Significance of maintenance

A properly organised good maintenance

will….
 Reduce the chances of fault occurrence
which Increases the life & reduces the
down period of machine/equipment.
 Provide planned shut down during the
period of inactivity or least usage for the
purpose of major overhauls.
 Ensure continuity of operation & reduces
danger of breakdowns in peak loads.
 Detect troubles in the early stages &
corrective actions can be taken before
breakdown
 Types of maintenance

1. Routine maintenance

2. Preventive maintenance

3. Breakdown maintenance

4. Predictive maintenance
 1. Routine maintenance
It is the maintenance which is scheduled to be
carried out (mostly) daily.
It includes….
 Cleaning the dust by blowers
 Recording load current, voltage,
temperature.
 Oiling, greasing
 Checking the noise level
 Tightening the end connections
 Checking vibrations.
 Checking oil level of transformer &
breather.
 2. Preventive maintenance

It is the planned & organised schedule of

maintenance which is to be carried out
in order to avoid the breakdowns.

It may be weekly, fortnightly, monthly,

quarterly or yearly.
It includes….
oinspection of loose parts, oiling , greasing
oRepairs or replacement of wearied out
parts
 3. Breakdown maintenance

It is to be carried out immediately when the

breakdown occurs.
The breakdown may be due to short circuit
fault in winding, earth fault, failure of
bearing in rotary machine.
In this type of maintenance Immediate steps
are taken to remove the fault.
It includes rewinding, replacement of
bearings
Corrective steps such as checking of…
1.The tightness of stationary parts
2.Free movements of rotating parts
3.The reasons for occurrence of fault
4.Atmospheric conditions
are taken to avoid future
failures.
 4. Predictive maintenance

Predictive maintenance is a proactive

maintenance strategy that uses data to
predict when equipment needs
maintenance.
It uses sensors to monitor equipment
performance and condition in real time.
The goal is to identify potential failures
early so that maintenance can be performed
before equipment breaks down.
 4. Predictive maintenance

Predictive maintenance reduces labor and

material costs whereas preventive
maintenance costs less to implement.

The main difference between the two is that

preventive maintenance is scheduled at
regular intervals while predictive
maintenance is scheduled as needed (based
on asset conditions).
FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE
At a particular time of year the industry
is heavily loaded while for other period
it is lightly loaded and the maintenance
can be carried during this period of
time.
At a particular time the production is
most urgent and profitable than the
cost of breakdown & down period of
machine.
Some times the cost of maintenance is
more than cost of replacement
FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE

Whether the location or position of

machine to be maintained is easily
accessible or not.
The age of machine also affects the
schedule.
The policy of replacement in the
industry.
 FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE

1. Mode of operation of plant

2. Cost of plant outage due to failure
against cost of maintenance
3. Consequence of outage
4. Cost of standby machine or equipment
5. Access to machine for carrying out
maintenance
6. Likelihood of failure
7. Replacement strategy
 Maintenance schedule for transformers
(<1000 kVA) as per IS10028
Inspection Items to be Inspection Action to be taken if
Frequency inspected notes inspection sows
unsatisfactory conditions
Hourly Load (Amps.) Check against --
Rated Values
Oil & Ambient
Temperature Temperature.
Check against
Voltage Rated Values

Daily Dehydrating breather Check that air if silica gel is pink

passages are change by spare charge
clear, check the old charge maybe
colour of active reactivated for use again
agent
Inspection Items to be Inspection Action to be taken if
Frequency inspected notes inspection sows
unsatisfactory conditions
Monthly Oil level in the Check If low ,top up with dry oil.
transformer transformer Oil
level if loose, tighten
connections check tightness
Quarterly Bushings examine for Clean or replace
cracks and dirt
deposits
Half yearly Non conservator check for improve ventilation
transformer moisture under check oil level
Cable boxes, cover inspect
gaskets, joints,
gauges and general
paint work
Inspection Items to be Inspection Action to be taken if
Frequency inspected notes inspection sows
unsatisfactory conditions
Yearly Oil in transformer check for Take suitable action to
dielectric restore quality of oil Take
strength and suitable action if earth
water content resistance is high.
check for
acidity and
sludge

Earth resistance Examine relay &

Relays, alarms their alarm contacts,
circuits etc. their operation,
fuses etc.
Check relay
accuracy
Inspection Items to be inspected Inspection Action to be taken if
Frequency notes inspection sows
unsatisfactory conditions
2 yearly Non conservator internal filter oil regardless of
transformer inspection condition
above core 5 yearly overall
inspection including
lifting of core and coils
wash by hosing down
with clean dry oil
5 yearly overall wash by hosing down
inspection with clean dry oil
including lifting
of core and coils
 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028

Inspection Items to be Inspection Action to be taken if

Frequency inspected notes inspection sows
unsatisfactory conditions
Hourly i. Ambient Check Shut down the
temperature Temperature tranaformer
ii. Winding rise is and investigate either is
temperature reasonable presently higher than
iii.oil temperature normal.

