15. Cooling System

Weekly inspection. - See that air is not too hot when delivered to
the receiver. Check flow of cooling water. Note any leaks in
cooling water piping. Note accumulation of dirt and lint on air-
cooling fins.

Annual inspection. - Flush and clean out all waterlines. Repair
leaks. Clean air-cooling fins. Paint fins with aluminum paint.
Clean and paint as needed.

16. Receiver Tank

Weekly inspection. - Open the receiver drain valve and blow down
until water is removed. This includes receivers equipped with
automatic discharge valves. Check joints and seams for leaks.

Annual inspection. - Open and clean all rust and sludge from inte-
rior of all receivers having a volume of more than 1-1/2 cubic
feet. Repaint as required using compatible paint. Examine all
fittings for tightness. Inspect manhole gasket and seating sur-
faces. Reface surfaces and renew the gasket if needed. If re-
ceiver shell deterioration exists, it should be hydrostatically
tested to 1.50 times the maximum allowable working pressure. Air
receivers without manholes should be subjected to a similar hydro-
static test every 5 years. Hydrostatic tests are not required on
receivers associated with circuit breakers.

17. Air Intake and Cleaner

Weekly inspection. - See that screen and intake are not obstructed.

Montlily inspection. - Remove intake cleaner and clean the screen.
If compressor is in a dusty location, it may be necessary to clean
the intake screen at more frequent intervals.

18. Gages
Weekly inspection. - Note operation of gages and pressure being

held. Check for loose or stuck pointer. Do not operate the
compressor without a good pressure gage.

Annual inspection. - Remove all gages and calibrate. Renew defec-
tive parts and reinstall.

46


OPERATING TESTS:

NORMAL CLOSING SOLENOID VOLTS____ 125 AMPS. _. _30 —---- TIMEX. 12 hertz
MINIMUM CLOSING SOLENOID VOLTS.
NORMAL CLOSING CONTROL RELAY OR VALVE-
MINIMUM CLOSING CONTROL RELAY OR VALVE
NORMAL TRIPPING VOLTS.__.125.
MINIMUM TRIPPING VOLTS_
CLOSING SOLENOID RESISTANCE_.
CLOSING RELAY OR VALVE RESISTANCE. 25 9
TRIP COIL RESISTANCE )
TOTAL TRIP CIRCUIT RESISTANCE_.
CLOSING AIR PRESSURE -NORMAL_
AIR LEAKAGE - PRESSURE DROP PER HOUR
READING OF COMPRESSOR OPERATION COUNTER
TIME TO PUMP UP AIR PRESSURE____
COMPRESSOR CONTROL SWITCH - CUT IN.
NUMBER OF CLOSURES WITHOUT RECHARGING TANK__
SAFETY VALVE SETTING. --PSL

CLOSING SPRING MOTOR LOAD - VOLTS.
TIME TO CHARGE CLOSING SPRING.

AMPS_

Auxiliary Switch_contacts_cleaned
Ag t. readjusted_

Tightened potential device conne:

INSPECTED By._ J!

USE SPARE LINES FOR OTHER ITEMS AS NEEDED Al Smith
*SOVERALL TIME FROM CLOSING OF CONTROL SWITCH CONTACTS

67 Dockof Form oom st



18. Closing Solenoid Air Cylinder, Motor, or Spring

Weekly inspection. - Visual inspection to see that equipment is in
operating condition. Drain condensation from air cylinder.

Annual inspection. - Observe mechanism during several closing oper-
ations to see that everything is in proper working order. Check

solenoid plunger for sticking in guides. Check coil resistance and
insulation resistance. Dismantle air cylinder and clean and relu-

bricate. Check closing springs for proper tension and closing
energy.

19. Manual Operating Device

Annual inspection. - See that manual operating lever or jack is
Kept on hand and in useable condition. See that breaker is close-
able with it.

20. Latch and Trip Mechanism

Weekly inspection. - Visual inspection to see that mechanism is in
operating condition.

Annual inspection. - Observe mechanism during several tripping oper-
ations to see that everything is in working order. Check pins,
bearings, and latches for wear, binding, and misalinement. Clean
and relubricate as in Section 17 on Operating Rods, Shafts, and

Bellcranks. Check latch carefully to see that it is not becoming
worn so as to unlatch from vibration or stick and fail to trip.

Tighten bolts and screws.

21. Tripping Solenoid

Weekly inspection. - Visual inspection to see that solenoid trip
device is in operating condition.

Annual inspection. - Observe operation during electrical tripping.
ee that full energy with snappy action of plunger is obtained.
Check plunger for sticking in guides. Check coil and insulation
resistance.

22. Solenoid Valves

Annual inspection. - Check condition of valve seat, and refit as

necessary. See that moving parts are free to operate. Check re-
sistance and insulation resistance of solenoid coil.

63


Photo PX-D-67506

2. Battery Electrolyte

Monthly inspection. - Check electrolyte level and add distilled
water as necessary.

3. Connectors
Annual inspection. - Clean acid corrosion from connectors and
terminals. Tighten terminals.

4, Hydrometers

Annual inspection. - Check condition of hydrometers used for
monthly readings.

5. Equipment

Annual inspection. - See that the funnels, fillers, and other
distilled water and acid-handling facilities are kept clean and in
good usable condition.

40


1. Inspection Checklist - Continued

Inspection
Items of inspection interval

Blocks and hooks M A
Electric motors See Chapter on

Motors, p 17
Electrical control equipment See Chapter on

Controls,

p 31
Electrical wiring A
Hydraulic-hoist cylinder, piston, and rod NS
Hydraulic pump M NS
Hydraulic control valves and piping M NS
Oil Reservoir M
Guide rails and shoes M A
Safety devices M A
Operation W
Elevator Inspection A

W - Routine weekly inspection when in service.

M - Routine monthly inspection when in service.

A - Annual inspection.

NS - Not scheduled, frequency as required to maintain the equipment
and assure its operating functions.

Note: Always make detailed operation and maintenance checks of
cranes and hoists prior to lifting heavy loads.

