MAINTENANCE STANDARD GUIDELINE ONTARIO ...extportal.vale.com/maint/Sud/pdf/MGUID-50006.pdfMaintenance Standard Guideline Page 2 of 16 Electrical Electrical Department MGUI-50006 Electrical

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MAINTENANCE STANDARD GUIDELINE ONTARIO OPERATIONS

TITLES:

Electrical Electrical Department Electrical Maintenance Best Practices

VALE

MGUID-50006

PAGE

Page 1 of 16

DATED

2016-04-26 REV

2

Training Code (If applicable):

N/A

Document Owner: Name: Phil Langlois Position: Lead Electrical Engineer, Electrical Department

Table of Contents

1.0 PURPOSE....................................................................................................................................................................... 2

2.0 SCOPE ........................................................................................................................................................................... 2

2.1. EXCEPTIONS ................................................................................................................................................................ 2

3.0 REFERENCES .................................................................................................................................................................. 2

4.0 CONTEXT ....................................................................................................................................................................... 3

5.0 COMMITMENTS ............................................................................................................................................................ 3

6.0 DEFINITIONS ................................................................................................................................................................. 3

7.0 ELECTRICAL MAINTENANCE BEST PRACTICS .................................................................................................................. 4

7.1. DRAWINGS ..................................................................................................................................................................... 4 7.2. BREAKER MAINTENANCE ................................................................................................................................................... 5 7.3. HIGH VOLTAGE SWITCHGEAR RELAY TESTING ........................................................................................................................ 7 7.4. NGR TESTING ................................................................................................................................................................. 8 7.5. PERSONAL AND OTHER PROTECTIVE EQUIPMENT ................................................................................................................... 9 7.6. ELECTRICAL ROOM MAINTENANCE .................................................................................................................................... 10 7.7. OVERHEAD LINE MAINTENANCE ........................................................................................................................................ 11 7.8. POWER SYSTEM STUDIES ................................................................................................................................................. 12 7.9. HIGH VOLTAGE SWITCH MAINTENANCE (S&C) .................................................................................................................... 13

8.0 APPENDICES ................................................................................................................................................................ 15

Appendix A: Revision Notes and Approvals ....................................................................................................................................... 16

Maintenance Standard Guideline

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Electrical Electrical Department

MGUI-50006 Electrical Maintenance Best Practices Rev 2

1.0 PURPOSE

Electrical maintenance programs vary a great deal from site to site as electrical maintenance management either does not possess the necessary expertise or time to research such requirements. This guideline has been created to provide sites with information on best practices to consider when setting up an electrical maintenance program to ensure zero harm in the workplace. Where a defined best practice is “required to achieve regulatory or standards compliance”, it has been written in normative (mandatory) language. It is the site’s responsibility to ensure its processes in these areas are in compliance with current legislative requirements and standards as is applicable.

2.0 SCOPE

This guideline may be referenced by all Vale Ontario sites.

2.1. EXCEPTIONS

None

3.0 REFERENCES

The following documents were used in the development of this document or are related to it. They shall be used in their most recent revision.

CSA-M421-11 Use of electricity in mines

CSA-Z462-15 Workplace electrical safety

IHSA/EUSA Infrastructure Health and Safety Association/Electrical Utility Safety Association – rules for utility work

NFPA-70B Recommended Practice for Electrical Equipment Maintenance

OSHA Occupational Health and Safety Act

Regulation #854 Mines and Mining Plants

CSA Z463-13, Guideline on Maintenance of Electrical Systems

OESC-12, Ontario Electrical safety Code, Part I


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4.0 CONTEXT

Without getting into site-specific electrical maintenance requirements or specific programs for all equipment, there are industry accepted “best practices” which should be considered for all Vale sites. This guideline identifies best practices including references to federal and provincial - guidelines, standards and acts where applicable. Personnel safety and equipment reliability will suffer if these mandatory requirements are not met. Best practices in this document have been grouped into the following categories:

