disconnect switch assembly. Look

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

If control wire modifications are included

 

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

Complete all electrical clearing of

 

4 PREP
equipment per the criteria defined in the
Electrical Safe Work Standards,
Isolation of Energy Sources (IOES) and
local procedures.

Review all technical specifications,

5 PREP operating manuals and previous
 

inspection data if appropriate.

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After de-energizing, appropriate
lockout/tagout, and grounding if
6 PREP required by EWP-33, remove the panel
 

main door/cover to facilitate visual

inspection.

Perform the “test before touch” per

EWP-30 and 32. Be aware and take
necessary precautions against contact
with energized systems (wires, relays,
7 PREP terminal blocks, etc. If power is found
 

on a system that should not be

energized (per review of control
schematics - Step 2 above), STOP THE
JOB and investigate.

For panels that feed heavy loaded

devices (HVAC, pumps, motors, etc.),  

8 INFRED Note 1) Note 1)

perform an infrared inspection of all
connections prior to de-energizing.

Operating Equipment adjustments, tolerances, settings, and/or test values shall be per this
Limits and procedure, manufacturer requirements/recommendations or other EMETL practices
Deviations and procedures. Deviation from these established norms will require an EMETL
MOC. Contact your supervision and/or Electrical DAS as needed to resolve any
discrepancy outside of these established norms.

Failure to perform proper adjustments, establish proper settings/tolerances or not

obtaining passing test values may result in bodily injury, equipment damage and
EH+S concerns.

Identify the
Facility/Plant _________________ Building Number _____________________
Equipment
Room Number ________________ Equipment Number/ID_________________
Must be the
same as on Description:_________________________________________________________
SWP or other
authorization

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

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Step Service Action OVHAUL ACCTST
P/PM
offline

Compare equipment nameplate

1 VISIN1 information data with actual operating


conditions, drawings and specifications.

Inspect the physical condition of all

electrical and mechanical components
for deterioration and missing, broken, or
loose parts, etc. This includes the
2 VISIN1
 

inspection of insulation materials, signs

of overheating or electric sparks,
enclosure class IP-20 / IP-41 and door
fastener functionality.

Inspect grounding bars, wires, or other

3 VISIN1
 

grounding devices for proper condition.

Inspect indicators for mechanical

4 VISIN1
 

damage.

Tighten all accessible electrical

connections to the manufacturer's
torque specifications, if provided. If such
information is not available, re-tighten in


5 TORQUE accordance with G7M-0020-26, G7M-



0020-28, and G7M-0020-29. Use a Note 2)

suitable marker or paint pencil and mark
each connection/bolt after being
torqued.

Tighten control, VT, CT, and metering



6 TORQUE wires on all devices and terminal



blocks. Note 2)

Clean the enclosure using approved

7 CLN methods and materials. Clean all
 

accessible components.

i
Electrical Tests Follow the steps below to perform electrical tests on the equipment.

Step Service Action OVHAUL ACCTST

P/PM
offline
Using a 500V megger, measure the
insulation resistance of the total power
1 MEGGER panel bus system, phase to phase (or
 

pole-to-pole for DC) and phase to

ground.

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GLOBAL 13-AUG-2007
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Step Service Action OVHAUL ACCTST
P/PM
offline

For panels equipped with GFI breakers,

test the earth leakage functionality of
2 GFITST Note 3)


the outgoing circuits by means of test

button of the earth leakage switch.

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

Step Service Action OVHAUL ACCTST

P/PM
offline
Verify that the branch breakers in the 

1 FUNTES panel are properly sized for the loads



that they feed.

As part of startup, test each branch

2 FUNTES


circuit to confirm desired functionality.

Notes:
1) On-line IR inspections are required for all "Critical" panels where failure would result in an EH&S
concern or process upset..
2) Checking connection tightness is only required where infrared testing or visual inspection
indicates a need to tighten a connection.
ii
3) GFCI checks are compliance driven and must be performed during on line inspections. See
compliance task A0029 Fixed GFCI-RCD Receptacles Inspections and Testing.

Related and • G7M-0815-01 MAINTENANCE DATA FORM FOR LIGHTING PANELS

Reference
Documents • 06.05.C.03 Electrical Safe Work Standard and associated Electrical Work
Practices (EWP)
• G7M-1210-00 GBL - APPROVED VOLTAGE TESTERS FOR "TEST BEFORE
TOUCH" PURPOSES

• 06.05.C Isolation of Energy Sources (Red Tag) Standard

• Compliance Task A0029 Fixed GFCI-RCD Receptacles Inspections and
Testing

• The Electrical Discipline Activity Specialist (DAS) listing may be found at:
http://globaldt.intranet.dow.com/electrical/HelpFinder_DAS.asp

• G7M-0010-01 GBL - MEGOHM INSULATION TEST (MEGGER TEST)

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Document This document is part of the Electronic Most Effective Technology Library (EMETL).
Management Management system and procedures may be found at http://emetl.intranet.dow.com/.
This document is managed as per EMETL requirements.

Validation and This procedure is the most effective way to perform maintenance on common electrical
Procedure equipment. This procedure is maintained and validated by the 0800 Motor Control,
Approval Switches, Panelboards Technology Resource Network (TRN). A listing of Electrical
TRNs may be found at: http://globaldt.intranet.dow.com/electrical/HelpFinder_TRN.asp

EMETL MOC# 2007_04499

Revision
History The following information documents at least the last 3 changes to this document,
with all the changes listed.

Date Revised By Changes

3/14/07 Don Hull EMETL MOC 2007_04499. General revision to better align with ODMS.
Added note 1) and remove GFCI testing as a requirement for off line or
on line testing since this is covered by Compliance Task A0029.
MOC2003_01057 Supersedes Issue Date: 19-MAR-1999, Under the
05-May- Gary Wiseley heading ELECTRICAL TEST, Steps 10, 11 and 12, removed the formula
2003 (1 kohm/Volt) x 2 and installed the wording ‘per G7M-0020-08’ for
minimum Megohm value.

ii
13-AUG-2007; MOC 2007_05214; By: Peter Willhoeft; Superseded Issue Date 14-
MAR-2007; In FUNCTION TESTS, updated Note 3 for GFCIs to be performed during
‘on line testing’.

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