2. Crane Rails, Supports, and Stops

Annual inspection. - Check rails for alinement and obstructions.
Check supports for cracks and spalling of concrete and for corro-
sion and loose rivets and bolts if steel. Repair concrete as nec-
essary. Tighten or calk loose rivets and bolts. Check stops for
security to building or rails.

3. Hoist and Bridge Framework

Annual inspection. - Check framework for looseness and cracks.
eck rivets and bolts for tightness. Check girders for aline-
ment. Examine girders for corrosion. Clean and paint as neces-

sary. Check trucks for skew.

50



CHAPTER VI - SWITCHBOARDS AND CONTROL EQUIPMENT

P4e-100-277 A

1. Inspection Checklist

Inspection
Items of inspection interval
Switchboards and Control Panels

Panels and cabinets A
Panel wiring and terminal blocks A
Auxiliary and control relays WoeoA
Control switches and pushbuttons WoA
Indicating lamps WoeoA
Meters and instruments WoA
Position indicators WoA
Protective relays WoeoA
Test switches or blocks A
Rheostats and resistors A

W - Routine weekly inspection when in service.
A - Annual inspection.

References

Power O&M Bulletin No. 16, Field Test Procedure for Protective Relays
Power O&M Bulletin No. 22, Watthour Meter Maintenance and Testing

31


9. Bushing Current Transformers and Potential Devices

Annual inspection. - Check tap settings and adjustments at terminal
board to see that they agree with diagrams. Check insulation resist-
ance of wiring with devices connected. Check ratio and phase-angle
adjustments of potential devices if changes have been made in sec-
ondary connections or burden. Tighten connections, including poten-
tial device tap into bushing.

10. Main Terminals and Ground Connections

Weekly inspection. - Check for presence of foreign materials, birds’
nests, etc., in or near connecting bus work; loose heating connec-
tions; and loose or broken frame ground connections.

Annual inspection. - Tighten all bus and ground connections. Re-
finish joint contact surfaces if they have been overheating. In-

spect ground cable to see that it is not loose or broken.

11. Main Contacts

Annual inspection. - Remove the tanks or drain out oil so that the
contacts can be inspected. Dress contacts, if rough, with a fine
file. It is necessary to remove only the projecting beads. Pits
in a flat, smooth surface are not objectionable. Check contact
drop with "ducter" or by direct-current millivolt drop. Frequency
of breaker contact maintenance should be based on number and
severity of faults interrupted rather than a definite time period.
Experience will tell how many faults can be interrupted before con-
tact repairs are necessary. Data should be kept on each breaker to
guide future maintenance. Inspection schedules might be extended
further as oil-handling methods, methods for determining oil con-
dition, and other improvenents are made. The following factors
should be established before intervals between inspections can be
extended:

a. All new breakers must have a complete inspection at the
end of 1 year.

b. Only breakers with good operating service records should
be scheduled for less frequent inspection periods.

c. Breakers used on special applications, such as capacitor
and reactor switching, should be considered separately.

d. If recurring troubles are found on a certain type of

breaker, the inspection schedules should be adjusted until
the trouble is eliminated.

61


19. Pressure or Float Switches

Monthly inspection. - See that all pressure or float switches cut
in and out at proper pressure or liquid level.

Annual inspection. - Check and clean switch contacts. Check spring
tension. Clean and adjust moving parts.

20. Unloader

Monthly inspection. - See that compressor is not being loaded until
operating speed is reached in starting and is unloaded when the
pressure switch breaks circuit to the motor and unloads at the
proper pressure.

Annual inspection. - Inspect valves and air lines for leaks and
valves for proper seating. Lap valves if needed. Check weights
for security to lever arm and all springs for proper tension.
Examine solenoid for deteriorated insulation or loose connections.
Examine dashpots for excessive play and refill with oil if needed.

21. Piping and Valves

Annual inspection. - Renew valve packing as needed. Reseat valves
as needed. Repair leaks. Clean piping and repaint.

22. Safety Valve
Monthly inspection. - Test safety valves to make sure that they
operate on an increase of pressure of 10 to 15 pounds per square

inch above maximum normal system pressure or maximum allowable
working pressure, whichever is lower.

23. Guardrails or Grills

Annual inspection. - See that guardrails and grills are tightly
secured to foundations. See that guards and grills are adequate
and give complete protection to both compressor and personnel.

24, Operation

Weekly inspection. - Operate all idle equipment for a few minutes
weekly to insure that it is in operating condition and ready for
service.

47


16. Blocks and Hooks

Monthly inspection. - See that the blocks have sufficient lubrica-
tion. Examine hook for bending, cracking, stretching, and condition
of safety latch.

Annual inspection. - Check block pins for wear and distortion. Renew
or machine pins as needed. Check blocks for weakening. Measure
hook for distortion. If distorted, replace.

17. Electrical Wiring

Annual inspection. - Check and tighten connections at terminal points.
Check for damaged insulation or broken or overheated conductors.
Check insulation resistance of wiring and connected devices and
equipment.

18. Hydraulic Hoist Cylinder, Etc.

Not scheduled. - Inspect cylinder walls for scoring and piston for
wear and fit. Check rod for wear and alinement. Refit or aline
if necessary.

19. Hydraulic Pump
Monthly inspection. - Test pump to see that it delivers full pressure.

Not scheduled. - Inspect pump working parts for wear and fit. Renew
if needed. Test pump.

20. Hydraulic Control Valves and Piping

Monthly inspection. - Inspect piping for leaks. Test control valves.

Not scheduled. - Check valve seats for wear and refit as needed.

21. Oil Reservoir

Monthly inspection. - See that oil in tank is sufficient for emergency
operation. Keep sight-glass cocks turned off to prevent loss of oil
if glass is broken when not attended. Check for leaks.

