MAINTENANCE AND
TROUBLE SHOOTING OF
MACHINES AND
EQUIPMENT
PREVENTIVE MAINTENANCE:
It is the orderly and routine checking, cleaning,
drying, tightening of bolts, re-greasing, testing,
monitoring, etc. of electrical equipment, machines
and devices, to ascertain their normal operations.
Every date and activity done must be properly
recorded.
PREDICTIVE MAINTENANCE:
CLASSES OF INSULATION:
For ordinary building wiring based on 30C or 80F
ambient.
60C RUW, T, TW, UF etc.
75C FEPW, RH, RHW, RUH, THW, THWN, XHHW,
ZW
Megger Reading 1
24 volt system
120 volt system
480 volt system
1000 volt system
100 V megger
250 V megger
500 V megger
1000 V
2500 V
5000 V
7500 V
R1 = R2 (V1-V2) / V2
where:
R1 = insulation resistance
R2 = voltmeter resistance (voltmeter
sensitivity times full deflection)
V1 = voltmeter reading with switch closed
V2 = voltmeter reading with switch open
INSULATING LIQUIDS
Used for oil immersed transformer for cooling
and insulation and also used for breakers and
switches as insulation, coolant and as arc
quencher.
Three kinds of insulating oil are available.
Mineral Oil
Insert Synthetic insulating oil, popularly known
as askarel. Askarel are sold with such trade
names as, Pyranol, Chlorextol, Inertene,
WEMCO-C etc.
High temperature insulating liquids like silicon.
Non inflammable
Chemically stable
Non sludging (can not corrode, sludge
means oxidized oil).
0.1
1
DBV
Minimum Acceptable
For mineral oil = 22 KV
For askarel = 25 KV
TYPE OF FILTERING
Filter Press
Centrifugal Purifier
de- gasifying method.
4.
5.
METHODS OF CLEANING
BATTERY
To be sure of performance, when recommending
dry cell (primary battery) specify only those with
expiry dates marked on the battery itself.
HYDROMETER
+0.020
+0.016
+0.012
+0.008
+0.004
0.000
-0.004
-0.008
-0.012
I.
BATTERY CHARGING
The current to charge the battery must not be
higher than the ampere-hour (AH) rating of the
battery. Example, If the battery has a rating of
100AH, the current must not exceed 100amps.
TRICKLE CHARGING
Because of some impurities of the active
materials of the battery, a certain degree of
local discharging occurs. To neutralize this, a
small amount of charging current is needed,
this is called trickle charging.
I.
IV.
6.
7.
BATTERY MAINTENANCE
Corroded poles should be brushed using steel
brush while washing with water.
To avoid oxidation on the poles, it must be
treated with petroleum jelly.
AC GENERATOR
BRUSHLESS GENERATOR
ALTERNATOR MOTORIZATION
In the parallel operation of the alternators, if one
of them draws power from the bus rather that
supplying power to it, this is called motorization.
The synchronous generator will run as a
synchronous motor. The possible causes of
motorization are ; Low speed and low voltage,
although no mechanical damage will be done to
that motoring unit. Since the direction of rotation
is the same yet the harm is on the fact that the
remaining unit will be overloaded and eventually
trip causing total power failure.
SYNCHRONIZING PROBLEM
If two alternators are to be operated in parallel,
synchronizing is a very critical condition- when
only synchroscope is installed, a possibility of
deliberate wrong reconnection for the purpose of
sabotage or to destroy the credibility of
operations Engineer and is very common
occurrence. To make sure of proper
synchronization, synchronizing lamps are installed
to confirm synchroscope indications.
A.
1.
2.
3.
4.
5.
Maintenance of a generator,
particularly stand by generators
AC MOTOR
Before operating any electric motor, the
following information must be checked:
5.
6.
7.
8.
9.
10.
11.
12.
Service AC or DC
Kind for AC, squirrel-cage, wound rotor,
induction motor or synchronous motor.
Operating voltage and frequency
Type of enclosure- ODP, TEFC, weather proof,
explosion proof, etc.
Class of insulation
Service factor
Number of terminal leads
NEMA code letter classification
2.
