 Wear and tear

 Loose Connection
 Harmonics Problem
 Overloading
 Unbalance Loading
 Transformer Oil Impurities
 Corrosion
 Location is Extremely Hot/Temperature
Consideration
 Unqualified Personnel Operating The
System
 Lack of Preventive Maintenance
 Force Majeure
 Initial data gathering
THERMOGRAPHY
 What is Thermography?

 All objects of which the absolute temperature is greater than 0°K

radiates infrared rays. The amount of radiation depends on the
temperature (the amount of infrared rays is proportional to the forth
power of the temperature raise.

 Thermography is a device to measure the temperature and the

distribution by using this law. It consists of camera part and the
processor part. The sensor in the camera detects the amount of
infrared rays radiated from the object, converts it to electrical signal
and transmits to the processor. The processor converts these signals
to temperature information and displays the temperature
distribution distinguished by using different colors. Then the
temperature at a certain point on the monitor can be read directly by
numeric values.

 Simply saying that thermography is a device with utilizing infrared

rays displays the area of a high temperature in a red and the area of
low temperature in blue.
 Features of Thermal Scanner:

 a. Non-contact Measurement
It is able to measure the temperature at the place apart from the object without
contact to it.

 b. Passive Measurement
Because it only receives infrared rays radiated by the object, it does not provide any
damage or disturbance to the object.

 c. Area Measurement
Unlike point measurement of thermoelectric couple or radioactive thermometer, it
can measure on wide area as two dimensional information.

 d. Real Time Measurement

Unlike thermoelectric couple of slow response, it can measure precisely the
temperature changes quickly and the temperature of the object moving.

 e. Easy recording and analysis

The thermal image can be recorded easily onto and accessed from the unit itself. The
data can be precisely analyzed in the computer using its program.
 Why need the diagnosis during operation?

 For the diagnosis of operating facilities,

thermography has become a necessity to be use
quite often. Because the measurement of
thermography is non-contact and the operation is
very simple, it is very easy to repeat the checkout
of specific area as many as necessary. The
characteristic data can be managed easily by
evaluating the secular changes of the facilities. The
data are useful for early detection of malfunctioned
area. The improvement of availability of facilities
and making maintenance plan easier.
 Electrical Data Logging

 Load Studies-Verify electrical system capacity before

adding loads.

 Energy Assessment-Quantify energy consumption

before and after improvements to justify energy
saving devices.

 Harmonics Measurements-Uncover harmonics issues

that can damage or disrupt critical equipment.

 Voltage Event Capture-Monitor for dips and swells

that cause spurious resets or nuisance circuit breaker
tripping.
FEATURES :

 Record power and associated parameter up to 45 days.

 Monitor maximum power demand over user defined averaging periods.

 Prove the benefits efficiency improves with energy consumption test.

 Measure harmonics distortion caused by electronic loads.

 Easily confirm instrument setup with color display of waveforms and

tends.

 Measure all the three phases and neutral with included 4 flexible current
probes.

 View graphs and generate reports with included power log software.
 Step3.
Active Preventive
Maintenance
( Tobe performed during Scheduled
Shut down)
A. TRANSFORMER

Testing Standard
1.TURN RATIO TEST

Turns Ratio Test

Winding Terminals Tap Expected As Found Percent Remarks
Ratio Ratio Diff. ( % ) Limits ± 0.5%
H1H2 - X1XO 129.90 129.7800 0.0925 Passed
H2H3 - X2XO 129.90 130.0200 -0.0923 Passed
H3H1 - X3XO 129.90 129.9500 -0.0385 Passed
2. Insulation Resistance Test

Insulation Resistance Test ( MEGGER )