53



CHAPTER X - CRANES, HOISTS, AND ELEVATORS

The above photograph shows the Trauger Pumping Plant and
Crane of the Lindsay-Strathmore Irrigation District, Friant
Division, Central Valley Project, Lindsay, California.
Photo P214-D-58284

1. Inspection Checklist

Inspection
Items of inspection interval
Crane rails, supports, and stops A
Hoist and bridge framework A
Bumpers A
Rails and wires A
Trolley shoes M
Catwalks A
Ladders A
Cab A
Driving gears, shafts, bearings, and wheels W A
Brakes M A
Cable drums and sheaves M
Cables or chains M A
Lifting beams A
Counterweights A

49


e. Breakers interrupting a large number of faults should be
given special attention to determine whether or not early
internal inspection is required.

f. When oscillographs indicate abnormal breaker operation,
an immediate inspection of the breaker should be made.

12. Contact Pressure Springs

Annual inspection. - Check springs for loss of temper, breaks, or
other deterioration.

13. Flexible Shunts

Annual inspection. - Check flexible shunts at contact hinges for
overheating and fraying. Tighten connections.

14. Magnetic, Air, or Oil Blowout Devices

Annual inspection. - Check arc-rupturing blowout coils, magnetic
circuit, arc chutes, deion grids, oil blast, or other interrupters

for proper operation.

15. Crosshead

Annual inspection. - Check contact crosshead for misalinement,
breaks, bends, or looseness on lift rod.

16. Lift Rods and Guides

Annual inspection. - Check contact lift rods for breaks, weakening
or warping, and pulling out at ends. Check adequacy of guides.

17. Operating Rods, Shafts, and Bellcranks

Annual inspection. - Check for loose locknuts, setscrews, keys,
bearings, bent rods or twisted shafts, etc. Clean moving parts of
rust, dirt, and accumulated grease and oil. Wash out bearings,
pivots, and gears with chlorothene or other suitable cleaner and
operate breaker several times to work out dirt and old lubricant.
Lubricate with new grease or oil. In cold climates, it is impor-
tant to use lubricant which will not stiffen too much when cold.
Wipe off excess oil. Enclosed dusttight bearings should require
less servicing.

62


4. Drive

Weekly inspection. - Note belt for slippage, chain for looseness,
and gears for lubrication, excessive noise, vibration, or over-
heating. Dress and tighten belt as needed. Tighten chain as
needed.

Annual inspection. - Check belt splices for weakening. Renew if
needed. Check chain for wear or distortion. Replace when dis-
torted or worn excessively, Examine gears for wear or sharp edges,
reface, and refit or replace if needed.

5. Pulleys, Idlers, and Couplings

Weekly inspection. - See that bearings are getting sufficient lu-
brication. Check for looseness, excessive wear, or misalinement.

Annual inspection. - Check wheels for broken rims. Check axles
for wear. Build up and machine or replace as needed. Refit bush-
ings as needed. Check weights or springs on idlers for security
or proper tension. Check alinement at coupling and wear of flex-
ible coupling.

6. Crankshaft

Not scheduled. - Check crank for alinement. Check journals for

scoring, signs of overheating, and wear. Build up and machine
as needed.

7. Connecting Rod

Not scheduled. - Inspect for distortion or bending. Examine bear-
ing nuts and bolts for distortion and wear. Replace as needed.

8. Crosshead

Weekly inspection. - If visible, check for looseness, noise, over-
heating, and sufficient lubrication.

Annual inspection. - Examine shoes for scoring and wear. See that
they are tight to the crosshead body if shoes are removable. Check
pin for wear and bushings for looseness. Refit if needed. Adjust

shoes with additional shims if needed. Note guides for scoring or
excessive wear.

44


2. Knife Switches
Annual inspection. - Check hinges and clips for good contact.

Tighten connections. Check door interlocks of safety switches if
provided. Clean insulating base if dirty.

3. Fuses and Circuit Breakers

Annual inspection. - Check to see that fuse ratings agree with the
ratings shown on the drawings. See that fuses are tight in the
clips and contact surfaces are clean. See that renewable links are
tight in holders. See that spare fuses are on hand. Where small
enclosed circuit breakers are used for circuit protection instead
of fuses, check mechanical operation of breaker and tighten
connections.

4. Contacts and Shunts

Annual inspection. - Dress contacts, if rough, with a fine file. It
is necessary to remove only the projecting beads. Pits in a flat,
smooth surface are not objectionable. Check for alinement and adjust-
ment. Check rolling or wiping action and spring pressure. Check
flexible shunts and replace if frayed. Tighten connections.

5. Blowout Coils and Arc Chutes

Annual inspection. - See that turns of blowout coils are not short
circuited and that coil is properly assembled to blow arc outward,
not inward. See that arc chutes are in good condition.

6. Solenoids

Annual inspection. - Note if coil is operating too hot, and if so,
check resistance for possible short-circuited turns. Check aline-
ment of matching faces of magnet frame. Check shading ring for
open circuit. A noisy alternating-current solenoid generally indi-
cates poor alinement or a broken shading ring, either of which will
cause heating of the solenoid.

7. Operating Shaft

Annual inspection. - See that shaft is free to move in its bearings
or rods are free in the guides.

36



1. Inspection Checklist - Continued

Inspection

Items of inspection interval

Manual operating device A
Latch and trip mechanism W A
Tripping solenoid W A

Control and protective relays

Solenoid valves

Auxiliary switches
Operation counter
Position indicator
Dashpots or snubbers
Mechanism cabinet

Cabinet lights and heaters
Power supplies and wiring
Oil dielectric test
Filter oil

Operation

See Chapter on
Controls, p 31

A

A

M A
A

A

A

W A
W A
A

NS

NS

W - Routine weekly inspection when in service.
M - Routine monthly inspection when in service.

A - Annual inspection.
NS - Not scheduled.

References

Power Maintenance Instruction No. 9, Retaining Glaze Burned
nsulators in service,

dated September 21, 1967

Power O&M Bulletin No. 11, Maintenance of Liquid Insulation -

Mineral Oils and Askarels

Power O&M Bulletin No. 14, Painting of Transformers and Circuit

Breakers

2. Foundation

Annual inspection. - Check foundation for cracks and settling. A
shift of the breaker tanks may break bushings or cause misaline-

ment of contacts or binding of operating mechanisn.