1. Drawings 2. Breaker Maintenance 3. High Voltage Switchgear Relay Testing 4. Neutral Grounding Resistor (NGR) Testing 5. Personal and Other Protective Equipment 6. Electrical Room Maintenance 7. Overhead Line Maintenance 8. Power System Studies 9. High Voltage Switch Maintenance (S&C)

For each category, a table is provided that provides information in the following format:

1. Background 2. Applicable requirements (federal or provincial - guidelines, standards, codes or acts) 3. Recommended “best practices” approach

5.0 COMMITMENTS

This guideline (MGUID-50006) is committed to comply with:

The Vale HomeSafe program; and

The Occupational Health and Safety Act.

6.0 DEFINITIONS

Best Practice: Procedures that are accepted or prescribed as being correct or most effective.


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7.0 ELECTRICAL MAINTENANCE BEST PRACTICS

7.1. DRAWINGS

Background

Updated drawings permit safe isolation and guide troubleshooters. They assist planners, engineers and consultants thereby reducing ongoing costs.

Requirements mentioned in the Act, regulations, codes, standards and guidelines

OSHA, 29(2), “…six months…” Reg#854, 22, “…maintained…legible…” CSA-M421-11, section 4.2.1, “…annually or after any significant change…” CSA-Z462-15, section 5.2.2, “…single line…legible…kept current”, Annex B5, Annex E(3)(i) OESC-12, section#36-006(5), “…metal enclosed switchgear…legible…single line diagram” CSA Z463-13, section 4.7.5(b), 5.16.2(b)

Recommended “Best Practice” approach

Each site will appoint a Drawing Coordinator for electrical and instrumentation mark-ups (single lines, schematics and wiring, panel schedules, loop diagrams, layouts, etc.).

All drawing revisions are to be channeled through the Coordinator for updating services provided by the Central Engineering Department (CED).

The Coordinator will verify the quality of the plant mark-ups and make sure that references are adequate before sending the drawings to CED.

When drawings are returned from CED, the Coordinator will distribute the revisions to the correct crews (if paper copies are involved, e.g. single lines for posting in electrical rooms).

All returned drawings are checked by the Coordinator for missing information or for code violations cited by CED and action is taken or scheduled to obtain resolution.

Each Site Coordinator will track the missing information and code violation requests to make sure there is resolution on these matters.

CED will track how many drawings have been sent for revision on an annual basis, how many drawings are returned and the time taken to obtain those revisions. These quantities are measurable metrics which can be audited.


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7.2. BREAKER MAINTENANCE

Background

Maintained breakers assure safe operation when called to do so. During faults, their timely action permits the selected PPE to adequately protect the worker and limit outages to the faulty or overloaded areas only.


OSHA, 25(2)(h), “…every precaution reasonable…”, 29(1)(a)(ii), “…facilities…maintained as prescribed…”

CSA-M421-11, section 4.10, “…electrical equip…maintained…safety not compromised”

CSA-Z462-15, section 5.2.3, section 5.3.5, “…maintained to function in accordance to their designed operating times”, section 5.6, Annex B12

NFPA-70B-10, section 11.10 for low voltage breakers, section 11.16 for high voltage and chapters 15 & 17

CSA Z463-13, section#8.2.7 & Table M.4.1 “circuit breakers”

OESC-12, section#2-300, “…operating electrical equipment shall be kept in a safe and proper working condition”

Recommended “Best Practice” approach

The following services can be supplied by Vale’s Power Department (Protection and Control) in the Sudbury area if the breakers are located on surface. For underground breaker testing, the service must be obtained by non-Vale personnel at the current staffing levels.

A list will exist which contains all the site’s MCCBs, LVCBs & HVCBs and their scheduled service intervals. The maintenance paperwork will be kept in an easily accessible area in the event of ministry investigations.

Dated stickers will be affixed to the breakers after servicing. Breakers which exhibit issues during servicing are to be re-serviced three months after servicing to make sure the issues have gone away.