Primary to Ground Primary to Secondary Secondary to Ground
Time Test Voltage = 5000 V Test Voltage = 5000 V Test Voltage = 1000 V
RDG's in Mega - Ohms RDG's in Mega - Ohms RDG's in Mega - Ohms
1 min 10300 13200 2000
Limits
( RDG > ) > 829 M-Ohms > 829 M-Ohms > 11 M-Ohms
Remarks Passed Passed Passed
3.Winding Resistance Test
Winding Resistance Test ( DLRO )
Winding Terminals Tap Readings Primary in Ohms Difference w/ the two Remarks
Secondary in Milli-ohms Windings ( Percent ) Limits ± 5%
H1H2 10.780 1.206 -0.093 Passed
H2H3 10.650 -1.221 -1.315 Passed
H3H1 10.790 0.093 1.297 Passed
X1XO 0.59 -3.792 -2.797 Passed
X2XO 0.61 2.721 -0.967 Passed
X3XO 0.62 0.958 3.653 Passed
SPECIAL TESTING

 1. IPF ( Insulation Power Factor )

 2. Oil Analysis ( Dissolved Gas Analysis )
B. HIGH VOLTAGE SWITCH GEAR

 Perform Electrical Insulation Test.

 Perform Contact Resistance Test (Ducter).
 Perform re-tightening of termination, load
and line side.
 Perform functional check on mechanical
linkages and apply contact cleaner if needed.
 Perform Vacuum Cleaning on the whole
equipment compartment.
 Establish visible marking on the tightened
bolt.
C. LOW VOLTAGE SWITCH

 Perform electrical insulation test on circuit breakers.

 Perform contact resistance test (Ducter) on circuit
breakers.
 Perform functional check on operational test on all
circuit breakers electrical circuit.
 Perform functional check on indicator lamps and
accessories.
 Perform re-tightening of termination, load and line
side.
 Perform functional check on mechanical linkages and
apply grease if needed.
 Perform Vacuum Cleaning on the whole equipment
compartment.
 Establish visible marking on the tightened bolt.
 Perform purging/cleaning using high pressure
nitrogen
D. CAPACITOR BANK

1.CAPACITANCE TEST

 Capacitance Reading

 Any reading with Less than 10% from ( rated

capacity+-5% tolerance ) is considered Derated.

 Any reading with Less than 20% from ( rated+-5%

tolerance ) is considered Defective.
2. Ampere Reading

 Rated Current reading (10% less +-5% rated

capacity) depending on the actual voltage is
considered derated.

 Rated Current reading (20% less +-5% rated

capacity) depending on the actual voltage is
considered defective.
E. VFD / SOFT STARTER

 Check electrical connections and re-torque as

needed. If possible, perform an IR thermal scan of the
VFD’s power input and power output.

 Check line voltage

 Check motor & output phase balance

 Inspect DC buss capacitors (older drives)

 Record the VFD’s parameter settings using

 Confirm the VFD doors and covers are in place and

properly closed
F. ATS / MTS
1.Visually inspect the following:
A. Cabinet Integrity
B. Internal Sub-Assemblies
C. Wiring Harnesses
D. Breakers
E. Contactors
F. Cables
G. Other Major Components.

2.Perform temperature checks of all electrical power connections.

3. Verify proper annunciation of all indicator lamps and/or status

screens.

4. Measure and record:

A. Input Voltage (phase to phase and phase to neutral)
B. Input Current (phase to phase and phase to neutral)
C. Output Voltage (phase to phase and phase to neutral)
D. Output Current (phase to phase and phase to neutral)
5. Verify unit display is within 2% of those measured.

6. Clean interior and exterior of unit.

7. With customer’s permission, transfer unit to alternate source and

verify proper operation.

8. Verify/calibrate system settings to factory specifications.

9. Transfer system back to normal source and verify proper operation.

Notes: ƒCertain preventative maintenance functions may require a

shutdown if no external bypass is installed. ƒCertain preventive
maintenance functions are not applicable to all makes or models. ƒ
Preventive Maintenance Inspection Reports are mailed and emailed
within 10 business days from date of inspection.
G. GENSET

COOLING SYSTEM

1. Engine coolant level.

2. Radiator core/heat exchanger.

3.Coolant lines/connections/hoses
& connections.

