2

Maintenance
Introduction
Maintenance is the process for maintaining any equipment or machinery
in aproper and efficient condition. For getting satisfactory and trouble
[ree service from any electrical equipment or apparatus or any other
alectric machines, it requires careful planed programme of checking
and inspecting and also for preventing maintenance. It is necessary to
keeothe proper record of inspection, insulation resistance and all main
tenance and repair operation etc. Only then, it will be possible to find
out the chronic troubles.
A machine should never be allowed to run without lubrication. Proper
care should be taken for its cooling and overloading. The machines must
be kept free from the moisture, humidity, dirt, oil etc. as these factors
affect the insulation of windings and may result in rusting the various
parts of the machines.
The periodic inspection and maintenance details may vary with the
type of machine and its working conditions.
Some spare parts, sub-assemblies, lubricants depending upon the
need and importance of the machine or apparatus or equipment, and
some spare-coils, brushes, brush holders, starting gears and bearings
etc. should be kept ready in stock.
2.1. Fundamentalof Maintenance
Maintenance can be defined as those activities required to keep the
equipmernt in operating condition so that it continues to meet specifica
Wons. Thus, maintenance ensures that the production plant or equip
Inent is available for use at minimum cost, for scheduled hours.
When an electrical equipment fails or its performance degrades, it is
required to restore its operation with minimum of down time. Thus main-
tenance restores the equipment operation economically and efficiently.
Maintenance increases the availability of equipment by reducing down
time. It assures the equipment availability for instant operation.
Since a large number of equipments are used in an organisation, it
involvess
of
a SOund policy for maintenance of the equipments used. Most
manufacturers
tomers.
of the equipment offer after-sales service to their cus-
 MaintenaIca
MnintenanCe of|lecti 135
CommiseioningA
tnetallato, fo
Thotorm routine
sorvicirng
and irispectiorn
include, the visual in
he of log so0ingthat olectic maching,
14
schedule is
wsually in Ench
tobulated
honts spoctionor
oporato at norrmal loads transtomers,
startirng and corntrol
Regular visual inspection
ato cotumn tho dovicos
oquiprmont, checking of bearings, wirnding, te of all parts
maintenance
the yeat maintehnCG
wilth aFurthor each major rnperature etc.
The
weeks,
monthsofprovided bo
of dore, Servicirng work include likg rocifying rminor detects, should
tightening
in equipment inspoction
which factory fastenings and such other
big
plantorin against each Thedelails
indicafed history card,
aboul
opoaton loose
disrmantling should also be don9.
operations which do not require any
catds. naintenanco duty. The
is a
provided withwritten Routine testing should include the periodic measurernent of
temarks are
'spates' are
inthese
important for
control.
inventory accordingto the according
spatos ate lion resistance, insulation testing, testing of transforrner insula-
oil, measure-
ment of air gap between stator and rotor of rnotors and all other tests as
The proper done
with consulted, Tho
keptin store
The
jobs the
work as
maintenancemanufacturer is
reques! with
manufacturer re
necOssary payment. required by operating instructions.
Preventive Maintenance-Essence
of difficult personnel on Preventive maintenance neans proper maintenance, it consists of
vIdes trained of Maintenance
Ciassification maintenance adoption of measures to know before breakdown and prevent them be-
breakdown fore they occur than allowing breakdowns to happen and then take ac-
Corective or
(a)
(b) Preventive maintenance
tion.
Basically the functions of this section are :
(c) Contracted maintenance
Periodic visual inspection of various equipments to locate con-
(a) Corrective maintenance
dition leading to breakdown.
(a) Corrective Maintenance when an equipment 9 Up keep of equipment and plant and repair defects at their initial
Corrective
maintenance is
carried out
fails or stage.
satisfactory. 3 To attend major breakdown and repairs.
does not work
(b)Preventive maintenance out to reduce the Anv well planned preventive maintenenace programme will have the
The preventive
maintenance is carried failure d following basic aspects :
equipment to minimum.
1. Inspection : What to inspect and how to inspect ?
(c) Contracted maintenance
contract terms are agreed upon by th 2. Frequencies : How often to inspect ?
In contracted maintenenace,
user, and may include both prevenivs
Supplier of the equipment and 3. Schedules : When to inspect ?
and corrective maintenance.
4. Organisation : Who to inspect ?
Maintenance Introduction
2.1.1. Preventive 5. Records : What to record and how to record ?
to wear and tear in
All electrical machines and equipments, oWing
components, ageing of the material may suffer partial or
one or more 2.2. Advantages of Preventive Maintenance
complete breakdown. Whenever the parts in any piece of equipment 1. It prevents unscheduled interruption to various machines and
show signs of damage they must be timely repaired. equipments and premature failures.
If the electrical equipment is to give trouble-free and continuous 2. It makes an effective use of systematic maintenance and in
service, and if its life span is to be prolonged then it is necessary to spection to determine the need for minor and major repairs.
implement an effective system of preventive maintenance. An effective 3. It reduces breakdown to a minimum and increses the efficiency
system will include routine servicing and inspection, periodic repair ol
of equipments and machinery.
equipmernt acc irding to a fixed schedule and routine, testing at specitc
intervals of time depending upon the operating conditions. 4. Satisfactory maintenance of machines and other equipments at
With proper operation and an effective maintenance system, low cost.
possible to ensure that electrical equipment will be kept in a tit operd D. It helps to plan flexibility iin operation due to accurate knowl
ing condition and breakdown and premature failure will be edge of machinery conditions.
minimum.
reduced to
 Maintenance of
Commissioning & Electrical

