Elect Maint Practices - GPG

TO
TRAINING PROGRAMME
AT
National Fertilizers Ltd.
Vijaipur, Distt. Guna (MP) - 473111
Topic: Electrical Maintenance Practices
G.P.Gupta
Sr. Manager (Electrical)
03/22/19 NFL Vijaipur 1
1.0 Introduction
2.0 Electrical Power Distribution System
3.0 Types of Maint. for Electrical System
 BREAKDOWN MAINTENANCE
 PREVENTIVE MAINTENANCE
 CONDITION MONITORING &
PREDICTIVE MAINTENANCE
 RELIABILITY CENTERED MAINTENANCE
 TOTAL PRODUCTIVE MAINTENANCE
4.0 Maintenance Strategy
5.0 Case Studies & Conclusion
1.0 Introduction
Our Fertilizer Industry, in general, is
energy intensive and Electrical Power
plays a major role in the world economy.
An index of prosperity of a country is
determined by per capita consumption of
electrical power. Every modern activity
right from lighting of bulb to Internet
connectivity and detecting signals from
stars is not possible without Electric
Power. Dr. Homi J. Bhabha rightly said:
“No” Power is costlier than “No Power”.
Introduction Contd..
In Electrical system, insulation of equipments
is the weakest link.
Insulation is an organic material and
deteriorates due to presence of moisture, high
temperature, dust and corrosive gases.
We have to test and monitor all electrical
installations for their deterioration. Thermo-
scanning is done for bus bar joints, cable end
boxes, motor terminal boxes and checking of
cable alleys in motor control centers (MCC) to
identify hot spots. Low IR value of electrical
equipment causes tracking and flashover,
which may result in fire, damage of electrical
equipment. We cannot afford it.
Introduction Contd..
Therefore, we have to test various
equipments for their healthiness as per
Indian Standards and Indian Electricity
Rules.
We must Pressure Test the equipment like

bus bar, transformers, breakers and cables
as per I.S. at least up to working voltage.
Let the equipment fail during testing than

to have a failure during running.
We should not live with a sick baby
2.0 ELECTRICAL POWER DISTRIBUTION SYSTEM
National Fertilizers Ltd. (NFL) Vijaipur has 3
Gas Turbine Generators (G.T.G.) of
17.225MW 11KV, 50Hz, PF 0.85, out of which
two are running in parallel with isolation
from grid and catering the total complex’s
average plant load of 32 MW. Third GTG is
standby.
The 11KV Ring switchgear has 3 types of
loads feed by buses, namely non-essential
bus, semi-essential bus and essential bus
meeting the total requirement of electrical
load for line-I&II Plants.
ELECTRICAL POWER DISTRIBUTION SYSTEM Contd..
There are two DG Sets of 2000KVA, 415V, 3 phase

for safe shutdown of the plants in case of tripping
of GTGs.
PLC based Load Management System (LMS) is
there for electrical load shedding in case of
tripping of any one of the running GTGs.
90% of total Electrical Load is of Induction Motors.
The highest capacity induction motor is 1450KW,
11kV, 596 rpm.
The highest capacity of transformer is 8 MVA ONAN
Transformer.
What is “Electrical Maintenance” ? Why it is
Required ?
Enemy of Electricity is dust , moisture , water, heat,
Gases
What do we understand by “Maintenance” ?

To ensure & keep healthiness of the machine. It reflects
directly on plant performance , it is a continuous running
plant, the m/c are continuously running it requires
grease, oil , any abnormality like sound, heating ,
vibrations, noise etc
What is the “Role” of Electrical Maintenance?

