ZESCO LTD COPPERBELT DIVISION

GRADUATE ASSESSMENT REPORT

TECHNICAL SUPPORT SERVICES MAINTENANCE PLANNING

2011

ELECTRICAL TECHNOLOGIST- SAMUEL NDOPU

ZESCO LTD COPPERBELT DIVISION

GRADUATE ASSESSMENT REPORT

ELECTRICAL TECHNOLOGIST: SAMUEL NDOPU

TECHNICAL SUPPORT SERVICES MAINTENANCE PLANNING

REPORT SUBMITTED TO THE HRD FOR THE GRADUATE ASSESSMENT PANEL SITTING ON THE DEVELOPMENT PROGRAMME PERIOD

2011
3

ACKNOWLEDGMENTS My thanks go to Mr. M. Mugala Divisional Manager, Mr. F. Nundwe Technical Services Manager, Mr. D. Habuzila Principal Protection Engineer and Mr. J. Musulwe Senior Protection Engineer for their guidance and willingness to help me throughout the development programme period. I also acknowledge my indebtedness to all my workmates, for the knowledge they imparted in me and guidance that has made it possible for me to produce this report.

CONTENTS Acknowledgements4 Contents..5 List of figures..6 List of Tables..7 List of abbreviations8 1.0 Nature and scope of a Maintenance Planner 9 1.1 Purpose .9 1.2 Principle accountabilities .9 1.3 Reporting relationships10 1.4 Weekly activity process...12 2.0 Maintenance management system...14 2.1 Concept of Maintenance management14 2.2 MMS responsibilities and duties.15 2.3 Types of maintenance works...16 2.4 Works order management in PEMS17 3.0 Preventive maintenance in protection..23 3.1 Protective relay maintenance...23 3.2 Oil and SF circuit breaker maintenance.28 3.3 Battery chargers and batteries maintenance 31 3.4 Transformer tests at New Scaw substation-Kitwe...32 3.5 Preventive maintenance checklists.33 3.5.1 3.5.2 3.5.3 3.5.4 Protective maintenance form34 Circuit breaker maintenance form35 Battery charger and batteries maintenance form..36 PSM Curves...37

List of figures Fig 1: Reporting relationship.11 Fig 2: Weekly activities process12 Fig 3: Work request details General data...19 Fig 4: Work request details Other data...20 Fig 5: Work order..22

List of Tables Table 1: Record keeping13 Table 2: Standard relay setting for OC/EF maintenance27 Table 3: Secondary results for Mufulira Sub 50 on Sub 22 feeder28 Table 4: Circuit breaker maintenance results..30 Table 5: Measurement of voltage per cell31 Table 6: Transformer ratio test.32 Table 7: Insulation resistance test33 Table 8: General transformer checkups33

List of abbreviations MMS Maintenance Management System WR Work Request WO Work Order PM Preventive Maintenance PEMS Plant and Equipment Maintenance System CBD Copperbelt Division KPI Key Performance Indicator MS Microsoft TSM Technical Services Manager BDV Breakdown voltage PSM Plug-setting multiplier CT Current transformer E/F Earth fault O/C Over current CTR Current transformer relay SEC Second TMS Time-setting multiplier R Red phase I set Current setting If Fault current OCB Oil circuit breaker SF Sulfur-Hexafluoride

1.0 NATURE AND SCOPE OF A MAINTENANCE PLANNER 1.1 PURPOSE To develop, enforce and monitor implementation of preventive/predictive maintenance plans and periodic overhauls of infrastructure and other maintainable assets in order to ensure that the rehabilitated and other existing assets do not go into a state of disrepair. To ensure that maintenance plans are cascaded with the approved budgets and system distribution demands.

1.2 PRINCIPAL ACCOUNTABUILITIES Performed regularly To manage the provision of maintenance management system. Documentation and review of work methods Planning and supervision of scheduling of annual maintenance activities in PEMS To plan, direct, monitor and control the utilization of maintenance resources using PEMS, MS project and other planning tools. To manage the operations of the Library / Archives and ensure latest revision of drawings / manuals are available. Define and review Key Performance Indicators (KPIs) for evaluation of maintenance programs and overhaul schedules. Backlog tracking and reporting for maintainable equipment. Work priority processing. Ensure quality and integrity of maintenance data in PEMS.