equipmentEqUsp.meny
Installation,
136 Maintenance
machine and other
wear and tear of
6. It lowers better. (6) Checking of movable 137
workingcondition parts.
7. Itmakes machine.
(c) Checking of
increases the life of
the
equipment is needed.
working condition of
whichequipment or machinery.
8. It (d) Checking of
9. Less
standby
safety and
protection to the
workers. has to work i.e. surroundings in
atmospheric the
machinery or
10. Provide
greater
reparing is reduced. (e) Checking of safety
measures. conditions. equipment
11. The cost of () Checking of protective
Preventive Maintenance devices.
2.2.1.Classification of (g) Checking of facilities available.
1. Routine Maintenance
carried out daily, if
possible. It includes
visual (h) List of consumable and non
It should be
as replacement of small parts and
inspec. equipments and machinery. consumable items to be used in the
maintenancetmenin.
adjus
such
tion, minor repairs operation. Routine
equipment so that it remains in electrical
() Checking of stores and spared
of
cludes all work required in cleaning of equipment Checking of tools, inventory.
powerfrom
fitting, tank cover and bushings of dus trackles, jacks, and fixtures etc.
and dirt, cleaning of the and mTving contacts of starters, trans. 2.2.2. Planning
formers, cleaning the fixed
ment of burnt Contacts.
maintenance of electric motors
involves
washing
replace. It is an important feature of modern
monly used in the maintenance department.
industry and it is most com-
cationRoutine
of bearings, checking of control equipment and replacement of and lubri. should inspect the plant periodically under The maintenance engineer
routine maintenance is when it is at rest with god planning and working conditions and also
carbon brushes etc. Generally, the carried ou made during lunch time recess. preparation.
The planning Many tests can be
without dismantling the equipment, but it mustThe
always be of maintenance should be
from supply before any repairs are
Work is carried out by the
undertaken.
maintenance staff.
routine dimaisconnect
ntenanceed
categorized in the following ways:
1. Routine maintenance.
2. Periodical (weekly, fortnightly, monthly, quarterly or half
2. Periodic Maintenance yearly)
maintenance.
It should be carried out weekly, fortnightly, monthly, quarterly or hal 3. Maintenance of fault as and
yearly depending upon the requirements and condition of the machine. when the fault occurs.
It includes inspection of loose parts, ventilation, replacement of worm 2.3.Breakdown
parts, change of oil, checking of insulation etc. When industrial plants or electrical machines are
3. Overhaul incidently, it is known as breakdown. running, and stop
It should be carried out half-yearly or yearly. It consists of replace. Causes of Breakdown
ment or renewal of the main units, assemblies and parts of electrical The following are main causes of breakdown :
equipment. Generally, it is carried out on yearly basis. It involves such (a) Faulty design construction
work as rewinding of motor stator and rotor, replacement of bushing of
(b) Incorrect installation or use
high voltage circuit breakers and involves partial or complete isman
tling of the equipment. (c) Overload
4. Maintenance on Fault (o) Negligence
It is carried out immediately as and when a (e) Wear and tear
fault occurs e.g., blow
ing of fuse, short circuit or () Accident.
overloading
The tollowing factors should
etc.
be taken into consideration at the time 2.3.1. Breakdown Maintenance
of preparing the schedule for
maintenance: Breakdown maintenance is carried out as and when neccessary.
(a) Checking of ie ToliOwing are the main recommendations for implementation to break
staiionary parts. down maintenance.
 Mantenance 139
Mantenance of Electrical
Connissionng& equipment
Misuse of
Instalaton (v Poor maintenance
(iv)
maintenance depends material Used in the
1.EngineeringRecords breakdown recorded. The proper Low quality equiprnent
(vi) very easy to rectify those reasons, when detected.
Thetimely
éxtent upon
fultilment of the work is
whch
in
the way the repar card
into
ofthe
tell
electrical

us the
overall equipment
conditiontheof
erlt: It
eTools
is
and
Tackles
Propertools and taackles are more essential for the continuously
detectedfaults This card will helps in
all importance
repairs
required and planning
records promotes
operatingunits. Proper tools also reduce the amQunt of manual labour
specal
equipment and kind of
repairs The
proper keeping of better plar. requiredfor handling heavy equipments. Heavy and time consuming
requiredfor can be reduced by:
manual work
ningof work
upon the
Mechanising the lifting and handling operation.
2. Inspection mainly depends and
inspection. 1.
2. Employing infrared heating and induction heat loss method for
maintenance work senior competent
The be
by
carried out maintenance work. The persor drying Out motors, transformers, etc.
fore.
inspection must knowledge of
thorough
who has got into two main groups
namely: inspecinn Jointing wires and rods by welding instead of soldering.
Stores and Spares
can be
drvided Inventory Control of
( External inspection 7. necessary for maintenance section to make the
It is also very much
() Internal inspection all the spares required and should be made readily avail-
inspection is carried out inventory of
Inspection. The external like vibration. when whenever required.
() External
in operation.
Condition abnormal SOUnd. able for use
the equipments are clearance lubrication etc. can be 2.3.2.List of commonly
used Instruments for Maintenance
wear and
slackness, fits and obseved The instruments required in electrical maintenance department will
action can be taken.
and corective upon the repair work to be done. In most of industries
Internal inspection is to
be carried out
during largely depend
(i) Internal Inspection. can be done monthly or quarterly or half sufficient instruments are available to enable the staff to carryout main-
shut down which
pre-planned
operatingconditions. tenance and minor repairs. The testing generally determine the condi-
yearly depending upon the tion of plant and help in early detection of any fault. The following instru
3. Servicing and maintenanea ments are generally used for maintenance in industry.
This refers to cleaning, adjustment, lubrication (a) Voltmeter with Switch:Voltmeter with switch is used to find out
functions without dismantling the equipment. voltage between main phases and between phase and neutral at
4.Testing the supply point.
The testing of the electrical equipments must be done very care.
(b) Asmall switch board fitted with various sizes of lamp holders
fully. Because the performance of the equipments specially protective
device, such as relays etc., depends upon the testing, and proper set and socket outlets including fluorescent lighting fittings, into
ting. which other components such as choke coil, starter, switch may
Testing work shoul: be done by responsible person who has thor be connected, for testing two flexible leads with two insulated
ough knowiedge of use and proper handling of testing equipments. Tes test lamps. These may be used for continuity and insulation
entry should be made in the forms available. test.
5. Engineering Analysis (c) An oven provided with a ventilated fan and preferably heated
It is observed that a few equipments require more
frequent repalis electrically underhand or thermostatically control for drying out
as compared to others. The following are the main machine and other apparatus.
reasons :
() Defective design (0) Intra-red lamps may be used for heating in place of resistance
() Faulty material heaters or stream pipe heating.
(in) Unhealthy operating conditions
 AMainteNance of
instatn CmnsSnin
& EleCtncal Maintenance
140