3. Frame and Tanks

Weekly inspection. - Check for oil leaks and note tank temperature
by touch.

59



Low-Voltage Feeder Busway - Trinity Powerplant, California.
Transition Box and Busway for 300-kva Transformer - Front View
Cover Removed. Photo P389-D-68173NA

3. Bus Insulators and Supports

Annual inspection. - Inspect and clean insulators or insulating
block supports. Paint chipped spots on porcelain with red glyptal.
Tighten bolts. Check supports for strength and rigidity. Inspect
tape insulation on bus bars and revarnish if dull.

4. Bus Enclosures and Barriers

Annual inspection. - Check metal or transite bus enclosures and
interphases, barriers, tightness, and adequate ventilation. Clean
as needed.

5. Switchgear Panels and Enclosures

Weekly inspection. - See that interior and exterior of enclosures
are kept clean and free of oil, insect webs, etc.

Annual inspection. - Clean inside and outside of enclosures. Use
solution of mild soap and water to remove dirt and grease from

panels. Many cleaning compounds are harmful to the painted sur-
faces and should not be used. Clean out control wiring and hard-

to-reach places with an industrial-type vacuum cleaner (with non-
metallic hose and nozzle), or clean, dry compressed air.

56


6. Indicating Lamps

Weekly inspection. - Check lamps to see that they are not burned out,
and replace as necessary.

Annual inspection. - Inspect indicating lamps, series resistors, and
color caps. Check to see that each lamp gives correct intended indi-
cation. Tighten connections.

7. Meters and Instruments

Weekly inspection. - Note sticking of moving element of indicating
and recording instruments and watt-hour meters, unsatisfactory ink-
ing of record on recorders, and incorrect timing of recorder charts.
Have these faults corrected at first opportunity.

Annual inspection. - Check calibration of important instruments and
Tecorders or others suspected of being incorrect. Check watt-hour
meters against rotating standard and adjust as necessary. Check to
see that movement is free and unobstructed. Check pivots and bear-
ings and repair or replace as necessary. See that cover gaskets are
tight so as to exclude dust, dirt, moisture, and insects. Clean
cover glasses using a damp cloth so as to avoid placing a static
charge on the glass which affects the indication of some instruments.
Check external resistors, reactors, and potential fuses. Tighten
connections. Check wiring connections if any changes have been made
in associated circuits or equipment.

8. Position Indicators
Weekly inspection. - Note sticking pointers.
Annual inspection. - Check for correct positioning between transmitter

and receiver. Check for friction and vibration of moving element and
excessive heating.

9. Protective Relays

Weekly inspection. - Visual inspection for anything unusual about con-
tacts, coils, or moving elements. Check targets and reset them.

Annual inspection. - Dress contacts if rough with fine file. Pits in
the contact surfaces are not objectionable, but projections should be
removed. Replace contacts if repairing is impractical. Blow out dust,
check arc chutes, blow out coils, and barriers. Tighten connections.
Check contact shunts. Check contact spring pressure and contact wiping
action. Check insulation between circuits or phases. Note whether

33


2. Panels and Cabinets

Annual inspection. - Repair finish and panel and door hardware and
clean up as necessary. Tighten bolts and screws. Check boxes and
cabinets in damp locations for corrosion and rust. Clean and re-
finish as necessary.

3. Panel Wiring and Terminal Blocks

Annual inspection. - Check for general housekeeping. Blow out wiring
and equipment on back of panels with clean, dry, compressed air or

use an industrial-type vacuum cleaner with nonmetallic hose fittings
if available. Inspect wiring for open circuits, short circuits, and
damaged insulation. Check insulation resistance of wiring or equip-
ment on which the insulation appears to be questionable. Re-mark con-
ductor tags or designations before they become obscure. Replace lost
conductor tags. Tighten connections at terminal points.

4. Relays

Weekly inspection. - Check condition of contacts wherever possible,
Note whether coil temperature is excessive. Check noise and vibra-
tion of alternating-current contactor magnet frame and armature.

Annual inspection. - Dress contacts if rough with fine file. Pits
in the contact surfaces are not objectionable, but projections should
be removed. Replace contacts if repairing is impractical. Blow out
dust, check arc chutes, blow out coils, and barriers. Tighten con-
nections. Check contact shunts. Check contact spring pressure and
contact wiping action. Check insulation between circuits or phases.
Note whether operating coil temperature is excessive. Check aline-
ment and vibration of alternating-current magnet frame and armature
and examine shading ring.

5. Control Switches

Weekly inspection. - Try out operation of control switches or push-
buttons wherever possible to see if operation is correct.

Annual inspection. - Examine contacts and refinish with fine file if
burned or corroded. Check contact operating cams, levers, or drums.
Check contact spring pressure. Tighten connections. Examine
insulation.

32



9. Piston

Not scheduled. - Check piston for wear. Check clearance with
micrometer. Examine rings for tightness and fit. Renew if nec-
essary. Check rod for trueness. See that rod is not bent or
distorted. Examine bushings for wear and fit. Renew parts as
needed.

10, Cylinder

Not scheduled. - Check cylinder walls for wear and scoring. Meas-
ure inside diameters at top, bottom, and sides on two directions
90° apart. If out of round or oversize, rebore cylinder.

ll. Valves

Not scheduled. - Inspect valves and seats for scoring and proper
seating. Lap valves if needed. See that stems and guides are
not bent or cocked. See that springs have proper tension. Check
feather valves for proper operation.

12, Bearings

Not scheduled. - Check bearings for fit, scoring, signs of over-
heating, and proper lubrication. Renew or refit as needed.

13. Packing Gland

Weekly inspection. - Check for leakage or scoring of shaft or rod,
and adjust as necessary.

Annual inspection. - Renew packing as needed.

14. Lubricating System

Weekly inspection. - See that oil and grease cups are full or
crankcase oil is at the proper level. Replace as needed using
approved-type compressor lubricants. See that forced-oil system
is working properly. Check for leaks in piping.