Performed periodically Weekly To review and report to management on the weekly performance of the maintenance crews. Develop planned Work estimates.

Monthly Monthly maintenance management report. Failure analysis on PEMS Tracking and enforcing recommendations from the system audits for major and critical equipment. Annually Updating annual register in PEMS. Identify and ordering non-stock materials required by maintenance planning department.

Performed at irregular intervals In liaison with maintenance engineers and supervisors, revise maintenance planning procedures in conformity with maintenance best practices.

10

1.3 REPORTING RELATIONSHIPS

TSM - CBD

MAINTENANCE PLANNER

MAINTENANCE SCHEDULER
Fig 1: Reporting relationships

MAINTENANCE INSPECTOR

11

1.4 WEEKLY ACTIVITY PROCESS The process flows as shown in the flow chart below:
Start 50%
Preventive Maintenance jobs due on the 52 week plan (Enforced by Planning) Backlog jobs due (Monitored by planning) Procurement/ Recruitment process
Step 2B

35%

Notifications & Requests (Controlled through PEMS)

15%

Initial investigations & attach planned materials in PEMS

Step 1B Step 1 Step 1

No

Does work require immediate attention? & Are Resources Available?

If resources are available

Step 3

Yes
Executors Load jobs on Weekly projection form & attaches material resources & commitments of available man-hours
Step 2

Planning generates a draft weekly schedule

Yes
Step 3

Production planning meeting as per procedure

Approved jobs on Weekly Schedule

Step 4

Planning Generates Maintenance Works Order

Step 6

Feed-back

Materials commitment by Stores

Step 5

Step 7

Execute maintenance As per Plant & Equipment Maintenance Process A Man power utilization Work planning factor Schedule attainment Labor cost variance Materials cost variance Attendance Plant non conformances

Yes No
Is job executed to correct standard?

Feed-back

KPI Weekly Performance Review Report

Step 8

Fig 2: Weekly activity process

12

Record Keeping In the course of implementing the above process, the following record is generated and maintained in the hard Copy form. NO. 8.1 8.2 RECORD NAME Weekly Schedule Weekly Maintenance Reports Weekly Projection Form PEMS feedback WHERE KEPT Planning Office Planning Office RETENTION TIME DEPOSITION 3 Months Shred 6 Months Shred

8.3 8.4

Planning Corporate server

6 months Indefinite

Shred N/a

Table 1: Record Keeping

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2.0 MAINTENANCE MANAGEMENT SYSTEM MMS is one of the most cost-effective methods that ensures reliability, safety, and efficiency in the Copperbelt Division. Inadequate maintenance of the power line systems and switchgear is a major cause of loss of energy and revenue. A good maintenance practice generates substantial saving and is considered a resource. 2.1 CONCEPT OF MAINTENANCE MANAGEMENT MMS is a system whereby maintenance tasks and resources are keenly planned, organized and controlled to meet the following objectives: Reduced maintenance costs as a result of planning intervention that aims at minimizing the frequency of equipment breakdown. Increased equipment availability and reliability due to reduce equipment breakdown frequencies. Increased tool time arising from advance preparation of all maintenance logistics. Increased labour productivity as each employee is scheduled for a shift of meaningful work prior to shift start. Control of maintenance activities through the work order system. Increased useful life of the equipment. Optimizing the stock of spare Parts.

DRIVERS OF MMS

Maintenance Planners and Schedulers Assets Register. 52 week maintenance plan Commitment and involvement of stakeholders. Weekly scheduling of maintenance activities An effective maintenance work order system. An effective backlog control system Clear and concise Key Performance Indicators (KPI) A well managed notification system.

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2.2 MMS RESPONSIBILITIES AND DUTIES Operations Department: Maintenance function within the region Coordination between maintenance, faults and operations functions Reporting defects affecting system Making operating equipment available for scheduled maintenance

Planning Department: Planning and scheduling maintenance to be carried out at Divisional or Regional Level. Providing statistical reports on the performance of the maintenance management system Coordinating materials needed to carry out the maintenance function updating of maintenance backlog inventory Monitor Data integrity on PEMS. Analyzing maintenance procedures and document so as to improve efficiency and best work practices Managing the storage of maintenance records.

Maintenance Supervisors: Assigning maintenance and controlling work being performed under their direct supervision Identification and execution of work in the respective sections Ensuring that all pertinent maintenance is recoded on PEMS

Maintenance assistant and artisans: Providing correct feedback on maintenance as demanded by maintenance document. Execution of maintenance work in a good workman like manner.

