Industrial Process

Control.

Maintenance of Production Lines

Dr/ Ahmed Swidan
Supervision EN/ Abdelrahman Emam
prepared by Eman Saad Ibrahim
1. Maintenance Planning Questions (for Each Maintenance Type):

Q: What are the types of maintenance required?

A:

Preventive maintenance (periodic).

Corrective maintenance (after failures).

Predictive maintenance (based on performance and condition monitoring).

Emergency maintenance (in case of sudden failures).

Q: What is the recommended checklist table for each type of maintenance on

motors, generators, and turbine parts?

A:

Preventive Maintenance:

Inspect belts, blades, and electrical connections monthly.

Test insulation resistance and grounding every 6 months.

Change oil and grease annually or according to operating hours.

Corrective Maintenance:

Immediately replace damaged components upon fault detection.

Predictive Maintenance:

Use vibration and temperature sensors for condition monitoring monthly.

Emergency Maintenance:

Immediate intervention in case of major faults threatening operation.

Q: What tools and diagnostic equipment are required for each maintenance
activity?

A:

Vibration analyzers.

Insulation resistance tester (Megger).

Current and voltage clamp meters.

Visual inspection tools (flashlights and thermal imaging cameras).

Laser shaft alignment tools.

General hand tools (screwdrivers, wrenches, pliers).

Q: What are the safety protocols for each maintenance task?

A:

Disconnect electrical power before starting work.

Wear personal protective equipment (helmet, goggles, gloves).

Secure the turbine to prevent unintended movement.

Use only certified and properly maintained tools.

Follow standard operating procedures (SOPs) and documented instructions.

Q: What are the potential failure modes of each component, and how can they be
anticipated?

A:

Motors and Generators:

Insulation failure, overheating, excessive vibration —> anticipated by insulation testing and
vibration monitoring.

Turbines:

Blade erosion, gear or bearing failure —> anticipated by vibration analysis and visual
inspections.

Control Systems:

Software errors, sensor failures —> anticipated by regular software and sensor testing.

2. Reliability & Performance Check Questions:

Q: How is the performance of motors and generators measured?

A:

By monitoring output parameters such as voltage, current, power, and efficiency.

Using thermal imaging to check for overheating.

Measuring vibration levels to detect mechanical issues.

Q: How is wear detected in mechanical parts like gears, blades, and bearings?

A:

Through vibration analysis to detect unusual patterns.

By visual inspections for cracks, erosion, or deformation.

Using oil analysis to identify metal particles indicating internal wear.

Q: How are insulation resistance and grounding checked in electrical components?

A:

Insulation resistance is checked using a Megger (insulation tester) to ensure no leakage

currents.

Grounding is verified by continuity tests and measuring ground resistance with earth testers.

Q: What are the root causes of common electrical faults, and how can their
recurrence be prevented?

A:

Root Causes: Poor insulation, loose connections, overheating, moisture ingress, component
aging.

Prevention Methods:

Regular inspections and testing.

Proper sealing against moisture.

Tightening connections.

Scheduled replacement of aged components.

2. Reliability & Performance Check Questions:

Q: How is the performance of motors and generators measured?

A:

By monitoring output parameters such as voltage, current, power, and efficiency.

Using thermal imaging to check for overheating.

Measuring vibration levels to detect mechanical issues.

Q: How is wear detected in mechanical parts like gears, blades, and bearings?

A:

Through vibration analysis to detect unusual patterns.

By visual inspections for cracks, erosion, or deformation.

Using oil analysis to identify metal particles indicating internal wear.

Q: How are insulation resistance and grounding checked in electrical components?

A:

Insulation resistance is checked using a Megger (insulation tester) to ensure no leakage

currents.

Grounding is verified by continuity tests and measuring ground resistance with earth testers.
Q: What are the root causes of common electrical faults, and how can their
recurrence be prevented?

A:

Root Causes: Poor insulation, loose connections, overheating, moisture ingress, component
aging.

Prevention Methods:

Regular inspections and testing.

Proper sealing against moisture.

Tightening connections.

Scheduled replacement of aged components.

3. System Component Clarification Questions:

A. Electrical System Components:

Q: Mention the main components of the electrical drive system and clarify them.

A:

Electric Motors: Convert electrical energy into mechanical energy.

Generators: Convert mechanical energy from wind movement into electrical energy.

Voltage Transformers: Regulate the output voltage to match the grid requirements.

Electrical Control Systems: Manage operations such as start-up, shutdown, and speed control.

Connection and Protection Units: Including circuit breakers and fuses to protect the system
from faults.
Q: What sensors are used (e.g., current, voltage, temperature, speed) and how are
they calibrated?

A:

Types of Sensors:

Current sensors.

Voltage sensors.

Temperature sensors.

Speed/Encoder sensors.

Calibration Method:

Compare sensor readings with a certified reference device.

Adjust the signal electronically or through software to achieve accurate readings.

Perform periodic calibration to maintain measurement accuracy.

B. Mechanical System Components:

Q: Mention the main mechanical parts in the turbine and clarify them.

A:

Blades: Capture wind energy and convert it into rotational motion.

Gearbox: Increases the rotational speed transmitted from the blades to the generator.

Shaft: Transfers rotational energy from the blades to the generator.

Bearings: Support rotational movement and reduce friction.

Nacelle: Houses all the major equipment mounted on top of the tower.

Yaw System: Rotates the turbine to face the wind direction.

Q: What types of lubrication systems are used, and what is the lubrication
schedule?

A:

Types of Lubrication Systems:

Automatic centralized lubrication system.

Manual lubrication for specific points as needed.

Lubrication Schedule:

Inspect oil and grease levels monthly.

Replace oils and greases in bearings and gearbox every 6 to 12 months, or according to
manufacturer recommendations.