can be used tor

of
testing the armature the
motors
Equpmey
motor,
141

(e Prawier
sion oe motor,
sernes ACand
universal
battery can be used
repu Standard Screw Driver
supply from a car Thin Blade Screw
( Alow voltage resistance tor making
voltage
switch and variable drop tesst on Driver
amature.
100 o
for measuing earth resistance upto Square blade Screw Driver
() Anmeggar
gA earth fault loop tester for impedance tests of earthing cir Fig. 2.1. Screw drivers
Precautions : Avoid greasy or oily handle. Do not use in
cuits.
(0 A dip-on multiìrange ammeter, a double range ac voltmeter, do place of
ammeter are also used Firmer Chisel. Use proper size for particular Screws.
voltmeter and multirange dc for mainte 2.Combination PIiers
nance work. ote one of most commonly used tools for
Astrong torch is used specially
fitted with aterminal or for holding and grippingsmall articles in maintenance work. It
output for simple continuity test and
testing fuses etc. socket is used
use hands. The different types of situations where it may
essential items are : Neon tester, speed counter, stop Other be unsafe to pliers are :
Ia Long nose plier. It is Userul for forming eyes of
tachometer, small magnifying glass & mirror, portable watch,. to be used where they are held fast under wires which are
cleaner and blower, electrical soldering iron of 300 Wandvacuum screw long nose plier
60 W is shown in Fig.2.2 (a).
rating. glow lamp and light measuring meter, lifting apparatus
and pulley drawing system should be availatble as required to
gether with normal workshop facilities.
Listof Commonly Used Tools For Maintenance
Installation and maintenance work necessitates the use of a laroa
variety of measuring tools and gauges etc. Without the aid of proner
toois it is difficult to carry repair work. The total maintenance time and Fig. 2.2. (a) Long nose plier
efficiency of the service personnel depend upon the availability of tools
The size of long nose plier is 10 cm. Do not cut steel substance with
Sometimes, it may be difficult to carry out job for want of the particular nose plier.
tools. Proper selection and use of hand tools reduces fatigue, reduces
damage due to use of wrong tool and improves the maintenance quality. (b) Side Cutting Pliers. The material used for this cutter is steel.
It is preferred to purchase better grade tools. The following electrical Such a plier is used for cutting wires, gripping operation by hand,
tools are commonly required for servicing and maintenance of electrical twisting wires and a number of other operations required in elec
machines. trical work. It is usually provided with snub-nosed jaws and have
1. Screw Drivers a cutting edge only on one side as shown in Fig. 2.2 (b). Usually
It is a common hand tool for maintenance and 15 cms. or 22.5 cms. plier is used. An insulated plier is always
assemblyWork. The
shank is made of steel set into a wooden or plastic handle. preferred.
The blade is
shaped to fit recesses in the heads of screws, Screw
in many sizes but commonly used of 25 drivers are made
cms screw driver with 15 cms
blade in order to meet different types of
Various types of screw drivers are jobs.
(a) Standard screw drivers for available today :
in ordinary work.
(b) Offset screwW driver is
used when ordir.y drivers cannot Fig. 2.2. (b)Side cuting plier
square hole of the screw.screw
be used due to the
 Maintenance ot Electrical E
142
installation,
Commiseioning&
Equpment Maintenance

fixing clip and making straight hole in wall.

143

used lor The

Cutters are frequently while using should not be greasy. handle of ham-
3. Cutters
are made from steel. prior to connections.required mer
The cutters for removing insulation
work electrical wires.
Diagonal Cutters
showscuuttheter
during repair cutting and stripping
rods. Fig. 2.3.
for or
are also used be used to cut steel wire cms.
should never generally 20
cutter. The size of cutter is
diagonal
CROSS PEEN HAMWER
Fig. 2.5. Cross peen hammer
(c) Straight Claw Hammer. Astraight claw hammer is preterred by
cutter electricians because the straight claw can be inserted behind, beneath
Fig. 2.3. Diagonal beetween wooden boards to be removed. It is shown in Fig. 2.6.
or
Precautions :
wires.
1. Do not use steel
2. Protect trom rust.
substances.
3. Do not cut hot
4. The Hand Hammers hammer The..
most used of all tools is the
It is made of steel. The specific type of
heads, each designed for a
are many shapes of hammer in weights varying from 100 ams
to
work. Engineer's hammers are made driving pulleys and collars on to Fig. 2.6. Straight claw hammer
necessary for ( Straight peen Hammer. This is similar to ball-peen hammer with
1/2 Kg. Heavy hammer is be free from knots etc.
should the difference that the one end of straight peen instead of ball peen and
the shaft. Hammer shafts
following types of
Types of Hammers. For electrical work generally face is similar in shape.
hammers are used Straight psen
nails into wooden
(a) Ball Peen Hammer. It is required for driving necessery to
batten and forcutting wall plaster and bricks when it is
for rivetting purposes.
take wire from one room to another. It also used
from 1/4 kg to 2 kg. The hammer
The size of ball-peen hammer is varies
should never be used with loose handle.