To run the plant & m/c continuously, safely &
redundantly without any interruption that will give good
production and Target achievement
MAINTENANCE
ECONOMICS
 PRODUCTION GIVES INCOME
 MAINTENANCE COSTS
EXPENDITURE
BUT …..
 MAINTENANCE NOT CARRIED OUT
COSTS MUCH MORE EXPENDITURE

Definition:
A formal definition of maintenance

is “that function of manufacturing
management that is concerned with
day to day problem of keeping the
physical plant in good operating
condition”

Objectives:
 Minimize loss of productive time
 Minimize repair time & cost
 Keep productive assets in working
condition
 Minimize accidents
 Minimize total maintenance cost
 Improve quality of products
Importance:
 Dependability of service
 Assured quality
 Prevent equipment failure
 Cost control
 Huge investment in equipment

Areas of Maintenance:
1. Civil maintenance- Building construction
and maintenance, maintaining service
facilities
2. Mechanical Maintenance- Maintaining
machines and equipments, transport
vehicles, compressors and furnaces.
3. Electrical Maintenance- Maintaining
electrical equipments such as generators,
transformer, motors, telephone systems,
lighting, fans, etc.
HISTORY OF
MAINTENANCE
 BREAKDOWN MAINTENANCE
 PREVENTIVE MAINTENANCE
 CONDITION MONITORING &
PREDICTIVE MAINTENANCE
 RELIABILITY CENTERED MAINTENANCE
 TOTAL PRODUCTIVE MAINTENANCE

CHANGING MAINTENANCE
TECHNIQUES
Third Generation:
Condition monitoring
Design for reliability and
Second maintainability
Generation: Hazard studies
Scheduled Small, fast computers
overhauls Failure modes and
First Systems for effects analyses
Generation: planning and Expert Systems
Fix it when Multi skilling and
controlling work.
it broke Big, slow teamwork.
computers.
1940 1950 1960 1970 1980 1990 2000>

ORGANISATION MAY USE ANY
OR ALL THE FIVE TYPES OF
MAINTENANCE
 Breakdown maintenance or corrective
maintenance
 Preventive maintenance
 Predictive maintenance
 Routine maintenance
 Planned maintenance
BREAKDOWN
MAINTENANCE
 Occurs when there is a work stoppage
due to machine breakdown
 Maintenance becomes repair work
 Seeks to get the equipment back into
operation as quickly as possible
 To control the investment in
replacement spare machines.

BREAKDOWN
MAINTENANCE
 EQUIPMENT PRODUCTIVITY
 HIGHDOWNTIME
 FREQUENT FAILURES
 POOR QUALITY
 REDUCED SAFETY
 EMPLOYEE PRODUCTIVITY
 HIGH WORKTIME
 HIGH WAITING TIME
 LOW MORALE

The level 1 challenge
• How to keep existing, sometimes
elderly, plant going at max performance
and min cost, avoiding unexpected
downtime
• Moving from BD to PM to CBM (PdM) is

a frequently chosen route
Problems With Breakdown
Maintenance
 “Run it till it breaks”
 Might be ok for low criticality
equipment or redundant systems
 Could be disastrous for mission-
critical plant machinery or
equipment
 Not permissible for systems that
could imperil life or limb (like
aircraft)
Preventive maintenance
 It is undertaken before the
need arises and aims to
minimize the possibility of un
-anticipated production
interruption or major
breakdowns.
Contd..
It consists of:
 Proper design and installation of
equipment
 Periodic inspection of plant and other
equipments
 Repetitive servicing and overhaul of
equipment
 Adequate lubrication, cleaning and
painting
PREVENTIVE MAINTENANCE
Contd…
PLANNED MAINTENANCE BASED ON
PERIODICITY
ADVANTAGES
REDUCTION IN FAILURES
ENABLES PLANNING
DISADVANTAGES
OVERMAINTENANCE
HUMAN INTERVENTION IN
EQUIPMENT TECHNOLOGY
Implementing Preventive
Maintenance
 Need to know when a system requires
service or is likely to fail
 High initial failure rates are known as
infant mortality
 Once a product settles in, MTBF
generally follows a normal distribution
 Good reporting and record keeping can
aid the decision on when preventive
maintenance should be performed
Contd..
Benefits:
 Greater Safety
 Decreased Production Down Time
 Fewer large Scale & Repetitive Repairs
 Less Cost for Simple Repairs
 Less Standby Equipment Required
 Better Spare parts Control
 Proper Identification of Items
Another Maintenance Strategy
 Predictive maintenance – Using advanced
technology to monitor equipment and predict
failures
 Using technology to detect and predict
imminent equipment failure
 Visual inspection and/or scheduled
measurements of vibration, temperature,
oil and water quality
 Measurements are compared to a
“healthy” baseline
 Equipment that is trending towards failure
can be scheduled for repair
Predictive maintenance:
In this, sensitive instruments (e.g.
vibration analyzers, amplitude meters,
audio gauges, optical tooling and
resistance gauges) are used to predict
trouble. Conditions can be measured
on a continuous basis and this enables
the maintenance people to plan for an
overhaul.