When breakers interrupt faults approaching their interrupting ratings, they shall be inspected before being re-closed. Low Voltage Power Molded-Case Circuit Breakers (MCCBs-600volt)

MCCBs are to be serviced every three years.

MCCBs which have re-occurring issues are to be removed from service and replaced by other breakers. The problematic breakers are to be replaced in kind due to downstream arc flash incident energy level calculated risks on the posted labels.

All MCCBs having solid state trip units (such as the RMS-310 & Seltronic) are to have their units tested using secondary injection.

All MCCBs equipped with shunt trips (such as Startco NGR relays) will be tripped using this feature.


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All MCCBs equipped with manual trip buttons will be tripped using this feature.

All MCCBs will be exercised several times.

All MCCBs shall be maintained free of cracks in their cases and cracked or broken operating handles.

All MCCBs which are suspect or which exhibit hotspots during NDEs will be inspected internally as well.

In order to keep the Power Department (Sudbury area only) test equipment inventory to a minimum, standardize on the following solid state trip units for 600volt MCCBs: Cutler-Hammer Digitrip RMS310 or Seltronic units.

Low Voltage Power Circuit Breakers (LVCBs)

LVCBs are to be serviced every three years as a minimum (cleaned, exercised, racked-in/out, contact resistance tested, meggered, etc).

LVCBs which have re-occurring issues are to be removed from service and replaced by other breakers. The problematic breakers are to be sent for rebuild and not refurbishment. If sufficient funds permit, consider replacing the defective breaker with another type of breaker in order to minimize the different styles of breakers at the site. When selecting other types, select a type which allows the rack in/out process to be done using a racking screw type thereby allowing more distance between the user and the possible arc flash (permits adding an extension).

All LVCBs having solid state trip units (such as the Amptector, I-Tektor, Suretrip and Westrip) are to have their first trip performed electrically using a 9volt battery (terminals OP & ON) or using an alternative method thus proving that the breaker would have tripped before being serviced. Some older versions having high impedance trip actuators will not allow this functional test before servicing.

All LVCBs having solid state trip units are to have their units tested using secondary injection and the settings compared to the posted single line drawings.

In order to keep the Power Department (Sudbury area only) test equipment inventory to a minimum, standardize on the following solid state trip units for 600volt LVCBs: older units are the Westinghouse Amptector and I-Tektor while the newer units are the Westrip and the Cutler-Hammer Digitrip units. ABB-SACE breakers found on ABB-VFDs come with PRC111 trip units. All new trip units should be purchased with the arc flash maintenance mode feature on them and with LSIG functionality.

All LVCBs having dashpot protection will be replaced with breakers having solid state trip units since dashpots can only be tested using primary injection which apart from having serious safety implications, is too costly and cumbersome a program to implement. These old dashpots are likely missing oil which will cause nuisance trips or gummed-up causing them to trip slower or not at all. Also, the lack of testing is a liability when personnel are relying on arc flash labels for the proper PPE protection.

Local on-hand LVCB spares will be available


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Medium and High Voltage Power Circuit Breakers (HVCBs)

HVCBs are to be serviced every three years at a minimum for spring charge breakers and every 5 years for magnetically operated breakers (cleaned, exercised, contact resistance testing, hi-pot of vacuum bottles, cell interlock checks, etc.).

HVCBs will be first tripped using the relay protection relays thus proving the protection circuits and the functionality. This function is performed by the Power Department Technician in the Sudbury area.

HVCBs having an air breaking medium are to be converted to vacuum technology during rebuilds. For large and heavy breakers such as the GE Magna-blast breakers or the DHP breakers, converting them to vacuum will eliminate the asbestos shields and the ergonomic liability. When comparing rebuild options, try obtaining 3 cycle operating times to lower incident energy levels as well.

New HVCBs purchases will be standardized across the site and possibly the division to minimize training requirements, assurance of spares and local expertise.