Stores and Procurement: Ensuring that an effective materials and procurement plan is put in place to service the planned maintenance activities. Provide status on PR and Orders related to planned

15

maintenance works and backlog. Facilitate safe storage and easy retrieval of materials. Advise on materials costs. Human resources: Ensure manning levels are maintained as per organization chart. Provision of personal protective clothing to the work force. Leave over time projections. To provide security so that the assets are not vandalized. Interpretation of policies pertaining to maintenance management.

2.3 TYPES OF MAINTENANCE WORKS The under listed are the types of works encountered in the execution of jobs under MMS. Planned Corrective Work These works are executed from the 52 week plan and those jobs arising from requests which are non emergency or urgent jobs. Routine Maintenance These works are executed in connection with works that are routinely done on a regular basis such as inspection, cleaning, oiling etc. Predictive Maintenance Predictive Maintenance or Condition Based Maintenance attempts to evaluate the condition of equipment by performing periodic or continuous (online) equipment condition monitoring. The ultimate goal of Predictive Maintenance is to perform maintenance at a scheduled point in time when the maintenance activity is most cost-effective and before the equipment loses performance within a threshold. This is in contrast to time- and/or operation count-based maintenance, where a piece of equipment gets maintained whether it needs it or not. Predictive maintenance will always have planned or scheduled start date and time hence it is planned work. Project or Modification Work These works are executed in connection with project works or overhauls being carried out.

16

Emergency Unplanned Work These works are executed under emergency and urgent situations. This arises when there is loss of supply and where safety of life and equipment is threatened. Unplanned emergency works are executed on priority P0 or P1 and as such these jobs take priority over planned jobs.

2.4 WORK ORDER MANAGEMENT IN PEMS Work Request It is used when requesting for corrective maintenance works. It will also provide a means of screening and authorizing work requests in to Work Orders.

Work requests are raised in PEMS by Maintenance Planning Office, Operations or any Maintenance Supervisors. Validations (Acceptance/Rejection) are done by Maintenance Planning Department. When the need for a work request arises, the originator will raise a work request in PEMS by populating the under listed data fields in general data and other data panel;

Functional Code Supervisor Description of request Description of fault or work required Detection Date Operating Condition Work Type Priority Responsible department and section Originators identity

If the detected defect is an emergency, the operations or the control staff should use the quickest channel of communication to inform the executing department. The executing department shall proceed to carry out the work on the basis of the request. In the meanwhile, the operations or 17

control staff shall raise the work request in PEMS as documentary evidence. Upon completing the work, the executing department shall accept the work request in PEMS and update the resulting work order with what has been done.

If the detected defect is not an emergency, operations or control staff shall raise a work request in PEMS with a priority rating other than P0. The maintenance engineer shall carry out an initial assessment of the works to determine the tasks and the material requirements. Thereafter the maintenance engineer shall accept the work request and add the task and materials to the generated work order. This work order can break into the weekly schedule or be added to the backlog depending on priority and resource availability.

Work Request (WR) - General Data

Fig 3: - Work Request Details General data 18

Work Request Other Data

Figure 4 - Work Request Detail - Other Data

Work Order (WO) A work order is a tool that assists planning, organising and controlling maintenance activities by providing a formal identification and full definition of maintenance work required.

All maintenance works are planned, assigned and controlled by maintenance planning by means of PEMS generated Work Orders (WO). By and large, maintenance planning shall not be involved in emergence works except where the scope of work is significant and requires a planned approach. For instance repairing a faulty cable or where a significant portion of an overhead line has fallen.

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All planned maintenance Work Orders will be prepared by maintenance planning office. The Planning office will enter the following details: Functional Description Description of Maintenance Works Priority Operation Condition Work Type Responsible Supervisor Planned Dates Maintenance Group Maintenance Crew Attach procedures & Instructions Cost code

The planning office will then liaise with concerned executing supervisor to estimate, and then populate the fields for planned resources; i.e. labour, special tools, equipment, materials and spares required to complete the work.

Once the maintenance work order has been updated on PEMS, the Executors are able to have access using their profiles and can requisition the planned materials from stores and provide feedback by modifying the actual details. Maintenance Supervisors will responsible for changing status of WO from planned to progress and then to complete status.