Predictive Maintenance
Tools
 Vibration analysis
 Infrared Thermography
 Oil and Water Analysis
 Other Tools:
 Ultrasonic testing
 Liquid Penetrant Dye testing
 Shock Pulse Measurement (SPM)

Predictive Maintenance Vibration
Analysis
 Using sensitive transducers and
instruments to detect and analyze
vibration
 Typically used on expensive, mission-
critical equipment–large turbines,
motors, engines or gearboxes
 Sophisticated frequency (FFT) analysis
can pinpoint the exact moving part that
is worn or defective
 Can utilize a monitoring service

Predictive Maintenance Infrared
(IR) Thermography
 Using IR cameras to look for temperature
“hot spots” on equipment
 Typically used to check electrical
equipment for wiring problems or
poor/loose connections
 Can also be used to look for “cold (wet)
spots” when inspecting roofs for leaks
 High quality IR cameras are expensive –
most pay for IR thermography services
Oil and Water Analysis
 Taking oil samples from large
gearboxes, compressors or turbines for
chemical and particle analysis
 Particle size can indicate abnormal
wear
 Taking cooling water samples for
analysis – can detect excessive rust,
acidity, or microbiological fouling
 Services usually provided by oil vendors
and water treatment companies
Other Tools and Techniques
 Ultrasonic and dye testing – used to find
stress cracks in tubes, turbine blades and
load bearing structures
 Ultrasonic waves sent through metal
 Surface coated with red dye, then
cleaned off, dye shows cracks
 Shock-pulse testing – a specialized form
of vibration analysis used to detect flaws
in ball or roller bearings at high frequency
(32kHz)
Why Predictive?
Cost
50% breakdown maintenance
10% breakdown maintenance
Planned maintenance
Predictive maintenance
Breakdown maintenance
PREDICTIVE MAITENANCE
MAINTENANCE BASED ON MACHINE
CONDITION
 ADVANTAGES
BETTER AVAILABILITY
REDUCED MAINTENANCE COSTS
SAFETY AND QUALITY
OPERATION AND MAINTENANCE
PLANNING
DESIGN IMPROVEMENTS

 Routine maintenance: this
includes activities such as
periodic inspection, cleaning,
lubrication and repair of
production equipments after
their service life.

 Planned maintenance: it involves
the inspection of all plant and
equipments, machinery, buildings
according to a predetermined
schedule in order to service
overhaul, lubricate or repair,
before actual break down or
deterioration in service occurs.

1. Authorized by an official
2. Maintenance schedule
3. Issue materials against proper
authorization
4. Maintenance budgets
5. Equipment records

Issues:
 How much maintenance is needed?
 What size maintenance crews must be
used?
 Can maintenance be sub-contracted?
 Should maintenance staff be covered by
wage incentive schemes?
 Can effective use be made of computers
for analyzing and scheduling activities?

RELIABILITY CENTRED
MAINTENANCE
MIX OF MAINTENANCE TECHNIQUES
CENTRED ON RELIABILITY
 TOOLS USED
• FMEA : Failure Mode & Effect Analysis
• FMECA: Failure Mode & Effect
Consequence Analysis
• FAULT TREE ANALYSIS : Root Cause of
Fault

FMEA
 Failure modes and
effects analysis
(FMEA) is a step-by-
step approach for
identifying all possible
failures in a design, a
manufacturing or
assembly process, or
a product or service.

RPN: Risk Priority
Number
 It is a numeric
assessment of risk
assigned to a process,
or steps in a process, as
part of Failure Modes
and Effects Analysis
(FMEA), in which a team
assigns each failure
mode numeric values
that quantify likelihood of
occurrence, likelihood of
detection, and severity
of impact.

FMECA
 Failure mode, effects and criticality
analysis (FMECA) is an extension of
failure mode and effects analysis
(FMEA). FMEA is a bottom-up,
inductive analytical method which may
be performed at either the functional
or piece-part level.