Ball peen Eye Fig. 2.7. Straight-peen hammer

Handle 5. The Hack-Saw
Wedges. of metals such as conduits, ca
This is main tool used for cutting be
of sizes of hack-saw. Blades may
Neck Cheek OIes etC. There are many types of the blade for hand work is about
size
Poll Face Caroon or high speed steel, The teeth on a hack-saw blade have-a set
by 12 mm wide, The
0mm long 16-18 teeth per
Fig. 2.4. Ball-peen hammer all-round blade for hand use in the
O ne sides. The best adiustable. The blade is usually gripped
(b) Cross-Peen Hammer. It is made of steel and available in ditrerel frame is
C.0 Cm. The hack-saw
size. Generally weight of this hammer varies from 1/4 kg to 2 kg.
 Maintenance of Electrical Maintenance
Commissioning &
144
Instaltation,
nuts keep the
hexa-saw Equipmens
straight glasstubeis placed within a large radius (3) having aflat base (4).
145

means of wing
with the
frame by while When spirit levelamount
upon the
is moved, the air bubble will
of tilting of its base. move left or right
depending The angle of tilting can
cutting be quantified from calibrated graduations. The
work centre
levelled when the air bubble is exactly centered on the will be mark.
taken The
as
be moved in both horizontal or vertical directions.
level may
8.Chisel
Chisels are the most common metal cutting tool used in the shop
floor. They may be broadly classified into four categories
Fig. 2.8. Hack-Saw

teeth. The file is

6.The Fille
cutting tool generally have X-cut and parallel (a) Fiat chisel
This is a tapers in width thickness.
for about two-thirds
of its length and
files such as flat file, square file, round
file, Therhalfe
are different types of different purposes. The size of file is 8 cm to 35
round file etc. Used for (b)Round nose chisel
cm
handle (2) Do not uSO i
Precautions : (1) Do not Use without
hammer or screw driver.
(c) Cross cut chisal

Flat file

(d) Diamond point chisel

Fig. 2.11. Different types of chisels
Square file
Fig. 2.9. File
(a) Flat chisel : They are used for cutting of and surtacing
cutting grocves
(b) Round nose chisel : They are mainly used fo
7. Spirit Level and channels.
It is a common instrument to test or adjust horizontal surfaces. It is purpose
(c) Cross cut chisel: They are used for roughing
essential in all erection work or in repair works. chisel: They are used to cut grooves square
() Diamond point
small holes and to clean corners.
one-third of its length. On no ac
It is flattened and tapered about hard where it is struck by hammer.
count should the head of a chisel be
The chisel should not be oily.
9. Spanners an equip
turn nuts and is helpful when
Tnese are used to orip and Wrenches. It is
These are also known as
Fig. 2.10. Spirit level ment is being disassembled. spanner may lead to rounding
It is
simply a glass tube, 200 to 300 mm long (1) almost filled with USually made of steel. Use of wrong Size
liguid. An air bubble, (2) remain at the top-most position of the tube. The off the corners of the nut.
 Maintenance of Electrical
Commissioning &
Equipments
Maintenance
146
Installation, 147

Spanner sizes are determined by the width across flats. They are addition to this an adjustable wrench is also
each nut size. In used for
available in inches and
millimeter size to suit Square or
octagonal head bolts. Sucha wrench is shown in fig.handling
2.13.
11.BenchVice
used to clamp the material in its vice
It is for cutting
or threading
operations. For electrical Work generally bench vice is
used.
chine viceis used holding the item while they are being drilled. The ma-

Single-ended wrench

Double-ended wrench
Fig. 2.12
As the wrenches are generally made of cast steel, they are havino
less shock resistance capacity, therefore, they should never be used a8
hammers. Application of too much pressure should always be avoided Fig. 2.14. Bench vice
In case of adjustable wrenches, proper grease should be applied on jaw. It should not be used as base for hammering.
spindles. 12. Centre Punch
10. Pipe Wrenches When a hole is to be drilled in metals, the centre punch is usually
For connecting or disconnecting the rigid conduits pipe wrenches used for making a starting hole. It is usually made of high grade tool
are required. A pipe wrench which can handle a conduit upto dia of 35 steel hardened at both ends as shown in fig. 2.15.
mm is sufficient.
Conduit

Fig. 2.15. Centre Punch

13. Pocket Knife
tools in the work
The pocket knife is also one of the most important
removing insulation from the wires.
er's tool kit. It is generally used for steel. The closing type
Spring The knife must be made from high grade cutlery
Jaws on' bite" made from a bro
knife should always be preferred, although a knife
Of
(a) Pipe Wrenches ken hacksaw blade can serve the purpOse well.

Fig. 2.16. Pocket Knife

(b) Adjustable wrench
Fig. 2.13 14.Wooden Saw with wooden casing
capping or batten
The house wiring is also done
 Commissioning& Maintenance of Electrical
150
Instaliation,

Acraneis a hoisting machinery with the help of which heavy loata

EqUoe n Maintenance

Mobile Cranes
151

18. Cranes
honizontally. Today,
almost
every role Fig 2.22 shows a truck mounted crane The
former is used
every piantis
up and
are lifted
displaced
equipped

handing of matenials
with cranes. Cranes play very important

generally used :
worksho mobilityis of great importance and can move
even
Track
ground, while the latter is used
and mounted or crawler
should not be
quickly over smooth,where-
for slushy soils or
union
hard
ground.
cranes are moved on road otherwise road
Following types of surface will be damaged. The crawler Crane is
1. Stationarv cranes crawler belts. Cranes of this type are mounted upon endless
gantry cranes. travel speed is
from 16 km per hour tÏdriven by a diesel engine.
32 km per hour. The The
2. Overhead or different
3. Mobiie cranes cranes due to its parts of both the cranes are shown in the respective figures.
Gantry Cranes: These large
area, Overheed or fioor obstructions and three-way motion with electh
freedom trom
steel plants, ice
service
used in erection work, machine
drive is most widely
foundry, storage yards, power
houses
parts :
and big ships. factoies Sling
Boom Hoist Cable
main
It consists of two Hook Hoist Cable
() The Bridge
(ü)The troliey on the cratb
Cabin

-Crab
Track Mounted Crane Mounting
(Crawler Cranc)