4. Water jacket heater(s).

D.C. ELECTRICAL SYSTEM

1. Battery(s) electrolyte level/specific gravity

2. Battery compartment/heater cooperation

3. Battery connections/cables/casing

4. Shutdown mechanisms

5. Electrical starter/alternator generator

6. Electrical system, accessories & components

A.C. ELECTRICAL SYSTEM

1. A.C. wiring

2. Battery charger

3. Control panel/switchgear

4. A.C. generator voltage regulator

5. Electrical system accessories & components

AIR INDUCTION & EXHAUST SYSTEM

1. Air cleaner units/oil bath and dry type

2. Air induction piping and connections

3. Turbocharger/blower

4. Exhaust manifold/piping/connections
POWER UNIT

 1. Generator structure

 2. Clutch assembly (power take off)

 3. Coupling(s)
LUBRICATION SYSTEM

1.Engine oil level

2. Engine oil change
3. Engine oil filter change
4. Engine oil sample for analysis
5. Crankcase pressure
6. Crankcase breather
7. Oil leaks (hoses, connectors)
8. Engine governor oil level/linkage (UG8)
9. Fan drive bearings
10. Generator bearings
11. Engine starter oiler (air type only)
12. Gauges and safety mechanism
13. Accessory drives
FUEL SYSTEM

1.Fuel tank/day tank

2. Fuel filters-primary/secondary

3. Fuel system components/hoses/piping

4. Gauges and Safety mechanism

5. Condensation/water in fuel
 Retightening of loose connections to required
torque.
(Finding from thermographic shows
“HOT SPOTs” to be retighten)

 Replacement of protective equipment's such

as Circuit Breaker, Contractor, etc…

 Cleaning Nitrogen Purging.

 Application of contact cleaner

 Power Factor Correction
 P.F. Correction is the process of improving
the rated Power Factor of an electric system
by installing capacitive devices such as;

 Power Capacitor
 Synchronous motors
Improving the electric systems Power Factor
will provide the following benefits..
1. Improve voltage regulation
2. Reduction of line losses
3. Optimized Transformer Capacity
4. Saving from utility bills
kVA kVAr

kW
 S = kVA or apparent power
 P = kW or useful power
 Q = kVAr or reactive power

Thus : Power Factor is the ratio between the

useful power and the apparent power or :
 kw / kVA = cos
 An ideal power factor is where

 Kw = kVA or

1 = Cos

 Means power factor = 100%

 To compute for the require capacitor kVAr
given the following :

 Present kW (kW)
 Present P.F. (p.f.1)
 Target P.F. (p.f.2)
 kVAr = kw { tan [ cos-1 (p.f.1) ] –
tan [ cos-1 (p.f.2)]}
 Given :

 Present kW = 2000
 Present P.F.1= 75 %
 Target P.F. 2 = 98 %
 kVAr = 2000 { tan [ cos-1(.75)] –
 tan [ cos-1(.98)]}

 = 2000{ [0.882] –[0.203] }

 = 2000{ 0.679}
 = 1358 kVAr
 1. Optimize Transformer Capacity

From : kw / kVA = cos

 Transformer rating = 1000kVa
 Power factor = 75 %
 Maximum operating kW = 1000 ( .75)
= 750kW
While :
If Power Factor is = 98 %
Operating kW = 1000 ( .98)
= 980kW
 Power utilities like Meralco provide
penalty for Power Factor lower than
85% and provide discount for Power
Factor Above 85% up to 95%
 Penalty = 14% (0.85 – P.F. lower than 85%)
(on distribution charge (kW)only)

 Discount = 7% ( 0.85 – P.F. above 85% up to

95%. (on distribution charge (kW) only)
 Total
Savings = Penalty reduction
+ discount
YES!
1. Over Compensation would result in higher
voltage that may reduce the life of lightings
and other loads sensitive to over voltage
2. Capacitor could amplify harmonics that may
cause exponential danger to the whole
electrical system ( to be discuss on
harmonics topic)
Harmonics Correction
 Harmonics are disturbances in the electrical
system. This is an effect of combining non
sinusoidal loads in a pure sinusoidal system