•FaultTree Analysis (FTA) is a deductive reasoning
technique that focuses on one particular accident
event.
•The fault tree itself is a graphic model that displays
the various combinations of equipment faults and
failures that can result in the accident event.
•The solution of the fault tree is a list of the sets of
equipment failures and human/operator errors that
are sufficient to result in the accident event of
interest.
•The strength of FTA as a qualitative tool is its ability
to break down an accident into basic equipment
failures and human errors. This allows the safety
analyst to focus preventive measures on these basic
causes to reduce the probability of an accident.

TOOLS AND TECHNIQUES FOR RCM
1. HUMAN SENSES: VISUAL, SMELL, SOUND & TOUCH
2. THERMOGRAPHY: to monitor temperature
3. PERIODICAL AND EXTENSIVE VIBRATION MONITORING &
ANALYSIS: to check vibration of rotating machines and to
know the health of the rotating machines
4. SHOCK PULSE MONITORING (SPM): to know the condition of
Antifriction Bearings
5. TRIBOLOGY: studies covering lubrication surveys and
analysis of lubricants for assessing condition of machinery
and oil contamination can be taken up. Lubricating oil wear
debris analysis done to access the condition of machines and
lubricating oil
6. MOTOR CURRENT SIGNATURE ANALYSIS: helps in predicting
electrical motor conditions
7. ACCOUSTIC EMISSION TECHNIQUES: to find any developing
faults in side the stationery live electrical equipments like
Transformers, Oil Circuit breakers,
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RELIABILITY CENTERED MAINTENANCE
 Mix of Maintenance Techniques centered on Reliability. In
process industries, reliability is the most important attribute
required of physical assets. Reliability Centered
Maintenance (RCM) approach analyses the maintenance
requirements with the objective of reaching the desired
reliability through root cause and effect analysis
techniques.
R = e-T
Where, R = Reliability, T = Estimated Time Span
 = Failure Rate = No. of Failure / MTBF
MTBF: Mean time between failures
 So, in RCM approach we aim to diagnose the root causes
and effects leading towards failure and remedial actions
taken well in time to reduce the failure rate and the desired
reliability is achieved.
Reliability:
 Component Reliability
 Product Reliability

Component Reliability
Definition:
 It is the probability that a part or

a component will not fail in a
given time period or number of
trails under ordinary conditions
of use.
MEASUREMENT
 Component reliability is usually measured by reliability,
failure rates and mean time between failures, i.e.
CR=1-FR
number of failures
Where FR = number of components
tested
number of failures
FRn = unit-hrs of operation of the
component
1 unit-hr of operation
MTBF = FRn = No. of failures

When components or parts are
combined into a larger system, such as
a machine or a product, the combined
reliability of all the components or
parts form the basis for product or
system reliability
CALCULATION OF PRODUCT
OR SYSTEM RELAIBILITY
 When critical components interact during the
operation of the product or system, the
reliability of the product or system is
determined by computing the product of the
reliabilities of all the interacting critical
components.
SR = CR1*CR2*…..*CRn

TURN OUT A RELIABLE
PRODUCT
FIVE KEY AREAS
 Design of the product
 Production
 Measurement and testing
 Maintenance and
 Field of operation.
SYSTEM PERFORMANCE
P R O D U C T IO N P E R F O R M A N C E
C A P A C IT Y P E R F O R M A N C E A V A IL A B IL IT Y P E R F O R M A N C E
M A IN T E N A N C E
MAINTENANCE
ANALYSIS
AVA ILA BILITY
R E L I A B I L I TY M A I N TA I N A B I L I TY
M TB F M D T = M TTR + M W T
Measuring
 MeanAvailability
time between failures (MTBF)
 Mean down time (MDT), Mean waiting time (MWT)
 Mean time to failure (MTTF)
 Mean time to repair (MTTR)
 MTBF = MTTF + MTTR
 Availability = MTTF / (MTTF + MTTR)
Suppose OS crashes once per month, takes
10min to reboot.
MTTF = 720 hours = 43,200 minutes
MTTR = 10 minutes
Availability = 43200 / 43210 = 0.997
MAINTENANCE COST AS % OF TOTAL
MANUFACTURING COST ( 4% - 14%)
1. ELECTRICAL,
16 ELECTRONICS &
14 INSTRUMENTS (4%)
12 2. MACHINERY, FABRICATED
10 METAL, RUBBER/PLASTIC,
FOOD (7%)
%
8
6 3. PRIMARY METAL (9.5%)
4
4. PAPER &
2 CHEMICALS/PETROLEUM
0 (12%)
1 2 3 4 5 5. TRANSPORTATION (14%)

