THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-1055-00
GLOBAL 20-AUG-2003
Page 1 of 5
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OFF-LINE MAINTENANCE AND ACCEPTANCE TESTING PROCEDURES
FOR POWER FACTOR CORRECTION CAPACITORS

Equipment Group: E105 = Power Factor Correction

Equipment Type: E1051 = Capacitor Type

Scope This procedure defines the requirements and methods for Acceptance Testing
(ACCTST and off-line Predictive/ Preventive Maintenance (OVHAUL) of Power
Factor Correction Capacitors. The intent is to maximize the reliability of this
equipment at minimum cost through the combination of testing equipment upon
installation and employment of a regularly scheduled off-line maintenance with
the ultimate objective of eliminating all unexpected failures.

Definitions CAPACITOR: An energy storage device consisting essentially of two electrodes

separated by a dielectric, or a number of these devices, assembled in a common
container and with the terminals brought out. In AC systems, capacitors have
the ability to store energy twice in each cycle, but not at the same time.

POWER FACTOR: The ratio of the total active power in watts to the total
apparent power in volt-amperes. (Watts / Volt-Ampere)

POWER FACTOR CORRECTION: An improvement made to reduce the

inductive reactive current (power) by the application of capacitors connected in
shunt, thereby “correcting” a lagging power factor to be closer in value to 1.0
(100%).

INSULATION TEST (MEGGER): This test provides an assessment of the

insulation condition of a piece of equipment by imposing a DC voltage generally
between one of the winding and ground.

APPLIED POTENTIAL TEST: This test is sometimes referred to as the “high

pot” test. The purpose of this test is to check the insulation to ground and to all
other windings being tested.

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

for both acceptance testing and routine off-line PPM. A MOC approved by the
Transformer 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 a capacitor trips while in
service, supplemental tests may be necessary to identify the specific problem.
Such tests may include capacitance testing and 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 appropriate
TRL is required before such supplemental testing is initiated.

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THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE
ELECTRICAL G7M-1055-00
GLOBAL 20-AUG-2003
Page 2 of 5
Safety Safety is an integral part of any and all jobs. As such, all applicable Corporate
and site-specific safety and loss prevention practices and procedures shall be
rigidly applied in the execution of the work described in this Practice. It is the
responsibility of the lead person administering this Practice to assure that such
safety related Practices/procedures are identified and followed by all involved.

All electrical equipment to be tested off line should be in a de-energized state by

disconnecting or RED tagging and electrically locking out the power source.

Because of inherent dangers in any high voltage work, special care must be
taken to safeguard personnel during testing and inspection of equipment. Use of
personal protective equipment is mandatory when performing these job tasks.

Note: Before performing any tests or handling any capacitors, read the
manufacturer’s instructions with special attention on safety instructions, failure to
do so can result in severe personal injury or death by electric shock.

Follow the manufacturer’s instructions to discharge the capacitor!

Equipment Needed The following table list the test equipment and other equipment needed to
perform this procedure.

Field Test Equipment Other Equipment

Megger Manufacturer’s Instruction Manuals

Infrared Test Equipment Cleaning materials

Hand tools

Personal protective equipment such as

Nomex clothing, high voltage rubber
gloves, and flash equipment when
necessary.

P/PM Schedule The required frequency for P/PM inspections for capacitors is established via the
Condition Based Electrical PPM web site.

Data Form For execution of the above-mentioned Acceptance Testing and Predictive/
Preventive Maintenance tasks, a combined Data Form G7M_1055_01 (Future) is
available. This Data Form refers to the actions described on the following pages
and shall be used as a checklist and record for final data entry into the GEMTS
system. GEMTS should capture only the Service, Reason, and Cause codes,
and only test data by exception using the text comments for the work order.
Additional results or information, like replacement of electrical or mechanical
parts, modifications and notification of critical conditions, which should enter the
history or could effect the P/PM schedule should also be recorded in the text
comments of the work order.

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THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE
ELECTRICAL G7M-1055-00
GLOBAL 20-AUG-2003
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Preparation Follow the steps below before starting the tests and inspections on the
equipment.

OVHAUL
Step Service Action P/PM ACCTST
offline

Plan and schedule the inspection as

1 PREP established via the Condition Based
 

Electrical PPM web site.

Perform all necessary electrical safe

work steps according to the Corporate
2 PREP Safety Guidelines and local
 

requirements. Follow current ‘Electrical

Clearing Procedures’ for all equipment.

Review all technical specifications,

3 PREP operating manuals and previous
 

inspection data if appropriate.

Install safety grounds as necessary to

4 PREP
 

discharge capacitors before testing.

Off-Line PPM Follow the steps below to perform off-line PPM on the capacitors.
(OVHAUL) and
Acceptance Testing
(ACCTST)

OVHAUL
ACC
Step Service Action P/PM
TST
offline

Inspect for physical damage:

• Cracked support insulators

• Absence of corona and heat damage on

insulators, connecting cables, etc.
1 VISIN1
 

• Non-corroded terminals, terminal and

capacitor enclosures, etc.

• Tightness of connections

• Oil leaks

2 CLN Clean all insulator surfaces, etc.

 

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THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE
ELECTRICAL G7M-1055-00
GLOBAL 20-AUG-2003
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OVHAUL
ACC
Step Service Action P/PM
TST
offline

Visually inspect capacitor grounding system

and ground connections. This includes safety
3 GROUND
 

grounding systems (fences, barricades, etc.)

around the capacitor installation.

If applicable, check condition and operation of

4 VISIN1
 

automatic discharge contacts.

Torque all power connections. Ductor may be

used to check connection of power
TORQUE/
5 connections if desired (this is an acceptable
 

DUCTOR
substitution for TORQUE only or normal
OVHAUL PPM), not ACCTST).

Measure capacitance. The measured

capacitance should be between 100% and
110% of nominal capacitance.

6 PWRFCT Below 100% or above 110% should be  

discussed with manufacturer.

Above 120% indicates problems and should

be considered defective.

Measure resistance of any discharge

7 OHMTST resistors. DC current measured during testing
 

should be determined largely by the resistor.

Perform insulation resistance tests from

terminals to case for one minute. Presence of
a discharge resistor may result in the test not
8 MEGGER providing any information on the condition of
 

the insulation. Refer to manufacturer’s

literature for test voltage and minimum
resistance.

Perform electrical withstand tests (AC and/or

DC) from terminal to terminal and terminal to
9 HIPOT


case in accordance with manufacturer’s

literature.

Measure capacitance again after performing

10 PWRFCT electrical withstand tests to verify that the


testing has not altered the capacitance value.

Function tests all control devices associated

11 FUNTES
 

with switching the capacitors.

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THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE
ELECTRICAL G7M-1055-00
GLOBAL 20-AUG-2003
Page 5 of 5
OVHAUL
ACC
Step Service Action P/PM
TST
offline

After all testing is completed, verify all safety

grounds have been removed, all appropriate
red tags removed, and any other items
12 PREP
 

compromised during the test returned to their

original operational state before releasing to
owner.

All test forms and data sheets are to be

13 REPORT submitted to the appropriate authority for entry
 

into GEMTS.

Issue additional work orders as necessary to

14 REP
 

make additional repairs.

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20-AUG-2003, MOC2003.1000.104, By:Paul Gabba, Supercedes Issue Date 09-AUG-
2000, Complete rewrite for the Condition Based PPM process.

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