Annual inspection. - Clean oil pipes and crankcase or cups. Repair

leaks. Examine pump and strainer. Clean strainer and refit or
renew pump parts as needed.

45



CHAPTER VII - MOTOR STARTERS AND CONTROLLERS

Photo PX-D-68172NA

1. Inspection Checklist

Inspection
Items of inspection interval

Knife switches

Fuses and circuit breakers

Contacts and shunts

Blowout coils and arc chutes

Solenoids

Operating shaft

Mechanical and electrical interlocks

Latches and trip devices

Auxiliary switches

Overload trip

Step starter timers

Compensator or autotransformer See Chapter on
Transformers, p 76

Miscellaneous control devices A

PEPE SSS DOSED

Power Supplies and Wiring W

W - Routine weekly inspection when in service.
A - Annual inspection.


4. Bumpers

Annual inspection. - Check for looseness. Examine bumpers to see
that they are properly positioned. Tighten or adjust as necessary.
Check hydraulic bumpers for leaks and fill to proper level.

5. Rails and Wires

Annual inspection. - Check rails and wires for alinement. Check
Support for tightness. Adjust as necessary. Check contact surfaces
of wire or rails for corrosion and arc burning and clean as neces-
sary. Check and clean insulators. .

6. Trolley Shoes
Monthly inspection. - See that contact shoes or wheels are tight

and make good contact with rails or wires. Clean as necessary.
Check contact spring pressure.

7. Catwalks

Annual inspection. - Check runways and catwalks for obstructions,
broken floor material, or other safety hazards.

8. Ladders

Annual inspection. - See that handrails and ladders are firmly se-

cured and rigid. Check ladder rungs for corrosion and weakening.
Clean and paint as needed.

9. Cab

Annual inspection. - Check cab for loose articles which would inter-
fere with operation and for general housekeeping. Check for broken
windows or doors. Check doors and safety gates. See that lighting
is sufficient. Check seats, if fitted, for security. Check for
security to bridge girders.

10. Driving Gears, Shafts, Bearings, and Wheels

Weekly inspection. - Check lubrication. Examine for excessive wear.

ED


CHAPTER V - GATES AND VALVES

P477-100-

1, Inspection Checklist

Inspection

__ Items of inspection _ interval
Gates and Valves (In General) A
Seals and guides NS.
Seat, disk, or needle ring and spider NS
Stems A
Lubrication NS A
Spring and cushioning mechanism NS
Journals, bearings, and bushings NS
Wheels, pins, and rollers NS
Operating cylinder or gear mechanism NS
Control piping A
Packing glands W A
Operation check A
Gate hoist or crane See Chapter on
Cranes, p 49

Electric motors See Chapter on
Motors, p 17

Electrical control equipment See Chapter on

Controls, p 31

W - Routine weekly inspection when in service.

A - Annual inspection.

NS - Not scheduled, frequency as required to maintain equipment
and assure its function.

27


14. Power Supplies and Wiring

Weekly inspection. - See that all power and control supply circuit
switches are closed and fuses in place.

Annual inspection. - Check and tighten wiring connections at termi-
nal points. Inspect wiring for open circuits, short circuits, and
damaged insulation. Check insulation resistance of wiring with
devices connected.

38


8. Mechanical and Electrical Interlocks

Annual inspection. - See that interlocks are properly adjusted to
prevent closing of both contactors, such as on a reversing starter,
at the same time. Check enclosure door interlocks. Tighten oper-
ating arm supports.

9. Latches and Trip Devices

Annual inspection. - Check latches on latched-in contactors or man-
ually operated starters for wear and insecure holding. (Check trip
solenoid as in Section 6 above on solenoids.)

10. Auxiliary Switches

Annual inspection. - Clean and refinish contacts if corroded or
pitted. Check spring pressure. Tighten connections. Check oper-
ating levers or linkage. Check closing and opening adjustment with
respect to main contacts.

11. Overload Trip

Annual inspection. - Check operating current and time delay of ther-
mal or magnetic overload trip and see that it is correct for the
motor or other equipment controlled. See that trip device functions
reliably. Check time-delay dashpots for binding; leaking valves;
and low, dirty, or incorrect oil.

12, Step Starter Timers

Annual inspection. - Dress contacts if rough with fine file. Pits
in contacts surfaces are not objectionable, but projections should
be removed. Replace contacts if repairing is impractical. Check
time-delay device used for controlling steps on multistep starters
to see that proper time delay is obtained and operation is reliable.

13. Miscellaneous Control Devices

Annual inspection. - Check and clean contacts of control devices
such as pushbuttons, time switches, pressure, vacuum or float
switches, etc., and see that these devices are in proper operating
condition.

37



CHAPTER XII - OIL AND AIR CIRCUIT BREAKERS

115-kv, dead-tank oil-type power circuit breaker shown.
Photo P214-D-68171NA

1. Inspection Checklist

Inspection
Items of inspection interval

Foundation A
Frame and tanks W
Oil valves and plugs
Oil levels and gages Ww
Breathers and vents W
Panels and cabinets
Bushings or insulators Ww
Bushing current transformers and

potential devices
Main terminals and ground connections W
Main contacts
Contact pressure springs
Flexible shunts
Magnetic, air, or oil blowout device
Crosshead
Lift rods and guides
Operating rods, shafts, and bellcranks
Closing solenoid air cylinder, motor, or spring

>>rrrpr

Por r>r>rr ory

58


6. Locks and Interlocks

Weekly inspection. - See that all keyed locks provided to prevent

unauthorized operation of equipment are in place and locked. See
that all mechanical interlocks provided for personnel safety are

functioning.

7. Warning and Safety Signs

Weekly inspection. - See that adequate warning and safety signs are
in place around live parts or other safety hazards.

8. Current and Potential Transformers

Annual inspection. - Check oil level and oil leaks in oil-filled

transformers. Check for leaking compound from dry-type transformers.
Clean insulators. Check and tighten primary and secondary connec-

tions. See that short-circuiting device on current transformer
secondary is secured in the open position and that protector tubes

or thyrite protectors are not bypassing current at normal loads.
Check potential transformer fuses. Check insulation resistance of

windings.