Bndge
Fig. 2.22
Hoisting Cable
Gantry
Power
Control Boom
Cabin Hook
Unt

Fig. 2.21. Overhead Crane

The bridge consists of two main girders fixed at their ends to the
end carriages which are supported on tram wheels and capable of mov
Fig. 2.23. Truck Mounted Crane
ing on gantry rails. The movement is provid ed through a long shaft span mobile crane is the steam crane. It can have wheels
ning the whole bridge and geared to tram wheels at the two ends. An Another type of
wagon type wheels so that it can run
electric motor drives the shaft. (Snpie) to run on road or railway
medium of power and the steam is pro
The crab consists of a hoisting gear mounted on a frame. The ifa On railway gauge. Steam is the
to the boom to serve as
is mounted on another set of wheels and can travel
across tne mia duced in a boiler which is provided opposite jib and the load lifted in
of the
girders In this way three movement can be provided to the load noon vounterweight. It balances the moments
and each movenment is independently controlled. The the hook for hoisting.
(1) Hoisting movements
19. Standard wire gauge (S.W.G) British is standard wire gauge. The
(u) Cross traversing with Crab commonly used in used for deter-
e gauge instrument which is
(uu) Longitudinal traversing with the standard wire gauge (S.W.G) is an
The control cabin is fitted bridge.
usually under the bridge at one end.
 Installaion, Commissioning&Maintenance of Electrical quwpme
Maintenance
153
gauge commonly used
The wireconsists of a thin circularin
152

size of a
mining the standard
British
cable.
on
It
wire gauge. circumference as shown in
its numbers. Holes are provided
\ndian
Figpl. ate
o
Precautionsin Handling the Tools
Great caution and care are acquired in handling tools. A
worker is
the slots
number of ditfterent
steel witha marked with al he223 liable to time himself
injure
is
in addition to the
slacked in
damage caused to the tools, if
he, at any in the handling ofhandling
easily. them. The following are the safety
Each slot is removing the wires particular slot precautions tools:
slot for of a wire,
a is
end of eachdetermining the gaugejust slides is the slot of the found The sharp edged tools such as pocket knife,
awi should never be put in pocket without shield,chisels,
For
in whichthe
wire
trial. The slotmarked opposite tothe slot is the
required gauge
gauge of he ang
scratching
and while working
slides in slot No.20 and wite with such tools, care should be taken not to place hand or
finger
the numberNow suppose a wire just
in S.WG. Then the gauge
of the wire is said to be
diameter of 0.0048"20
does
no in the path of motions of the cutting tool. Also care should be
slide in slot No. 21.
40 with a SW.G
and the
taken not to hand over the sharp-edged tools with its sharp edge
gauge number is seven-zero) and written as first.
The smallest 7/0
largest is 0,000,000 (known as
should be noted
that higher the number of wirelwitha When cutting with a chisel, always cut away from you rather
diameter of 0.50. It than towards yourself.
the diameter. 2 Before using a hammer, its handle must be examined, whether
gauge, smaller is
it is properly secured or not.
4. When making a cut with a saw, the cut must be guided with a
6 finger and thumb of one hand, otherwise the blade is liable to
brake which may cause serious injuries.
5. After using tools, they should never be left at the top of the
ladder or any other place since they may fall accidentally and
33 O cause injury.
2 6. Only a suitable tool should be used for the proper purpose and if
32 aparticular tool does not suit the purpose, do not abuse the
STANDARD tool, try to have a new tool matching the need.
WIRE GAUGE 7. All injuries must be attended to immediately, since delay may
cause infection.
63025262G The list of remaining tools used for maintenance work is given below:
1. Pocker 2. Wedge
3. Soldering iron 4. Straight edge
Fig. 2.23. Standard wire gauge (S.W.G.) 6. One meter folding rule
5. Try square
The conductor used in a cable is either of copper or aluminium. The 7. Line tester 8. Electrician knife
size of a copper conductor is found by any one of the above three mer 10. Mallet
9. Plumb Bob.
tioned methods. However, the size of a conductor of a aluminium cabie
is not measured in S.W.G. It is either measured according to 11. Measuring tape
the coss
sectional area mm or by the number and diameter of wires. List of accesseries required for maintenance work:
If a stranded cable is of 7I22, it means that
the conductor 1S e 1. Nuts, bolts, washers.
of copper and there are seven strands in a copper and tinned lead).
cable 2. Fuse wire of different rating (Tinned
Similarly., it a conductor of aluminium cable has a each of 22 o area
cross-sectional copper material of different gauges.
of 25 mm², it can O. Super enamelled winding wire of
have a 712.24 strands in a
has
and each strand 4. Rubber gloves.
sectional area of 4 mm?. cable
5. Thimbles.
6. PVCVIR cable of different sizes.
 Conmissioning& Maintenance of Electrical

154
installaion,

terminals.
Equçme Maintenance

S.No. Weekly
155

7. Lead
for Maintenance and Check Programme of
8. Varnish.
Electric Motors
9. Sand paper Surrounding Care should be taken that amount of unusual
1. dust,
10. Relays. dripping water, acids, fumes may not enter the motor.
of starters. rating. Any board cover, canvas should not be left open to
11.Contacts capacitors of different avoid the hindrance to the ventillation or jam mov
12. Electrolyte ing parts.
13. Ball beaning. carrier of different sizes. Sleeve Bearings, The level of oil should be checked with oil guage
Cartridge fuse andfuse different ratings.
2 Motor Lubrication, etc. and if the level is down, complete it to the guage
14.
Double pole iron clad switch of ratings. line level.Check the bearing housings, if dry, then
15.
cladswitch of different oil them. Creeping of oil along the shaft towards
16.Triple pole ironoutlet and plugs. winding should be avoided.
17. Spare socket Ball Bearings The bearings should be checked for noise, oil them
18. Lamp holders. 3
little, add grease in the housings or replace hem.
19. Solder wire.
4
Brushes and When there is sparking note the colour and condi
20. Grease. Commutator or rings tion of the commutator and brushes. The pigtail of
21. Embry paper. the brushes for loose connection should also be
different sizes. checked. The surface of commutator should be
22. Carbon Brushes of
smoothened with the help of sand paper. Clean the
23. Pulleys. segments of commutator with the help of cleaning
24. Handles for starters. stick.
25. Starter coils Rotors and Armature
5. The uniformity of air gap in the motor should be
26. Lubricating oil checked in which the sleeve bearings are used.
Maintenance Schedule of Electric Motors If the dust particles are observed in the winding.
6 Windings
blow it with blower. Clean the dust with dry cloth.
S.No. Daity Maintenarnce and check Programme Note for the moisture contents in the winding. If
of Electric Motor
noticed,dry them up.
1. Earthing of Inspect and tighten if necessery Mechanical Condition Sometimes there is unusual noise is heard from
7
Power connections motor due to metal to metal contact or scorching
2 ControlGear Inspect fuses and Relay settings. varnish insulation. Stop the motor and check it and
3 remove the defects.
Temperature of Look out for over heating
winding 8 Mechanical Inspection Check the belt for suitable slackness and good
4
Bearing Surface condition. The gears should be checked
Look out for over heating.
5. for wear and tear. The controlling devices should
Lubricants Check lubricating system. be checked thoroughly.
6 Vibrations Watchout for excessive vibrations.
Monthly/Quarterly
insulation. It
1 Check the windings for their proper
Windings should be tested for insulation
short
resistance,
leakage. Moisture contents should
circuit and earth or
also be checked.
Contd..
 Maintenance of
Commissioning& ElectrIcal
156
Installation,
brushesfor their proper Equpmet Maintenance
157