The Maintenance Supervisor shall ensure the under listed details are updated before taking the WO into the status completed; 1. WO Management Narrative description of works carried out. Failure details(if the work type is breakdown) Stops Tasks(if any) Actual Start and End date for Job 20

2. Management Control Business Unit Cost Centre Expense Account 3. Resource Provision Actual Labour Utilized Materials requisitioned Other Data (if any)

The Maintenance Engineer, Area Manager and Operations Engineer, shall ensure data integrity before changing the status of the Work Orders to closed. The maintenance planning office will coordinate with other support functions to ensure that all logistics are in place for scheduled works.
WORK ORDER

Figure 5 - Work Order 21

3.0 PREVENTIVE MAINTENANCE IN PROTECTION In Protection, Preventive maintenance (PM) is adopted as the practice of maintaining equipment on a regular schedule, based on elapsed time only. The intent of PM is to prevent maintenance problems or failures before they take place by following routine and comprehensive maintenance procedures. The goal is to achieve fewer, shorter, and more predictable outages.

The tests done during preventive maintenance reveal failures which would have prevented the relay from performing when called upon to operate, while properly maintained records will reveal any trends which could lead to such failures. maintenance has been put as a good starting point. However, an annual schedule of

Some advantages of preventive maintenance are:

It is predictable, making budgeting, planning, and resource levelling possible. When properly practiced, it generally prevents most major problems, thus reducing forced outages, reactive maintenance, and maintenance costs in general. It gives managers a level of assurance that equipment is being maintained. It is easily understood and justified.

Preventive maintenance does have some drawbacks: It is time consuming and resource intensive. It does not consider actual equipment condition when scheduling or performing the maintenance. It causes problems in equipment in addition to solving them.

3.1 PROTECTIVE RELAY MAINTENANCE The protective relays remain stand still and without operation until a fault develops. However, the relay should be vigilant at times. For reliable service of protective relaying excellent maintenance is a must. Every relay has a provision of setting. Setting determines pick-up value and time. 22

Settings of various relays need co-ordination.

Secondary injection tests Secondary injection checks the operation of the relays but does not check the primary circuit of the CT.

The following details are considered when doing the test. Contact function: Manually close contacts and observe that they perform their required function of tripping. Pick up: Gradually apply current to see that pick up is within limits. Gradually applied currents will yield data which can be compared with previous or future data and should not be clouded by such effects as transients. Drop off or reset: Reduce the current until the relay drops off. This test will indicate excess friction, should the relay be sluggish in resetting or fail to reset completely, and then the jewel bearing and pivot should be examined. Plug setting: For 5A relays the plug setting is set as follows:

R = 50%, E/F = 20%, Y = 50% and for 1A relays it set at R =100%, E/F = 50%, Y = 100% Time setting: The time setting dial is calibrated from 0 to 1 in steps of 0.05. When doing a test, the time setting is set on 1. Correct time of operation: This time is obtained from the normal inverse curve by the following calculations. 5A Relay @ 50% O/C If = Current injected in amps [5, 12.5, 25], Iset = Relay rating x plug setting

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P.S.M =

=2

From the curve PSM = 2 Corresponds to 10s

Using the formula Time of operation =

( )

, Ko = TMS = 1,

P.S.M = 2

( )

= = 10 seconds

P.S.M =

=5

From the curve PSM = 5 Corresponds to 4.3s

Using the formula Time of operation =

( )

, Ko = TMS = 1,

P.S.M = 5

( )

= = 4.3 seconds

P.S.M =

= 10

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From the curve PSM = 10 Corresponds to 3s

Using the formula Time of operation =

( )

, Ko = TMS = 1,

P.S.M = 10

= = 3 seconds

5A Relay @ 20% E/F If = Current injected in amps [2, 5, 10], Iset = Relay rating x plug setting

P.S.M =

=2

From the curve PSM = 2 Corresponds to 10s

Using the formula Time of operation =

( )

, Ko = TMS = 1,

P.S.M = 2

( )

= = 10 seconds

P.S.M =

=5

25

From the curve PSM = 5 Corresponds to 4.3s Using the formula Time of operation =
( )

, Ko = TMS = 1,

P.S.M = 5

( )

= = 4.3 seconds

P.S.M =

= 10

From the curve PSM = 10 Corresponds to 3s

Using the formula Time of operation =

( )