9. Power Cables

Annual inspection. - Check visible portions of cable braid, rubber,
or lead sheath for signs of cracking, deterioration, or corrosion.
Check for signs of moisture at entrance to conduits or ducts. Check

cable terminals and tighten connections. Check for proper support.
Check insulation resistance. (See Power O&M Bulletin No. 3.)

10. Potheads

Annual inspection. - Check for oil or compound leaks, and stop as
necessary. See that potheads are filled to the proper level with
oil or compound. Clean insulators. Repair chipped spots on porce-

lain with lacquer such as red glyptal. Tighten connections, bolts,
and screws.

57



operating coil temperature is excessive. Check alinement and vibra-
tion of alternating-current magnet frame and armature and examine
shading ring.

10. Test Switches

Annual inspection. - Check taps, resistor settings, or other adjust-
ments against relay data sheets. Check setting for correct opera-
tion and adjust as necessary. Examine moving parts and see that
they are free and unobstructed. Examine relay and test switch con-
tacts and refinish with fine file if burned or corroded. See that
cover gaskets are tight so as to exclude dust, dirt, moisture, and
insects. Note excessive heating of coils and resistors. Tighten
connections. Check wiring connections if any changes have been
made in associated circuits or equipment. Try out trip circuit, if
possible, to see that relay trips all devices as intended. (See
Power O&M Bulletin No. 16.)

ll. Rheostats and Resistors

Annual inspection. - Clean contact buttons and brush, check to see
if corroded, burned, or cutting. Check brush and hub contact spring
pressure. Check resistor elements for burned-out or corroded sec-
tions. Test insulation from line to grounded parts.

34


25. Safety Cleaning

Air piping, compressor cylinders, air cleaners, or the receivers
shall not be cleaned using kerosene, gasoline, or other inflammable
products.

26. Impeller or Rotor

Not scheduled. - Inspect impeller or rotor for erosion of vanes.
Rebuild with suitable material and machine if necessary. Measure
seal-ring clearances. Refit if necessary. Balance impeller or
rotor after test run if needed.

27. Tanks

Weekly inspection. - Note amount of oil or water available in tanks
when in continuous use. Check for leaks, Clean up leaking oil
which might be a fire hazard. Keep sight-glass cocks turned off
to prevent loss of liquid if glass is broken.

Annual inspection. - Check and repair leaks.

Not scheduled. - Clean inside of tanks used for storage of clean
oil or drinking water. Clean and repaint as necessary.
28. Strainers

Weekly inspection. - Flush or remove and clean strainer. Utilize
differential gage if so equipped to determine cleaning frequency.

Annual inspection. - Replace strainer when corroded badly or
broken.

48


29. Power Supplies and Wiring
Weekly inspection. - See that all power and control circuit switches
are closed and fuses in place.

Annual inspection. - Inspect fuses or circuit breakers in all power
and control supply circuits. Check and tighten wiring connections
at terminal points. Inspect wiring for open circuits, short cir-

cuits, and damaged insulation. Check insulation resistance of wir-

ing with devices connected.

30. Oil Dielectric Tests

Annual test. - Check dielectric strength of the insulating oil in
the main tanks and oil-filled bushings.

31. Filter Oil

The necessity for filtering the insulating oil will depend on the
results obtained from the oil dielectric tests and the amount of
carbon in the oil. The oil should be filtered if the dielectric
strength is below 25 kilovolts or if there is a noticeable amount
of carbon in suspension or in the bottom of the tanks. Refer to
Power O&M Bulletin No. 11 for detailed test information.

32. Operation

Some breakers, particularly those carrying high values of current,
have a tendency to develop contact heating if left closed for long
periods. Opening and closing breakers several times at intervals,
as system operation will permit, may alleviate the heating by wip-
ing the oxide from the contact surfaces, as well as demonstrate
that the breaker is in operating condition.

At each inspeciton, it may be desireable that a more complete
report be made showing briefly what was found and what was done.
A form similar to Form O§N-152, Figure 6, pages 66 and 67 may be
used for this purpose.

65



CIRCUIT BREAKER INSPECTION REPORT

tocation..Indian Hills Substation _DATE OF INSPECTION...9-18-67

CIRCUIT DESIGNATION.
BREAKER DATA:

NTERRUPTING TIME.
6678

INSPECTION: (CHECK IF SATISFACTORY OR NOTE CONDITION)
OPERATION COUNTER READING - aS FouND..241
Founoation...OK____
TANKS OR FRAME:

ALINEMENT.OK

OPERATING MECHANISM
CLOSING SOLENOID
CLOSING SFRING MECHANISM
CLOSING AIR OR OIL CYLINDER.
AIR COMPRESSOR...
Latcnes...OK.
TRIP-FREE MECHANISM
AUXILIARY swiTcHes.Contacts
CABINET HEATERS...
LUBRICATION.

-TRIPPING SOLENOID.

pitted POSITION INDICATOR. _ OK.

-CABINET DOOR GASKETS._

MAIN CONTACT:
ALINEMENT._...OK

CONDITION - MOVING.

SHUNTS

porcecain.. Slightly chipped... OIL oR compound Leaxs._None.
ow vever._OK IL conpition#=__.OK tested
TERMINALS.

INSULATORS.
INSULATING OIL:
LEVEL...

REPORT OIL TESTS ON FORM O&M i109 Figure 6
USE SPARE LINES FOR OTHER ITEMS AS NEEDED

66


22. Guide Rails and Shoes

Monthly inspection. - Check guide rails and shoes for proper
lubrication.

Annual inspection. - Check rails for alinement and scoring. Check
and tighten supports. Check shoes for fit and scoring. Refit as
needed.

23. Safety Devices

Monthly inspection. - See that all safety devices are in service
and functioning properly.

Annual inspection. - Check all mechanical and electrical safety
devices for worn or broken parts and proper operation. Renew and
refit as needed.