sp(irtiinnggs pandresSurrea
Cheçkthe Maintenance Schedule of
2.
Brushes playinthe
brush holders. Brush
noticed. Worn out brushes
Synchronous Motor
should be Maintenance of synchronous machine may be
alternatorfor trouble
or synchro-
replaced.
Commutator surface
should be
Scratches examined
shoud t nous motoris'must' and can be termed as an insurance
performance of the equipment.
free

Commutator high bar, and \or hg Maintenance is also essential for the
3 mica and
mutator surface
should be roughness.
smoothened
longer life of electrical ma-
chinery.Thefollowing are main points required for the maintenance schedule
help of emery paper. wiih the of synchronous machines.
Check the bearingfor wearneSS, end 1. General : The machines should be stopped and isolated from all
Sleeve bearings
surtace. If dirt or sludge is observed inplaIheytheandbea.t
flusheddout with
supplies before any maintenance work is done.
ing, it should be lighter ol
refilling with grease.
betore The frequency of maintenance required depends to a large extent
uponthe site conditions. Frequent maintenance (say, oncea week) should
Theleakage of grease or oilIfrom thee
5 Ballor roller bearings
be observed. If the leakage is noticed. bear,clineganshousit. be
practical at first and the period extended as experience is gained.
Cleaning : The unit should be periodically cleaned internally by
Couplings and other Sometimes the belt becomes loose, adjust it. blowing out with a jet of dry air and by wiping away any deposits of
6
Drives grease and carbon dust with a clean dry cloth. At less frequent intervals
Oilin the gear boX should be checked for should be checked to ensure that they are tight.
7 Enclosed gears
for the flow for the presence of sand,
the tloH all nuts and
ScrewS

metal scale. If the oil is not found in good

water or 2 Brushes:The brushes should be examined initially after every
drain it out, flush and refill it. condition, 400 Hrs., running to see that they are bedding properly. Care must be
conditions token to see that the brush hoBders are not allowed to touch the sur
Changing load should be
8 Loads
observed
controlling devices troubles, poor handlings
i.e.
or wron faces of sliprings.
adjustments. The brushes should be replaced when they wear down to within 3 mm
of their Support arms.
HalfYearly/Nearly New brushes should be bedded by using 'fine' Carborundum cloth or
1. Windings Check the windings for insulation resistance, dy if not available fine' sand paper. Emery cloth should not be used.
cracks of insulation. If needed, dry out winding, The Carborundum (or sand paper) should be placed between the
clean it, varnish it and bake it. brushes and sliprings with rough side facing the brushes and then hold
drawn
ing one end of the cloth, rotate the armature. The cloth should be
2 Squirrel Cage Broken or loose bars of rotor should be observed
backwards and forwards with several strokes in the direction of rotation
Rotor thoroughly. Set them properly or get it soldered
only, lifting the brushes for return strokes. After bedding thoroughly clean
welded if needed.
3 Wound Rotor Collector, washers and connections should be with a jet of dry air and a clean dry cloth.
checked. If there are spots on the rings or if they a
are found rough or eccentric, get them turned on 4. Slip Rings : During normal running the sliprings should have
wear. If it is
the lathe. dark bumished appearance free from grooving and uneven
4 essential to skim the slipring, the brushes must be rebedded.
Armature stator Check the stator for open, short earth or leakage grease at works, and
fault. Insulation resistance should also be checked. 3. Bearings:The bearings are charged with hours of running. Do
ne bearing should be recharged after every 3,000
Lamination cores should be checked for its coro bearings. Periodically
5 Air Gap
SIon or loOseness, clean or tighten them propey not mix different grades of grease, or over fill the
Uniformity of air gap should be observed. clean and recharge the bearings.
6
Mechanical parts for lubricating the synchronous
The inside and outside of frames and belts should O. Ol Leakage: It may be noted
excessive oiling or insufficient lubrica
be checked the
rotor should be observed for its aunine it should be neither be
rubbing or misalignment. Uon. The lubrication should be appropriate and periodic.
 Maintenance of
Commissioning & Electrical
158
Installation,
Special care must be taken thatthere should not be any type Eqipme Maintenance
159

results into breakdown of Motor runs high speed. (a) Voltage available is (a) Ensure rated
on the stator. This he more than rated volt
leakage of oil
winding insulation.
insulationtemperature
and slaoN voltage.
age.

body (b) Load is too less.

7. Temperature : The
frequently. It should
must be recorded smoothiy.
that machine can
run
be within permissible
termperatIre (c) Shunt field coil is
(b) Increase the load or

(c)
put fixed resistance
in armature circuit.

D.C. Motors shorted. Replace it by new

Trouble shooting in coil.