, Ko = TMS = 1,

P.S.M = 10

= = 3 seconds 1A Relay @ 100/50% OC/EF Multiple of setting Time secs 50 Hz O/C E/F @100% @50% 2 10 1 10 5 4.3 2.5 4.3 10 3 5 3

Table 2: Standard relay setting for an OC/EF for maintenance 26

Secondary injection results

REGION: Mufulira SUBSTATION: Mufulira Sub 50 PRESENT SETTINGS PS 75% 20% SELECTED PS TMS 0.1 0.1 SELECTED TMS 400/5 400/5 CURRENT INJECTED IN AMPS 5 CTR PROT TYPE O/C E/F ACTUAL TIME TAKEN FOR OPERATION 10 4.3 3.0 10 4.3 3.0 10 4.3 3.0 CORRECT TIME IN SECS 10 4.2 2.8 10 4.5 3.0 10 4.2 2.8 PU = 3.0 DO =2.8 OK PU = 0.9 DO =0.8 OK PICKUP/DROP OFF CURRENT IN AMPS PU = 0.8 DO =2.6 OK REMARKS RELAY TYPE TJV AREA/BRANCH: Mufulira CIRCUIT: Sub 22 Feeder RELAY SER. No G21162 5A RELAY RATING CURRENT VOLTAGE 30V

R = 50%

12.5 25 2

Y = 20% B = 50%

5 10 5

12.5 25

Table 3: Secondary results for Mufulira Sub 50 on sub 22 feeder 3.2 OIL AND SF6 CIRCUIT BREAKERS MAINTENANCE Insulation resistance is measured by means of Megaohm meter (Megger). Normally 10000V (d.c) Megger is preferred. The insulation resistance of circuit breakers is very high (above 10000 megaohms of infinity).

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Trouble High Contact resistance between terminals, with breaker closed (above 100 micro-ohms)

Possible causes Reduced contact pressure Loose connections Contact surface damaged due to repeated operations Insufficient contact wipe Oxide film on contact surfaces

The contact resistance between terminals of each phase is measured by means of micro-ohm meter. (Ducter). Contact resistance is proportional to contact pressure. LOW contact pressure may be due to weak springs or worn out contacts. High contact resistance causes excessive heating of contacts while carrying normal current and possible welding during through short-circuit.

When the contact pressure is enough even a line contact can pass normal current without overheating.

Trouble Low Dielectric strength of oil.

Possible causes Tank has leaking gaskets Frequent of the breaker

Normally oil is changed or filtered if the dielectric strength (BDV) is below 25 Kilovolts depending on the level voltage or if there is a noticeable amount of carbon in suspension or in the bottom of the tanks. The minimum acceptable breakdown values are 22 Kv. on 11kv level.

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Trouble Breaking of bushings or misalignment of contacts or binding of operating mechanism.

Possible causes Shift of breaker tank Cracks on the foundation and objects

Circuit breaker maintenance results Town Sub OCB/SF6 Contact resistance R =98.7 Y =92.8 B =92.6 R =180.2 Y =92.3 B =96.1 R =199.7 Y =164.7 B =170.4 R =92.1 Y =91.0 B =87.0 R =79.6 Y =78.8 B =76.8 R =180 Y =117.2 B =900.2 R =1.2 m Y =277.5 B =376.8 Dielectric Strength (BDV) 40.1 kv

Mufurila

Sub 30

Local Tx

Mufurila

Sub 30

High cost T/ship Feeder Incomer Feeder 1

36 kv

Luanshya

Old Zamefa

Kitwe

East primary

Bus-section

24kv Changed for 60Kv SF6

kitwe

ravens

Kitwe south

SF6

Chingola

Chambeshi primary

kaompe

SF6

Chililabombwe Sub 2.2

Konkola T/ship

40kv

Table 4: Circuit breaker maintenance results.

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3.3. BATTERY CHARGERS AND BATTERIES MAINTENANCE Battery system provides last resort power for performing communication, alarm, control, and protective functions when other sources of power fail. Battery system maintenance should have highest priority.

Battery chargers, important to the health and readiness of battery system, require regular maintenance as well.