24. Operation

Weekly inspection. - Operate all idle equipment for a few minutes
weekly to insure that it is in operating condition and ready for
service.

25. Elevator Inspection

Annual inspection. - In states where elevator inspection is avail-
able, it speata be obtained for all elevators. Where state inspec-
tion is not available, the inspections and tests shall be made by
a certified inspector of an elevator or insurance company.

54


and stuffing box becomes so small there is doubt as to whether the
gland may be adjusted and kept tight until the next outage.

15. Operation Check

Annual inspection. - Make an annual operation check under balanced
conditions of yates having emergency closing facilities and which
are depended upon for closing in case of a power outage or similar
failure, to insure the equipment will operate when called upon.
Other gates and valves should be given an annual operation check if
conditions will permit.

Southern San Joaquin Municipal Utility District - Central Valley
Project, Gate Valves and Check Valves, Pumping Plant S8,
Lateral 127.7E. Photo P214-D-58277

30



6. Distilled Water

Monthly inspection. - Check adequacy and purity of distilled water.
See that enough distilled water and acid are kept in storage to
meet current needs. Check containers for cleanliness.

7. Battery Charger

Monthly inspection. - Check operation of battery charger and
setting.

41



1, Inspection Checklist - Continued

Inspection
Items of inspection interval
Air Compressors, Vacuum and Oil Pumps - Continued
Piping and valves A
Safety valve M
Guardrails or grills A
Electric motor See Chapter on
Motors, p 17
Electric control equipment See Chapter on
Controls,
p 31
Operation Ww
Cleaning See Section 25
on Cleaning,
p 48
Impeller or rotor NS
Tanks WA NS
Strainers W A

W - Routine weekly inspection when in service.

M - Routine monthly inspection when in service.

A - Annual inspection.

NS - Not scheduled, frequency based on equipment operating history.

References

Power O§M Bulletin No. 21, Lubrication of Powerplant Equipment

2. Foundation

Annual inspection. - Check foundation carefully with a level for
settling. Examine concrete for cracks and spalling.

3. Frame
Annual inspection. - Tap casting lightly with a hammer. A flat

Sound indicates a crack. Examine metal for corrosion. Clean and
paint as needed.

43


7. Springs and Cushioning Mechanism

Not scheduled. - Inspect springs in relief valves for proper tension
and for corrosion. Examine oil dashpots where used for tightness of
plunger, scoring on cylinder walls and plunger. Examine foot valves
if used. Renew oil if sludged or contaminated with water.

8. Journals, Bearings and Bushings

Not scheduled. - Disassemble and check clearance. Examine bearing sur-
faces and journals for scoring and wear. Replace bronze bushings, re-
babbitt and rebore babbitt bearings, build up journals with welding or
metalizing and machine to proper dimensions as necessary.

9. Wheels, Pins and Rollers

Not scheduled. - Check to see that all moving parts are free to move.
Examine for corrosion and deterioration. Check for alinement of
rollers and wheels. Check pins for bending and scoring. Check
rollers for wear and corrosion. Check bearing surfaces under link-
age. Check linkage for cracks, bending, or weakening.

10. Operating Cylinder or Gear Mechanism

Not scheduled. - Check hydraulic operating cylinders, pistons, rods,
guides, bellcrank bearings, etc., for wear. Check motor-driven re-
duction gears for wear. Flush out and relubricate gear boxes. See
that lubricant used is suitable for coldest weather encountered.
Check torque limit device if used.

11. Control Piping
Annual inspection. - Check for leaks and repair as necessary. Examine

for corrosion and need of paint. Repaint as necessary. Replace gas-
kets and renew or tighten bolts as necessary.

12. Packing Glands
Weekly inspection. - Inspect for leaks and adjust gland as necessary.

Annual inspection. - Clean gland and nuts. Measure clearance between
gland and stuffing box. Renew packing when clearance between gland

29



23. Auxiliary Switches

nual inspection. - Check condition of contacts and refinish with
ne file if burned or corroded. Check contact springs, operating
rods, and levers. Check closing and opening positon with respect
to main contacts while breaker is being slowly closed and opened
manually. Certain auxiliary contacts used for special purposes may
require close adjustment in this respect.

24. Operation Counter
Monthly inspection. - Observe and record reading of operation counter.

Annual inspection. - See that operation counter is properly register-
ing the breaker operations.

25. Position Indicator

Annual inspection. - See that position indicator or semaphore is

properly indicating the breaker position. Check operating rods or
levers for loose parts.

26. Dashpots or Snubbers

Annual inspection. - Check for proper setting and adjust as neces-
sary. Clean out and replenish liquid in liquid dashpots.

27. iWechanism Cabinet

Annual inspection. - Check condition of metal and hardware. Repaint

as necessary. See that door gaskets are tight and properly exclude
dust and dirt.

28. Cabinet Lights and Heaters

Weekly inspection. - Check cabinet heaters and see that they are in
service during cold weather. Replace burned-out lamps.

Annual inspection. - Check heating elements and replace if in poor
condition.

64


Annual inspection. - Check bearing clearances. Refit as needed.
Examine gears for broken teeth or rough or sharp edges. Misaline-
ment or improper meshing will cause rough edges at the tip of the
teeth. Check shafts for alinement and coupling for alinement and
lubrication if oil filled. Check wheels for flat sides and wear.
Rebuild or machine as needed.

11. Brakes

Monthly inspection. - See that braking surfaces are free from oil
and grease. Check spring tension.

Annual inspection. - Check brake lining to see that it has not hard-
ened or worn excessively. Renew as necessary. See that brake drums

are not scored. Check spring tension. Adjust brake with adjustment
nuts. Adjust spring tension if needed or renew if fatigued.

12. Cable Drums and Sheaves

Monthly inspection. - Check sheaves for broken or chipped wheels.
Lubricate, With cable removed, check all cable grooves for wear,
chipping, and corrosion. Check bearings for clearance and refit
if needed.

13. Cables or Chains

Monthly inspection. - Visual inspection for broken or frayed strands
or broken or elongated chain links.