COMPARATIVE COST OF MAINTENANCE
STRATEGIES (AS PER MODERN POWER SYSTEMS, JULY 1994)
 MOTOR MAINT. COST IN Rs./HP/YEAR
RUN TO FAILURE : Rs.800 – 900
PREVENTIVE MAINT. : Rs.500 - 600
PREDICTIVE MAINT. : Rs.325 - 425
PREDICTIVE MAINT. PRACTICES
FOR ELECTRICAL M/C CAN
REDUCE MAINT. COST BY 50%.

Maintenance Costs
 The traditional view attempted
to balance preventive and
breakdown maintenance costs
 Typically this approach failed to
consider the true total cost of
breakdowns
 Inventory
 Employee morale
 Schedule unreliability
Maintenance Costs
Total
costs
Preventive
maintenance
Costs
costs
Breakdown
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Traditional View
Figure 17.4 (a)
Maintenance Costs
Total
costs
Full cost of
breakdowns
Costs
Preventive
maintenance
costs
Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Full Cost View Figure 17.4 (b)
Maintenance Strategy
Comparison
Resources/
Maintenance Technology Application
Strategy Advantages Disadvantages Required Example
Breakdown No prior Disruption of May need Office copier
work production, labor/parts at
required injury or death odd hours
Preventive Work can be Labor cost, may Need to Plant

scheduled replace healthy obtain revamping,
components labor/parts Machine
for repairs lubrication
Predictive Impending Labor costs, Vibration, IR Vibration and
failures can costs for analysis oil analysis of
be detected detection equipment or a large
& work equipment and purchased gearbox
scheduled services services

Maintenance Strategy
Implementation
Percentage of Maintenance Time by Strategy
100%
80%
Predictive
60%
Preventive
40%
20%
Breakdown
0%
1 2 3 4 5 6 7 8 9 10
Year

Maintenance Scheduling:
Scheduling refers to timing and
sequences of operations.
It is an important segment of the

production planning & control
activity as well as the service
operations like plant maintenance
Importance of
scheduling:
 Facilitates optimum use of highly paid
maintenance staff
 Equipments can be utilized effectively
 Eliminates undue interruptions in the

production flow

 Eliminates chances of
sudden breakdown
 Facilitates proper sequence

in maintenance service

COST VS. RELIABILITY
TOTAL COST
OPTIMUM COST
C MAINTENANCE PRODUCTION
O R&D AND DESIGN
S
T
SPARES
RELIABILITY

RELIABILITY
 ABLE TO BE TRUSTED TO
DO WHAT IS EXPECTED
OR HAS BEEN PROMISED
 ABLE TO BE TRUSTED TO
BE ACCURATE OR
CORRECT OR TO
PROVIDE A CORRECT
RESULT

Strategic Importance of
Maintenance and
Reliability
The objective of
maintenance and
reliability is to maintain
the capability of the
system
Strategic Importance of
Maintenance and Reliability
 Failure has far reaching effects on a firm’s
 Operation
 Reputation
 Profitability
 Dissatisfied customers
 Idle employees
 Profits becoming losses
 Reduced value of investment in plant
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Maintenance and
Reliability
 Maintenance is all activities
involved in keeping a
system’s equipment in
working order
 Reliability is the probability
that a machine will function
properly for a specified time
Important Tactics
 Reliability
 Improving individual
components
 Providing redundancy
 Maintenance
 Implementing or improving
preventive maintenance
 Increasing repair capability or
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NPC 73
NPC 74
Reliability
Improving individual components
Rs = R1 x R2 x R3 x … x Rn
whereR1= reliability of component 1
R2 = reliability of component 2
and so on