S. No. Trouble
Causes
Remedial measures
(a)
(d) Shunt field coil is
reversed.
(d) Connect the coils
correctly.
Fail to start.
(a) Circuit open. Repairthe broken Motor does not slow (a) Unstable speed re-(a) Ensure that
1
leads
Switch.
or faulty 5
down due to increase gulation.
neutral
is available series
in load. field is required to
(b) Brushes are not (b) Adjust the springs.
in be checked for
making contact case, brushes are
with commutator. shorts, if so take
Worn OUt replace remedial measures.
them.
(c) Replace/Repair the Motor runs very slow. (a) Low voltage. (a) Check for correct
(c) Bearing is siezed. 6.
voltage.
bearing. (b) Over loaded. (b) Check bearings.
(d) Current is not (d) Check starter. check for excessive
available.
load.
2. On starting. it starts, Reverse polarity of D.C. Check generator for the (c) Armature bars (c) Get the motor re
then changes direction supply. reason of changing pola short. pair shop.
of its rotation. rity. 7. Motor runs very hot. (a) It is over loaded (a) Reduce load by re
3 Motor does not pick up(a) Over load (a) Inspect bearing to and drawing more ducing speed.
rated speed. ensure they are Current.
0.K. (b) Ventilation is defec- (b) Check up the venti
Check the load and tive. lation.
ensure it is within (c) Shorted coils. (c) Repair the windings.
the capacity of the (a) Voltage is more (a) Ensure correct volt
motor.
8 Field winding get hot.
than rated. age.
(b) Voltage low (b) Check the voltage. (b) Ventilation defec (b) Remove the restric
(c) Starting resistance (c) Starter needsthro tive. tions which are re
has not been com ugh checking. sponsible for bad
pletely cut out. ventilation.
(d) Armature winding (d) In case winding coils (a) In-correct neutral. (a) Correct the neutral
bars short circuit
9 Brushes are sparking. according to manu
found burnt commu
ed.
tator bars are found facture's setting.
black motor should (b) Shorted commuta- (b) Repair the coils.
be taken to repair ting pole turns.
shop. (c) Open circuited (c) Repair the coils.
(e) Neutral not avail (e) Test the motor tor coils.
able. Resolder them pro
tråe neutral.
(d) Poor soldered con- (d)
Contd. nections. perly.
Contd...
 &Maintenance of
Installation. Commissioning Electrical Maintenance
160

Brush are getting won

(a) Brushes too
soft. (a)
Replace
Equpmerty PFaultsin Synchronous Motor
161

shes with he(herecom.

10.
out very fast.
of brushes
bru Faults Causes
grate S. No.
Motor fails to start (a) Wrong connection. (a)
Remedial measures
mended by he 1. Check and correct
(b) Commutator is
found to be rough.
(b) manutacturer.
Grind its face. (b) More friction.
(c) Low voltage.
them.
(b) Check alignment.
(c) Reduce impedance
(c) Moisture. (c)
Protect the
from moisturemotoror (d) Wrong direction of (d)
of external circuit.

rotation. Interchange any

replace it by en. two leads.
closed motor,if situ. 2
Motor trips the circuit (a) Exciter circuit open| (a) Test with meggar
ation warrants. breaker for continuity.
11. (1) Unusual vibration (a) Mis-alignment. (a) Re-align. (b) Field short cir (b) Test the polarity.
(b) Tighten/correct the cuited.
which may indicate (b) Pully eccentric or
unbalance. loose. pully on shaft. 3
Motor does not have (a) Motor may be over- (a) Reduce load.
(c) Bent shaft. (c) Either straighten the proper speed loaded.
shaft or replace it. (b) Field may be over- (b) Examine the field.
(d) Foundation in cor (d) Add shims and level excited.
rect. the foundations. Motor is hunting (a) Fluctuating load on (a) Adjust field current.
4
(a) Brush singing and (a) Brush angle is re the motor.
(2) Giving unusual
noise. or chattering. quired to be Starter not working (a) Open circuited (a) Check and correct
5
checked, re-sur phase. it.
face the commuta
tor and brush. Maintenance Schedule of Transformer upto 1000 kVA
(b) Mounting is loose. (b) Tighten foundation Frequency of Inspection Inspection Action required
bolts. S.No. when conditions
inspection details
(c) Lamination of ar are unsatistac
(c) Replace the core.
mature are loose. tory
(d) Armature is rub (d) Re-align the rotor. starts fans if nece
bing the pole faces. 1 Hourly Load (Amp) tem-Check against
perature, voltage rated figure Ssary
(e) Mechanical vibra (e) Find the causes Check that air pas- It silica gel is pink
tion including noisy and take remedial 2 Daily Dehydrating sages are clear change it or reaci
breather
bearing. measure. Regard check colour of vate it for use again.
ing bearing refer to acting agent
the maintenance ol
transformer Iflow add dry oil, exa
bearings. Monthly Oillevel in trans-Check mine the transformer
formers oil level.
for leads.

Examine for cracks

Clean or replace
4 Bushings
Quarterly and dirt deposits Improve ventilation
Check for moisture
5 Conservator check ol.
Half yearly COver
Contd.
 Maintenance of
Commissioning & Electrical Maintenance 163

162
Installation,

Check tor dielectric| Take

Equpme Quarterly (a) Bushings Examine for cracks Clean or replace
(a) Oilin strength and water to suitable and direct deposits
Yearly transformer content, oil.restore
6 check for
acidity and sluge. qualtya (b) Oil in Check for dielectric Take suitable action
transformer strength and water
Contents
to restore quantity
of oil.
(b) Earth resist Take
if
sutable acuan (c) Cooler fan Lubricate bearings. Replace burnt
Yearly ance
Examinerelay,
(c) Relay,alarms alaram contacts,
resisttheancecompo.is hioh
Clean
bearing
motors and
check gear box,
examine contacts,
or worn contacts
of other parts.
Yearly and their nents and replaca operating check manual con
circuits etc. their operation
fuses etc., check contactsS and fuses
if necessary, charge
mechanism
Oil cooler
trols and interlocks.
Test for pressure
Halfyearly
relay accuracy etc. setting i i
7 Two yearly
Non-conservator| Internal inspection
above core. of condition.
neces ary,.
Filter oil regardless
4