CLASSIFICATIONS OF MOTORS
ACCORDING TO NUMBER OF LEADS
A.
A.
A.
A.
RECOMMENDED REGREASING
SCHEDULE
HORSEPOWER
TYPE OF SERVICE
TYPICAL EXAMPLE
10-40
50-200
EASY
OPERATING 1 HR/DAY
10YRS.
STANDARD
MACHINE TOOLS, FANS
7 YRS.
PUMPS, TEXTILE MACHINERY
SEVERE
CONTINOUS OPERATION,
4 YRS.
SEVERE VIBRATION, POWER
PLANTS, COAL MINING
VERY SEVERE
DIRTY, VIBRATING,SHAFT END
4 MOS.
HOT AND HIGH AMBIENT
-7.5
7 YRS.
5YRS.
5 YRS.
3 YRS.
2 YRS.
1 YRS.
9 MOS.
4 MOS.
TROUBLE
POSSIBLECAUSE
A.SYNCHRONOUS MOTORS
Fail to start
tripped breaker
1. blown fuse/
2. open in one phase
3. over load
4. low voltage
Runs hot
ventilating
coils
low
high
1. overload
2. clogged
ducts
3. shorted stator
4.
5.
6.
7.
Runs fast
1. high frequency
Runs slow
1. low frequency
Pulls out of
synchronization
1. over load
2. open in field coils
3. no exciter
voltage
4. open in the field
5. rheostat set too
high
circuit
3. no exciter
voltage
4. open rheostat
Vibrates severely
synchronism
1. out of
2. open armature
coil
3. open phase
4. misaligned
A.
3 SQUIRREL-CAGE INDUCTION
MOTOR
Fails to start 1. tripped breaker / blown
fuse
2. open in one
phase
3. shorted stator coils
4. low voltage
5. high voltage
6. low frequency
7. open stator coils
8. one phase open
9. grounded stator
10. uneven air gaps
11. rotor rubbing on
stator
Runs slow
coils
1.
2.
3.
4.
5.
over load
low voltage
low frequency
broken rotor bars
shorted stator
A.
touch
collector ring
7. open in rotor
circuit
Runs hot
1. overload
2. clogged ventilating
ducts
3. low voltage
4. high voltage
5. uneven air gap
6. shorted stator coils
7. open stator coils
8. one phase open
9. low frequency
10. grounded stator
11. rotor rubbing or stator
Runs slow
1. overload
2. low voltage
3. low frequency
4. too much resistance in
rheostat
5. shorted stator
coils
6. open stator coils
7. one phase open
8. open in rotor
circuit
A.
1. tripped breaker/blown
fuse
2. defective starting
mechanism
3. open in auxiliary
winding
4. open in main
winding
5. shorted capacitor
6. open capacitor
7. over load
Runs hot
mechanism
ventilating
coils
1. over load
2. starting
does not open
3. low voltage
4. high voltage
5. clogged
ducts
6. shorted stator
7. worn bearings
8. low frequency
9. rotor rubbing on stator
Runs slow
1. over load
2. low voltage
3. low frequency
A.
A.
A.
A.
POSSIBLE CAUSE
1. poor contact in
operating
2. fluttering of a relay in
pressure
Failure of contactor
or relay to pick up
1. low voltage
2. open coil
3. excessive magnet
binding
4. mechanical binding
5. open circuit in series
with operating coil
TRANSFORMER
Transformer to be highlighted in this seminar is
the substation type transformer, both outdoor
and the indoor type.
INDOOR TYPE
4.
5.
6.
7.
Circuit Breakers
* Service- AC or DC
* Mounting- Outdoor or Indoor
* Enclosure- Bakelite, metal,etc
* Voltage- Low, medium, high and extra high
* Medium of interruption- air, vacuum, SF6, oil etc
* Contacts- bayonet, explosion chamber, de-ion etc.
* Operation- gravity open, gravity close etc.
* Control- manual, electrically, remote etc
* Trip unit- thermal and magnetic
* Charging mechanism- spring, motor etc
THANK YOU!!
END OF
SEMINAR
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