7.3. HIGH VOLTAGE SWITCHGEAR RELAY TESTING

Background

Maintained relays assure safe operation when called to do so and at expected settings. During upset conditions, their predictable action permits the selected PPE to adequately protect the worker and for proper coordination and isolation of faulted circuits.



CSA-M421-11, section 4.5.5, “…before initial use and after every three years of use…”

CSA-Z462-15, section 5.2.3 & 5.2.4, “…industry standards”, Annex B.2

NFPA-70B-10, section 11.12, “…every 2 years…” in 11.12.1.1.2

CSA Z463-13, section#8.2.9 and Table M.6


Recommended “best practices” approach

All high voltage switchgear relays (electromechanical & digital) will be tested every three years to ensure their functionality and verify that settings have not been altered.

Relay settings will not be altered without the necessary engineering approvals, updating the power system studies and posting new arc flash labels.

Dated stickers will be affixed to the relay or relay cases thereby allowing the sites to know if their relays are due for testing during electrical room audits.

This service can be supplied by Vale’s Power Department (Protection and Control) in the Sudbury area if the relays are located on surface. For underground relay testing, the service must be obtained by non-Vale personnel at the current staffing levels.


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Where competing documentation exists, the area authority will either coordinate the updating of drawings and documents or clearly indicate “obsolete” on the old documents and drawings.

A standard job template is available for this task - SAP Task List Group 34883 1Y Testing,Kiruna Trly SubStn Relay, MEL (Contact: Plant Planner for more details)

7.4. NGR TESTING

Background

Testing the power connections on NGRs which do not have monitoring resistors assures the site that the ground fault protection is still available.



CSA-M421-11, section 4.5.6 & 4.6.2(b), general information only

CSA-Z462-15, section 5.2.3 “..in accordance with manufacturer’s instructions…”

OESC-12, section#2-300, “…operating electrical equipment shall be kept in a safe and proper working condition” and section 10-1100 to 10-1108 for general information


Each site will have a list containing all their NGRs.

NGRs having a resistor monitoring the primary connection will not require any yearly servicing.

NGRs not having a sensing resistor require yearly assessments of the power connections. This may or may not require an outage.

Keeping in mind to standardize with Startco’s SE-330, SE-325 and SE-105, the sites will consider adding the monitors to all NGRs

This service can be supplied by Vale’s Power Department (Protection and Control) in the Sudbury area if the NGRs are located on surface. For underground NGR testing, the service must be obtained by non-Vale personnel at the current staffing levels.


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7.5. PERSONAL AND OTHER PROTECTIVE EQUIPMENT

Background

It is a legal requirement to provide and maintain safety gear. Maintained gear will offer the intended protection to the worker.


OSHA, 25(1), “provide…maintain…safety equipment”, 25(2)(h), “…every precaution reasonable…”

CSA-Z462-15, section 4.3.7, personal and other protective equipment

IHSA/EUSA-09, section 134 & Table 3, live line tool maintenance


All plants will follow SPI-SAF-462 when purchasing arc flash PPE for their electrical crews.

Testing of Rubber Insulated Gloves (Refer to maintenance standard procedure: MPROC-50002). The Power Department and those utilizing gloves for “primary protection” will test low and high voltage gloves every 90 days and have expiry dates on their gloves to comply with EUSA-09 Section #134 and Table 3. All other sites and departments are not to request expiry dates on their gloves and are to test them every 6 months for high voltage and every year for low voltage.

Testing of Hot Sticks (Refer to maintenance standard procedure: MPROC-50005 – Hot Stick Procedure). Although it is permitted to test at an interval of every 3 years, hot stick testing will occur yearly for the Power Department and every three years for all other departments. All hot sticks will have expiry dates on them. Some departments may opt to replace them instead of testing them to be compliant.

Testing of high voltage detectors (Refer to maintenance standard procedure: MPROC-50009 – Modiewark Voltage Detector). It is permitted to test at an interval of every 3 years, but yearly testing will occur for the Power Department. All detectors will have battery replacement & test dates on them.