5
Yearlyor
earlierif
(a) Oil in
transformer
(b) Oil filled
Check for acidity
Test oil
Filter or replace
and sluge
do -
transformers transformer
Overall inspection Wash by hoSino can conve bushings
8 Five yearly lifting of core and down with clean nientlybe
or after inter dry oil. (c) Gasket Tighten the bolts
coils taken out
nal fault to avoid uneven
for checking joints
pressure.
Above 1000 KVA
(a) Ambient Check that temper-| If abnormal heatinn () Cable Check for ceiling Replace gaskets
1 Hourly temperature ature is reasonable shuttdownthe trans- boxes arrangement for if leaking.
former and investi. fitting holes, exa
(b) winding gate if heating is mine compound
temperature presistent higher for leaks.
than normal. (e) Surge Examine for crack Clean or replace.
(c) Oil -do -do divertor and and dirt deposit.
temperature gaps
(o) Load Check against Examine relay and Clean the compo
(9 Relays, nents and replace
(Amp.) voltagerated figures. alarm alarm contacts,
Contacts and fuses
2 Daily (a) Oil level in Check against If low add dry oil, and their their operation,
examine circuits etc. fuses etc., check if necessary. Change
transformer transformer oil
level. transformer for relay accuracy etc. the setting if nece
Ssary.
leaks. Take suitable action
(b) Oil level in (g) Earth
if it is high.
bushings resistance
Wash by hosing
(c) Leakage of 1000 to
Overall inspection
water into 6 5yearly down with clean dry
3000 KVA including lifting of
Cooler core coils. coils.
(d) Relief Replace if cracked
diaphragm or broken.
(e) Silica jel Check that air If silica jel ispink SUMMARY
breather passages are free. change it by active
Check colour of spare charge and and
1. Maintenance machinery in a proper
active agent. the old charge may any equipment or
Il is the process for maintaining maintenance vary with the type of
be reactivated for details may
elficient periodic
further use.
condition. The
machine and its working conditions.
Contd.
 Maintenance of
Commissioning & Electrical
164
Installation,

Fundamentalof Maintenance activities required to keep

Equipme Maintenance

(a) Voltmeter with Switch:Voltmeter with switch is used to find out voltage be-
165

definedasthose meet specifications. the

2 Maintenance
operating
can
condition
be
sothatit
continuesto
plant or
sto
equipment is
availablo Thus, Maeqnupmelena nea
for use at
tween main phases and between phase and neutral at the
(b) Asmall switch board fitted with various sizes of lamp holders supplyand
outletsincluding fluorescent lighting fittings, into which other
point.socket

ensuresthat
cOst. for
the production
scheduled hours.
equipmentsare used an
in organisation, minimun such as choke coil, starter, switch may be connected, for testingcomponents
with two insulated test
two flexible
lamps. These may be used for continuity and

manullaicnlvuorlevresst
number of equipments used. Most of leads
Since alarge of the insulation test.
the equipmentfor
maintenance
offer after-sales service to their Customers, which can be dass.
sOund policy (c) An oven provided with a ventilated fan and preferably heated electrically
underhand or thermostatically control for drying out machine and
fied as follows other appa-
Maintenance ratus.
Preventive
Advantages of various machines and (o) Infra-red lamps may be Used for heating in place of resistance heaters or
3
1. It prevents
unscheduled interruption to
premature failures.
equipmens ang steam pipe heating.
can be used for testing the armature of the motor, repulsion type
2. It makes an effective use of systematic maintenance and inspection \o deter-
(e) Prawler
motor, series ACand universal motors.
mine the need for minor and major repairs.
toa minimum.
I Alow voltage supply troma car battery can be used through a switch and
breakdown
3. It reduces wariable resistance for making voltage drop test on armature.
machines and other equipments at Iou.
4. Satistactory maintenance of (g) A meggar for measuring earth resistance upto 100 2.
5. It helps to plan flexibility in operation dueto accurate knowledge of machinery
(h An eath fault loop tester for impedance tests of earthing circuits.
conditions. à Aclip-onmultirange ammeter, a double range ac voltmeter. dc voltmeter and
and other equipments. multirange dc ammeter are also Usedfor maintenance work.
6. It lowers wear and tear of machine
7. It makes working condition better. Ih Astrongtorch is used specially fitted with a terminal or socket output for
8. It increases the life of the machine. simple continuity test and testing fuses etc. Other essential items are : Neon
9. Less standby equipment is needed.
tester, speed counte, stop watch, tachometer, small magnifying glass &
mirror, portable vacuum cleaner and blower, electrical soldering iron of 300
10. Provide greater safety and proetction to the workers. W rating.
4, Classification of Preventive maintenance
7. Commonly used Tools for Maintenance
1. Routine maintenance. It should be carried out daily. It includes visual inspec. The generally tools required for maintenance work are:Screw Driver, combina
tion, minor repairs such as replacement of small parts and adjustment d tion plier, spanne, Hammer, Hexa, Files, Chisel, Vice, Drilling machine etc.
equipment,so that it remains in operation. Maintenance Schedule of Motors
8
2. Periodic Maintenance. It should be carried out weekly, fortnightly, monthly, () To inspect the earthing of power connection.
quarterly or half yearly depending upon the requirements and condition of the
machine. It includes inspection of loose parts, ventilation, replacement o (i) To check control gears.
worn parts,change of oil, checking of insulation etc. (i) Inspection of bearing.
3. Overthaul. If consists of replacement or renewal of (iv) Lubrication of various parts of motor.
the main units, assemblies
and parts of electrical equipment. Generally, it is carried out (v) Tocheck commutator and brushes.
It involves such work as rewinding of motor on yearly bass.
stator and rotor, replacemento SHORT ANSWERQUESTIONS
bushing of high voltage circuit breakers etc.
5. Breakdown Maintenance
Breakdown maintenance is carried out as and 1.
Maintenance of equipment is necessery. why ?
6. when necessary.
List of
Commonly used Instruments for Why it is necessarv to keep the record fo all maintenance?
The instruments
required in electrical Maintenance department will largely yde-
3. Wnen the preventive maintenance is needed ?
pend upon the repair
are available to work to be done. In maintenance
most of industries sufficienti instruments
4
Whyperiodic inspection is necessary
enable the staff to carryout 5
testing and minor repairs.
The What is to be checked in routine maintenance ?
lault. Thegenerally determine the of maintenance
condition plant and help in early
following instrunments are detection of any
generally used for maintenance in industry