The following activities are carried out during maintenance: Inspect for correct voltage Inspect for inter-cell connectors if in good condition Replace cells if not ok Replace charger if not ok

Results from battery charger maintenance Region: Chingola Substation: 7

Date: 26/11/09 Battery Charger Details: ALCAD L11P Battery Details: Type BC 45/1.5

Measurement of Voltage per cell

Cell No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Voltage 1.27 1.29 1.28 1.29 1.29 1.29 1.29 1.30 73mV 1.28 1.29 1.28 1.29 1.29 1.28 Cell No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Voltage 1.29 1.28 1.30 1.27 1.29 1.28 1.30 1.30 1.28 1.30

30 Table 5: Measurement of voltage per cell

Total number of cells: Total Volts with charger OFF: Total Volts with charger ON:

25 32.2V 33.3V

REMARKS: Topped up Battery water and replaced cell No. 9 (1.28V) 3.4 TRANSFORMER TESTS AT NEW SCAW SUBSTATION- KITWE Ratio test KVA Rating 15000 Vector Group Dyn1 Tap position s/c Impedance s/c Resistance HV Volts 66000 HV Amps 131.2 1 8.10 0.43 LV Volts 11000 LV Amps 753.1 8 7.64 0.43 Freq Hz 50 Manufacturer ABB

17 7.18 0.45

Tap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Input voltage (volts) Magn. Current (mA) VRY VRB VYB IR IY IB 360 356 355 1.02 0.97 1.42 356 356 356 1.07 0.83 1.43 364 363 366 1.09 0.82 1.47 360.5 359.2 356 1.13 0.87 1.50 359.4 358.4 358.2 1.18 0.88 1.72 360 358.9 359 1.22 0.92 1.6 360 357 358 1.26 0.94 1.65 358 356 357 1.3 0.96 1.7 359 356.4 357.2 1.34 0.99 1.74 359 359 360 1.45 1.07 1.85 356 355 353.7 1.50 1.08 1.91 355.8 353.2 355.6 1.54 1.12 1.96 357.2 355.6 356.9 1.61 1.16 2.04 356.1 356.4 357 1.65 1.2 2.09 356.7 353 355.5 1.7 1.25 2.16 356 356 356 1.77 1.28 2.26 358 356 355 1.82 1.34 2.31

Output voltage Neutral (volts) voltage(volts) Vry Vrb Vyb Vrn Vyn Vbn 56 56 56 32.5 32.5 32.5 57.6 57.5 57.7 32.7 33 33 59.2 59.1 59.1 33.7 33.7 33.8 59.6 59.5 59.8 34 34.2 34.2 60.5 60.5 60.6 34.5 34.6 34.6 61.4 61.4 61.3 35 35.2 35.2 62.2 62.0 62.2 35.3 35.6 35.5 62.2 62.5 62.8 36.2 36.5 36.4 63.9 63.8 64 36.8 36.8 36.5 65.8 64.7 64.8 37.2 37.5 37.4 65.1 65.1 65.5 37.8 38.1 38.0 66.9 66.8 66.9 38.6 38.7 38.6 69.1 68 67.7 39.1 39.2 39.1 69.4 69.1 69.0 40 40.1 40.1 70.2 70.1 70.1 39.8 40.8 40.6 71.5 71.5 71.7 41.4 41.4 41.4 72.2 72.3 72.2 41.7 42.0 42

Ratio 6.3 6.2 6.2 6 5.9 5.9 5.8 5.7 5.6 5.5 5.4 5.3 5.2 5.2 5.1 5.0 4.9

Table 6: Transformer ration test

31

Vp =

@ Nominal Tap 8

Ratio = 5.7

Vp =

= 36.1 V

Magnetizing currents are in (mA). Winding Insulation Resistance Measurements Connection W1 - E W2 - E W1 W2 Table 7: Insulation resistance tests. Voltage withstand Test on transformer oil with spherical Test electrodes Radius 25mm and 25 mm spacing. Take samples Item 1 2 3 Sample Main tank oil OLTC oil Conservator oil Breakdown voltage (kv) 57 57 57 Remarks ok ok ok Test Voltage (Vdc) 5KV 2.5 KV 5KV M 1360.8 1454.3 1368.2

Table 8: Transformer Oil tests. General checks No. 1 2 Objects for Inspection Bushings Gas relay Inspection Trapped air has been released All porcelains are undamaged & clean Trapped air has been released Direction is correct from tank to conservator Silica gel is dry, dark blue color, at least of the content. Oil level up to the mark. Oil bubbling is observed. All valves are in correct position Oil levels in conservator tanks are correct No leaks observed Ok/Remarks ok ok