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7.6. ELECTRICAL ROOM MAINTENANCE

Background

Maintaining electrical rooms will not only benefit the equipment, but will promote positive behavioral changes. Achieving zero harm is not possible without it.


OSHA, 29(1)(a)(ii), “…facilities…maintained as prescribed…”


CSA-Z462-15, all sections

NFPA-70B-10, all sections

CSA Z463-13, all sections



Each site will have a list containing all their substations and electrical rooms.

Yearly, perform NDE on every substation and electrical room focusing mostly on the 600volt distribution racks. Re-scanning the “hotspots” after repairs are made is implied. Document all actions taken.

Depending on the site conditions, electrical rooms will be cleaned at appropriate intervals to keep them locked (controlled access), cleaned and dry.

Check condition of the signage and the labels.

Check that the posted single lines are the latest revision in j-DMS and that they are legible.

Remove all flammable/combustible materials.

Make sure all switchgear doors are closed and fastened.

Verify that cable entries and other openings have been sealed with fire retardant materials.

If any switchgear openings have been ignored, have knock-outs or other suitable barriers installed.

Replenish the locks and tags.

Verify that all relay stickers and breaker stickers are no more than three years old.

Verify that the arc flash labels are no more than five years old.

Depending on the seasons, either turn ON/OFF the heaters or turn ON/OFF the exhaust fans.

Check for water ingress and correct immediately.

Older out of service or spare switchgear that is still connected will be tagged for removal at the next outage to prevent using them out of convenience instead of adding new equipment. This will eliminate asbestos containing equipment, eliminate starters having two overloads and eliminate equipment rated at only 22 kA. ( a new procedure is being written to clarify this topic)


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Vale plant sites have SAP – Task Lists (standard jobs) specific to their area for conducting inspections of electrical rooms and power centers. NOTE: Refer to your plant’s Planner to ensure you are accessing or using the most recent SAP Task List for this inspection work. The following are samples of task lists available at the date of this guideline. Contact your Plant Planner for more details.

o Coleman Mine: SAP Task List 348861 – Inspect Electrical Switchroom, MEL o Garson Mine: SAP Task List 31631 3M Inspect, Switchroom, MEL o Creighton Mine: SAP Task List 30245 6M Inspect, Switchroom, MEL o Totten Mine: SAP Task List 32461 1M Inspect, Switchroom, MEL o Copper Cliff Mine: SAP Task List 31134 6M Inspect, Switchroom, MEL o Clarabelle Mill: SAP Task List 37014 3M Inspect/Clean,SwitchRoom,Area30,Mel o SAP – Task List 34887 1Y Testing Load Centre & Area Relay

7.7. OVERHEAD LINE MAINTENANCE

Background

Overhead lines are often assumed to be the property of the Power Department’s linegang which is not the case. All overhead lines rated below 69/44 kV are owned and maintained by the plant site.




CSA-Z462-15, too many sections to list

NFPA-70B-10, too many sections to list

CSA Z463-13, section#8.2.24 and Table M.1



Each plant will have a schedule set-up for overhead line maintenance for all lines which do not belong to the utility or to the Vale Power Department. The following seasonal tasks will be performed by trained and experienced personnel: Spring chopper/foot patrol:

The helicopter must fly at a speed which is slow enough for visual inspection

The helicopter must fly at a safe distance but close enough for visual inspection

Check for broken or burnt insulators

Check for defective cross arms

Check for brush & tree egress

Check for leaning poles & structures

Check that safety signs are still affixed to the poles (ESA requirement)

Check that all guy wires are still tight


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Fall foot patrol:

Check all items aforementioned in the spring patrol

Check that no garbage has been left around the poles

Ground rod visual inspection

Check for rusting & rotting on the guy wire anchors

Sound the poles with a hammer at its base and as high as possible while standing

Check soil condition surrounding the pole

Check pole crack depths

Check pole crack alignments from one side to the next

7.8. POWER SYSTEM STUDIES

Background

Power system studies contain short circuit calculations, device evaluation, coordination and arc flash hazard risk calculations for all electrical distribution components at each site and such are the plant’s go-to location for all major issues and upgrade inquiries.