Annual inspection. - Run cable or chain out and inspect carefully
for frayed or broken strands, stretched or weakened links. Examine
for wear and corrosion, especially down between the cable strands.
Lubricate.

14, Lifting Beams

Annual inspection. - Check beams for alinement, corrosion and tight-
ness of rivets. See that members have not been stressed beyond
their elastic limits.

15. Counterweights
Annual inspection. - Check counterweights to see that they are
secure to iis cables or chains and to the guides.

52


Note: Follow specific maintenance instructions on valves and

gates, if available.
Reference

Power O&M Bulletin No. 21, Lubrication of Powerplant Equipment

2. Gates and Valves

Inspect exposed metal parts of valves and gates for corrosion, crack-
ing, deterioration of paint, and other damage. Check rivets, bolts,
and welds and repair as necessary. Clean corroded surfaces by sand-
blasting or other approved means and repaint or apply cathodic pro-
tection as necessary.

3. Seals and Guides.
Not scheduled. - Check seals and guides for wear and deterioration.
Renew seals and build up guides where scored, as necessary. Remove

accumulated mineral deposit. Check alinement. Check slot heaters
if installed.

4. Seat, , Disk, ete.

Not scheduled. - Examine for mineral deposit and remove as necessary.
Inspect seat and disk or needle ring for scoring, pitting, and abra-
sion. Regrind or remachine as necessary.

5. Stems

Annual inspection. - Clean off all grease and dirt, and inspect for

wear and bre. kage of the threads, scoring, and wear of the sliding
surface. Renew or repair as necessary by huilding up scored surfaces
and broken threads. Relubricate.

6. Lubrication

Not scheduled. - Lubricate all underwater fittings with suitable
underwater grease. Lubricate all fittings exposed to the atmosphere.
Flush out fittings on such items as rollers on coaster gates, and

wheels on fixed-wheel gates. See that they are free and turn easily.

Annual inspection. - Examine all grease grooves to see that they are
not obstructed with hardened grease. Remove any hard deposit. See
that all grease supply pipes are clear. Flush all old grease from
fittings and refill with fresh lubricant.

28



4. Qil Valves and Plugs

Annual inspection. - Check condition of paint and repaint as neces-

sary. Inspect oil valves and plugs and stop oil leaks. See that
oil drain valves which can be operated without wrenches are plugged

or locked to prevent unauthorized opening. Tighten bolts. Clean
interior of tanks. Inspect underside of cover for moisture and

rust, and clean and repaint as necessary. Check tank liners and
interphase barriers.

5. Oil Levels and Gages
Weekly inspection. - Check oil level in gages of the tanks and oil-
filled bushings. Replenish oil if below normal.

Annual inspection. - Clean dirty gage glasses and connections into
tank. Drain out and replace bushing oil if dirty or discolored.

6. Breathers and Vents

Weekly inspection. - Check for external obstructions to breathers
and vents.

Annual inspection. - Check to see that screens and baffles in vents
or breathers are not obstructed or broken.
7. Panels and Cabinets

Annual inspection. - Check air circuit breaker or other panel insu-
ating material for cracks and cleanliness. Check condition of

enclosing cabinets including hinges, latches, locks, door gaskets,
and paint.

8. Bushings or Insulators

Heekly inspection. - Check for chipped or broken procelain, exces-
sive rt film, oil level, and oil or compound leaks.

Annual inspection. - Clean porcelain with water, chlorothene, or
other suitable cleaner. Repair chipped spots by painting with
lacquer such as red glyptal. Inspect gaskets for leaks. Tighten
bolts. Check insulation resistance with contacts closed and also
power factor. Check oil sample from bottom of bushing for dielec-
tric strength and presence of water and dirt which may be entering

at top. Replace or replenish oil if necessary. Check and clean
interior at least once every 5 years.

60


CHAPTER XI - LOW-VOLTAGE SWITCHGEAR, BUSES, AND CABLES

1, Inspection Checklist

Inspection
Items of inspection interval
Qil and air circuit breakers See Chapter on
Circuit
Breakers,
p 58
Disconnecting switches and fuses See Chapter on
Disconnecting
Switches,
p 68
Bus bars, joints, and connections A
Bus insulators and supports A
Bus enclosures and barriers A
Switchgear panels and enclosures W A
Locks and interlocks W
Warning and safety signs W
Current and potential transformers A
Meters, instruments, and relays See Chapter on
Controls, p 31
Control devices See Chapter on
Controls, p 31
Panel wiring See Chapter on
Controls, p 31
Power cables A
Potheads A

W - Routine weekly inspection when in service.
A - Annual inspection.

References

Power O§M Bulletin No. 8, Dependable Electrical Contacts
Power OGM Bulletin No. 3, Testing Electrical Equipment Insulation

2. Bus Bars, Joints, and Connections

Annual inspection. - Check bus bars, joints, and connections for
overheating. Tighten joint and connection bolts. Refinish joint
contact surfaces if annealed from overheating. (See Power O&M
Bulletin No. 8.)

$5



CHAPTER VIII - STORAGE BATTERIES

Photo P214-D-68174NA

1. Inspection Checklist

Inspection
Items of inspection interval
Storage Batteries

Electrolyte M

Connectors A

Hydrometers A

Equipment A
Distilled water M

Battery Charger M

M - Routine monthly inspection when in service.
A - Annual inspection.

References

Power O&M Bulletin No. 12, Storage Battery Maintenance and

Principles

39


CHAPTER IX - COMPRESSORS AND MISCELLANEOUS PUMPS

P214-D-58283

1. Inspection Checklist

Inspection
Items of inspection interval
Air Compressors, Vacuum and 0il Pumps

Foundations A
Frame A
Belt, chain, or gear drive W A
Pulleys and idler or coupling W A
Crankshaft NS
Connecting rod NS
Crosshead W A
Piston NS
Cylinder NS
Valves NS
Bearings NS

Packing gland
Lubricating system
Cooling system
Receiver tank

Air intake and cleaner

HZESEeze
> rPreErp>r>

Gages
Pressure switches M
Unloader M

42