Overall System Reliability
Reliability of the system (percent) 100 –
n=1
80 –
n=
10
60 –
40 –
n=
20 – = 50
n
10
n 0
=
0 – n = 200
n
=
30
0
40
0
| | | | | | | | |
100 99 98 97 96
Average reliability of each component (percent)
Figure 17.2
Reliability Example
R1 R2 R3
.90 .80 .99 Rs
Reliability of the process is
Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%

TYPICAL BATH-TUB
CURVE

LIFE CYCLE COSTS
 THE TIP OF THE ICEBERG

 MAINTENANCE COSTS
 THE BULK OF THE ICEBERG
• QUALITY COSTS
• DOWNTIME COSTS
• INVESTMENT COSTS
• DELAYED DELIVERIES COSTS
• ACCIDENTS COSTS

Total Productive Maintenance
(TPM)
 Designing machines that are
reliable, easy to operate,
and easy to maintain
 Emphasizing total cost of
ownership when purchasing
machines, so that service
and maintenance are
included in the cost
Total Productive Maintenance
(TPM) Contd..
 Developing preventive
maintenance plans that utilize
the best practices of operators,
maintenance departments, and
depot service
 Training for autonomous
maintenance so operators
maintain their own machines and
partner with maintenance
personnel
EXPECTATION FROM TPM
ACTIVITY
 Increase in value added Productivity
 Reduction of Breakdowns
 Reduction in defects
 Reduction of customers complain
 Reduction of maintenance cost
 Reduction in Inventory
 Reduction in Accidents & Pollution
 Intangible Benefits & Morale gains
Techniques for Enhancing
Maintenance
 Simulation
Computer analysis of
complex situations
Model maintenance
programs before they are
implemented
Physical models can also be
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Techniques for Enhancing
Maintenance
 Expert systems
 Computers help users identify
problems and select course of
action
 Automated sensors
 Warn when production machinery
is about to fail or is becoming
damaged
 The goals are to avoid failures and
perform preventive maintenance
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before machines are damaged
NFL Vijaipur 84
TOTAL PRODUCTIVE MAINTENANCE
 Group Working Techniques; It promotes initiative
and participation of all personnel from the top
management to the shop floor workers
 It facilitates group working of personnel from multi

functions to improve the overall equipment
effectiveness by more than two times
 TPM aims at Zero-Breakdown, Zero-Defect, Zero-

Accident and Zero-Loss.

TOTAL PRODUCTIVE
MAINTENANCE
(TPM) The Corporate Cultural Change

ZERO BREAKDOWNS
ZERO DEFECTS
ZERO ACCIDENTS

MAINTENANCE PRACTICES
TPM
Predictive Diagnostics
M Maintenance (CBM) Reliability
A Centered Maint.
I
N Systematic Planning & Checking
T
E
N Preventive Maintenance
A
N
C
E
P Inspect, Lubricate
R
A
C
T
I
C
E
S Repair After Failure
1930 40 50 60 70 80 90 2000 YEAR

RESULTS OF
MAINTENANCE
 AVAILABILITY
 RELIABILITY
 SAFETY
 PLANT LIFE

CONDITION MONITORING
C O N D IT IO N M O N IT O R IN G
S U B J E C T IV E O B J E C T IV E
(7 0 % ) (3 0 % )
S IM P L E A ID S IN S T R U M E N T A L T E C H N IQ U E S

CONDITION MONITORING
 VISUAL MONITORING
 VIBRATION MONITORING
 SHOCK PULSE MONITORING
 THERMAL MONITORING
 ELECTRICAL CURRENT MONITORING
 DISSOLVED GAS MONITORING
 PARTIAL DISCHARGE MONITORING
 ACCOUSTIC MONITORING
 WEAR PARTICLES MONITORING
 CORROSION MONITORING

SIMPLE TOOLS FOR DIAGNOSTIC
MAINTENANCE
 TENSIOMETERS
 LUBE OIL TEST KITS
 TEMPERATURE TAPES /
CHALKS
 GO / NO GO GAUGES
 EQUIPMENT BASED
MEASUREMENT METHODS
VISUAL MONITORING
 FIBRESCOPE
 STROBOSCOP
 DP / MP TESTS
 ULTRASONICS
 RADIOGRAPHY
 REPLICA / METALLOGRAPHY
TESTING
Autonomous Maintenance
 Employees accept responsibility for
Observe
Check
Adjust
Clean
Notify
 Predict failures, prevent
breakdowns, prolong equipment life
Conclusion:
 To ensure effective implementation of
activities, it is important that the
production facilities need to be maintained
in good working condition.
 Reduces cost, machinery breakdown etc
 Quality assurance
Therefore maintenance management is

an important aspect for any organization
We learnt
?