Air breather

ok

4 5 6

Valves Oil level Oil leaks

ok

No leaks

Table 9: General transformer checkups. 32

3.5 PREVENTIVE MAINTENANCE CHECKLIST Purpose To provide laid down preventive maintenance work activities on maintainable assets so that the artisan follows the recommended procedures for carrying out maintenance functions. To provide a standard procedure of preventive maintenance work reporting by the artisans

33

3.5.1 Protective maintenance form

ZAMBIA ELECTRICITY SUPPLY CORPORATION LIMITED COPPERBELT DIVISION DISTRIBUTION AND SUPPLY DIRECTORATE PROTECTIVE MAINTENANCE FORM REGION: SUBSTATION:. CIRCUIT:............ Maintenance Frequency Annually No. 1 2 3 4 5 CHECK LIST Check operation of auxiliary circuits Check for correct labeling of control cables Check trip circuit supervision Check tap changer operation Secondary injection Test
CTR PROT RELAY TYPE

OBSERVATION

ACTION TAKEN

Relay Make.
RELAY SER.No RELAY RATING CURRENT VOLTAGE

PRESENT SETTINGS PS TM O/C E/F SELECTED SELECTED PS TM

CURRENT INJECTED IN AMPS

ACTUAL TIME TAKEN FOR OPERATION

CORRECT TIME IN SECS

PICKUP/DROP OFF CURRENT IN AMPS

REMARKS

6 7 8 9 10 11

Secure properly control cables in the panel Carry out trip tests of all protection Measure substation earthing resistance Clean control relay panels Measure insulation of control cables Tools and Equipment - AVO meter, Secondary Injection Test set, split plug, Earthing resistance tester, 500v megger tester Maintained by Signature. Date Checked by Signature. Date

34

3.5.2 Circuit breaker maintenance form

ZAMBIA ELECTRICITY CORPORATION LIMITED DISTRIBUTION AND SUPPLY SERVICES COPPERBELT DIVISION CIRCUIT BREAKER MAINTENANCE FORM REGION:. SERIAL No.. SUBSTATION: MAKE/TYPE:.. CIRCUIT:. RATED CURRENT: VOLTAGE:. BRAKING CAPACITY:.. MAKING CAPACITY:.. PROCEDURE FOR THE CONTROL, OPERATION AND MAINTENANCE OF HIGH VOLTAGE APPARATUS SHOULD COMFORM TO ZESCO LIMITED SAFETY RULES CHECK LIST Check general cleanliness of breaker panel Check for oil level Check for proper operation of ON/OFF indication mechanism Check the condition of the heaters Check the fixed and moving contacts Check and clean Arc control device Check for proper operation of shutter assembly Check the condition of gas vent seal Check for any oil leakages Check and lubricate locating bolt and linkage of breaker Check for the gas pressure for SF6 recloser Check and lubricate racking up and down or out mechanism Check condition of tank gasket, tank lining & phase barriers Check and clean auxiliary contacts Check for slow closing TEST Measure the contact resistance Carry out continuity test in the open and close position Carry out timing tests (with speed curve meter) Test dielectric strength and crackle test Test the close and trip test manually and electrically Check fluid in the hydraulic unit (where applicable) Check the condition of the bushings Test the earthing OBSERVATION ACTION TAKEN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

RESULTS

ACTION TAKEN

16 17 18 19 20 21 22 23

REMARKS Maintenance frequency annually or depending on the number of operations Maintained by: Signature:. Date:. Checked by:.. Signature: Date:.

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3.5.3 Battery chargers and batteries maintenance form

ZESCO LIMITED PROTECTION DEPARTMENT

BATTERY CHARGERS AND BATTERIES MAINTENANCE SHEET CBD REGION:.. DATE:. SUBSTATION:.

Battery Charger Details:. ... Battery Details: Measurement of Voltage per Cell Cell # Volt S.G Cell # Volt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

S.G

Cell # 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Volt

S.G

Cell # 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

Volt

S.G

Cell # 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

Volt

S.G

Total number of Cells:________________________ Total Volts with charger OFF: __________________ Total Volts with charger ON:___________________ Off load charger output volts:___________________ Boost charging current:________________________ Float charging current:________________________ REMARKS:.. .

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3.5.4 PSM Curves

37