iv. Load (Amps.) Check against

v. Voltage Rated Values
 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028
Inspection Items to be Inspection Action to be taken if
Frequency inspected notes inspection sows
unsatisfactory conditions
Daily Oil level in
transformer
Oil level in bushing
Leakage of water
into cooler
Relief diaphragm Replace if cracked or
broken

Dehydrating breather Check that air If silica gel is pink

passages are change by spare charge
clear, check the old charge maybe
colour of active reactivated for use again
agent
 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028
Inspection Items to be inspected Inspection notes Action to be taken if inspection sows
Frequency unsatisfactory conditions

Quarterly i. Bushing Examine for cracks Replace if cracked

and dirt deposits or broken

ii. Oil in transformer Check for dielectric Take suitable action

strength and water to restored quality
content of oil

iii. Cooler fan Lubricate bearing Replace burnt or

bearings motors check gearbox worn contacts or
and operating examine contact other parts
mechanism check manual control
and interlocks check
iv. OLTC Oil in OLTC driving
mechanism check
ventilation
v. Indoor
transformers Check ventilation
 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028
Inspection Items to be inspected Inspection notes Action to be taken if inspection sows
Frequency unsatisfactory conditions

Half yearly Oil cooler Test for pressure

 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028
Yearly i. Oil in transformer Check for acidity and Filter or replace
sludge
ii. Oil filled bushings Test oil Filter or replace
iii. Gasket joints ----- Tighten the bolts
evenly to avoid
uneven pressure.
iv. Cable boxes Check for sealing Replace gaskets if
v. Surge diverters arrangement for filling leaking
and gaps holes examine Clean or replace
compound for cracks

vi. Relays, alarms Examine for cracks Clean components

their circuits and dirt deposit and replace
examine relay and contacts and fuses
alarm contacts their if necessary
operation uses etc. change the setting
vii. Earth resistance ---- If necessary take
suitable action if
earth resistance is
high
 Maintenance schedule for transformers
(>= 1000 kVA) as per IS10028
Inspection Items to be inspected Inspection notes Action to be taken if inspection sows
Frequency unsatisfactory conditions

5 yearly 1000 to 3000 kVA overall inspection wash by hosing

including lifting of down with clean
core and coils dry oil
7 to 10 Above 3000 kVA overall inspection wash by hosing
yearly including lifting of core down with clean dry
and coils oil
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)
DAILY MAINTENANCE
Examine visually earth connections and motor
leads.
Check motor windings for overheating (the
permissible maximum temperature is above that
which can be comfortably felt by hand).
Examine control equipment.
In the case of oil ring lubricated motors:
a) Examine bearings to see that oil rings are
working;
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

b) Note temperature of bearings;

c) Add oil, if necessary; and
d) Check and play.
NOTE - In order to avoid opening up
motors, a good indication is to observe
the shell temperature under normal
working conditions.
Any increase not accounted for, for
example by seasonal increase in ambient
temperature, should be suspected
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

WEEKLY MAINTENANCE
• Check belt tension.
In cases where this is excessive, it should
immediately be reduced and in the case of
sleeve bearing machines the air gap between
rotor and stator should be checked.
• Blow out windings of protected type motors
situated in dusty locations.
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

• Examine starting equipment for burnt

contacts where motor is started and
stopped frequently.
• Examine oil in the case of oil ring lubricated
bearings for contamination by dust, grit, etc
(This can be roughly judged from the colour of
the oil.)
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)
MONTHLY MAINTENANCE
Overhaul Controllers
Inspect and clean oil circuit breakers.
Renew oil in high speed bearings in damp
and dusty locations.
Wipe brush holders and check bedding of
brushes of slip-ring motors.
HALF YEARLY MAINTENANCE
Clean windings of motors subjected to
corrosive or other elements; also bake and
varnish, if necessary.
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

In the case of slip-ring motors, check slip-

rings for grooving or unusual wear.
Check grease in ball and roller bearings and
make it up where necessary taking care to
avoid overfilling.
Drain all oil bearings, wash with petrol to
which a few drops of oil have been added;
flush with lubricating oil and refill with clean
oil.
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)
ANNUAL MAINTENANCE
Check all high speed bearing and renew, if
necessary.
Blow out all motor winding thoroughly with
clean dry air. Make sure that the pressure is
not so high as to damage the insulation.
Clean and varnish dirty and oily windings.
Overhaul motors which have been subjected
to severe operating conditions.
Renew switch and fuse contacts, if damaged.
Check oil.
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

Renew oil in starters subjected to damp or

corrosive elements.
Check insulation resistance to earth and
between phases of motor winding, control
gear and wiring.
Check resistance of earth connections.
Check air gaps.
Test the motor overload relays and breakers.
RECOMMENDED MAINTENANCE SCHEDULE
(IS 900)

RECORDS
Maintain a register giving one or more pages for each motor
and record therein all important inspection
and maintenance works carried out from time to time.
These records should show past performance, normal
insulation level, air gap measurements, nature of repairs
and time between previous repairs and other
important information which would be of help for good
performance and maintenance.