Maintenance
Strategy
M A IN T E N A N C E
R U N N IN G IS O L A T E D
B R E A K D O W N P R E V E N T IV E P R E D IC T IV E RCM TPM
Types of
Maintenance
1. Breakdown Maintenance
2. Preventive maintenance
3. Condition Monitoring & Predictive
maintenance (CBM: Condition
Based Maintenance)
4. Reliability Centered Maintenance
(RCM)
5. Total Productive Maintenance
(TPM)
GOOD MAINTENANCE PRACTICE
 Go through the history card of the particular motor
 Before planning overhauling of the motor, ensure availability of
the required bearings
 Get the safety work permit
 Arrange for the crane of sufficient capacity if the motor is
required to be lifted
 Take the I.R. Value of the motor before disassembly and before
handing over the motor after maintenance
 Fill the format meant for the over hauling of the motor
 Measure the winding resistance with a single knob meter or the
motor checker
 Take no load trial run of the motor and record “No Load
Current”
 Record detailed history of the jobs done in the history card
 Do not take any short cut
MAINTENANCE FORMAT FOR MOTORS OVERHAULING
 NAME OF MOTOR ___________
DATE__________

 SWP /PTW NO._________
NAME OF SUPERVISOR________
NAME OF TECHNICIAN________
 INSTRUCTIONS:
 1. Maintenance to be done after proper isolation and also look for special
instructions mentioned in the permit
 2. Use proper tools and get it tied if used inside the motor body
 3. Enter all the tools and other equipment in the register and count them
after completion of the job
 4. Discharge the equipment before starting the job
 5. Slip rings if necessary should be polished before starting the job
 6. Clean the winding with cloth and blower. Apply only spirit or turpentine if
required. Do not use CTC or any other cleaner
CAUTION
 NOTE FOR ON LINE/OFF LINE MONITORING/
MAINT.
 CHECK FOR CONFIRM ISOLATION FOR OFF LINE
MONITORING / MAINT.
 NEVER APPROACH TO LIVE PARTS FOR ON LINE
MONITORING / MAINT.
 NEVER OVER LOOK EVEN A MINOR ABNORMALITY
AS IT MAY CAUSE A MAJOR MISAP / BREAK DOWN.
 ALWAYS BE CAREFUL FOR THE TYPE OF
TRANSFORMERS & THEIR PRIMARY &
SECONDARY CONNECTIONS.
 NEVER KEEP THE C.T. SECONDARY OPEN
CIRCUIT.

Case Studies:GTG-1 Stator Winding
Fault

BUS PT & Transformer
Panel

Instrumentation Box

Dropper in BUS PT Panel

Panel Component

Bus PT


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TO

We must Pressure Test the equipment like

Let the equipment fail during testing than

There are two DG Sets of 2000KVA, 415V, 3 phase

What do we understand by “Maintenance” ?

What is the “Role” of Electrical Maintenance?

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A formal definition of maintenance

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1940 1950 1960 1970 1980 1990 2000>

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• Moving from BD to PM to CBM (PdM) is

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50% breakdown maintenance

10% breakdown maintenance

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 It is the probability that a part or

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AVA ILA BILITY

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Preventive Work can be Labor cost, may Need to Plant

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It is an important segment of the

 Equipments can be utilized effectively

 Eliminates undue interruptions in the

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 Facilitates proper sequence

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.90 .80 .99 Rs

Reliability of the process is

Rs = R1 x R2 x R3 = .90 x .80 x .99 = .713 or 71.3%

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 THE TIP OF THE ICEBERG

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 It facilitates group working of personnel from multi

 TPM aims at Zero-Breakdown, Zero-Defect, Zero-

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(TPM) The Corporate Cultural Change

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1930 40 50 60 70 80 90 2000 YEAR