CSA-Z462-15, section 4.3.5.1(b), “arc flash analysis…updated when a major modification or renovation takes place. It shall be reviewed periodically, not exceeding 5 years…”


All sites will have their electrical distributions modeled within a power system study while performing arc flash modeling. This study will follow the maintenance standard procedure: MPROC-50003 – Power System Study Procedure.

In Appendix E of the study, confirm all “assumptions” before the next revision.

In Appendix E of the study, correct or implement solutions to eliminate equipment rating issues.

In Appendix E of the study, correct or implement solutions to eliminate relay, fuse and/or breaker coordination issues

In Appendix E of the study, correct or implement solutions to mitigate arc flash hazards permitting personnel to wear less PPE.


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7.9. HIGH VOLTAGE SWITCH MAINTENANCE (S&C)

Background

High voltage switches (mostly S&C brand for Vale) are assumed to be bullet proof. Although a good product, they still require exercising and servicing depending on their application.




CSA-Z462-15, too many sections to list

NFPA-70B-10, too many sections to list

CSA Z463-13, too many sections to list

OESC-12, section#2-300, “…operating electrical equipment shall be kept in a safe and proper working condition” General Information from various S&C Installation & Maintenance Manuals.

S&C is a quality robust product requiring very little maintenance over the years when

properly installed. Mechanical maintenance is generally not required. The only

maintenance recommended consists of periodic cleaning and inspection of

interrupter-switch, fuse and bus supports on intervals based on environmental

conditions. The integrity of the enclosure finish should be checked and any scratches

or chips should be touched-up with the appropriate touch-up finish. Also, occasional

exercising of interrupter switches and switch operators as well as inspection of keyed

interlocks is recommended.

Metal enclosed switchgear should be inspected 6 months to a year after installation

then every 5 years thereafter depending on the each user’s own experience as well

as environmental conditions. The Mini-Rupter and Alduti-Rupter switches should be

cleaned and re-lubricated every 10 years.

It is not unusual for regular operations of interrupter switches to take place once every

5 years. Fuse replacement is very infrequent since fuse operations (blowing) occur on

an average of once every 20 years.


For most feeder switches (switches which see less than one or two operations per month

on average over the years), operate them when servicing the low and/or high voltage

breakers approximately every three to five years. When operating them, open the door

and perform a visual to determine if cleaning and re-lubrication should be scheduled. Test

the Kirk-key as well.


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For feeder switches having higher than normal usage such as skip/cage hoists and trolley

substations, annual inspections are required to make sure the switches are closing

properly and for re-lubricating them. The site should calculate its weekly or yearly

expected operations and plan to replace the switches at roughly 500 operations. Leeway

is available here and the calculated incident energy levels from the models and the safety

& production implications due to downtime to the site should be factors to consider as

well.


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8.0 APPENDICES

APPENDIX A: Revision Notes and Approvals


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Appendix A: Revision Notes and Approvals

The Revision Notes and Approvals table only displays the latest revision number and a list of the last revisions made to the document. For details on previous revisions contact the document owner.

Rev Revision Notes

Last Revised by: Phil Langlois, Electrical Lead, Electrical Department, Ontario Operations

2

SPI-ENG-006 revised as follows:

updated SAP Task List references where applicable

document reformatted to maintenance standard guideline format

added clarification on purpose of the guideline and references to best practices that have legislative or standard adherence requirements

Added references CSA Z462 and updated OESC to recent revised editions.

1

SPI-ENG-006 released July 9, 2012

Documents

MAINTENANCE STANDARD GUIDELINE ONTARIO ...extportal.vale.com/maint/Sud/pdf/MGUID-50006.pdfMaintenance Standard Guideline Page 2 of 16 Electrical Electrical Department MGUI-50006 Electrical