 Note : Harmonics is like a noise in a Hi Fi

sound system
 Any equipment operated by a DC power such
as but not limited to:
 Variable Speed Drives
Computers
Thyristor controlled rectifier
IGBT’s
Others
 An equipment that does not produce
harmonics but when introduce in a system
with harmonics amplify the harmonics
distortion to dangerous degree

 Capacitor
 Synchronous motors
As per IEEE 61000-2-4-9 ( Voltage THD)
Limit Type of Industry
Class 1: 5% 1. High Rise Bldg, Hotels
Restaurant, Light Industrial

Class 2: 8% 2. Medium Industrial

Class 3: 10% 3. Heavy Industrial
as per IEEE 519-1992 ( Current THD )
Class 1 : > 13% of Total Current
1. Increase Hysteresis Losses
2. Increase Stray Load in Winding
3. Nuisance tripping of Relays and
Circuit Breakers
4. Fast ageing of capacitor
5. Die electric Puncture
6. Overloading on Ground Conductor
7. Skin and proximity effects of conductors
8. Unusual transformer noise.
1. Increase EMI.
2. Malfunction of Electronics Devices.
3. Breakdown of Electronic Devices.
4. Generation of transient.
5. Increase Eddy Current Losses in motor
6. Torque Ripple of Motor ( DOL Start ).
7. Erratic operation of electronics
equipment.
a. Minimized Harmonics producing loads
b. Balance Loading
c. Segregate harmonics producing loads
d. Use inductive coils on capacitor
e. Use passive filter on capacitor (detuned filter )
g. Use active filter on capacitor ( highpass filter )
h. Use filter on the system
i. Use of 1.1 transformer in between harmonics
producer and other loads.
 What is th effect of Harmonics on Capacitor?

Internal Stress, Causing Dieelectric Failure,

Resulting in faster “ageing”.
Note : Capacitor does not produce harmonics.
1. Capacitor only amplify harmonics
thus, making it more dangerous to
the system.

Note : Because a normal system normally has

Inductive (L) and Resistive (R) loads.
Adding Capacitor (C), will make it an
RLC Circuit will create a resonance
( amplifier )
1. Increase in Harmonics Distortion
2. More over heating
3. More equipment malfunction
4. Faster “ageing” of capacitor
5. More equipment breakdown
6. More nuisance tripping on relays and CB’s
7. More Eddy Current .......etc.
1. Over sizing of equipment
a. Allow distortion to flow
b. Dissipation of harmonics in the
form of heat.
c. Rate the system to handle harmonics
generation by oversizing cables,
equipment and protection device
2. Reduction of Harmonics
a. Minimized Harmonics producing loads
b. Balance Loading
c. Segregate harmonics producing loads
d. Use inductive coils on capacitor
e. Use passive filter on capacitor (detuned filter )
g. Use active filter on capacitor ( highpass filter )
h. Use filter on the system
i. Use of 1.1 transformer in between harmonics
producer and other loads.
1. Minimized flow of current.
2. Small Voltage drop on AC coil
3. Harmonics could still be amplified
4. Target power factor will be limited
( harmonics must not exceed IEEE limit )
1. Amplification effect of capacitor is limited.

2. Harmonics distortion will not effect the

capacitor.

3. Target power factor will be achieve without

worry.

4. No reduction of harmonics on the whole

system.
1. Reduction of Harmonics

2. Total system harmonics distortion will be

minimized.

3. Target Power Factor will be achieved

without worry.

4. High price consideration.

1. Capacitor must also be protected from
voltage distortion.
2. Reactors will draw voltage drop upon
switching.
3. An over voltage back flow will still damage
the capacitor by a factor of 2 for every 5
volts above voltage limit.
4. Longer Capacitor Life.
5. Lower Capacitor Power.
1. Minimized heat cause by Harmonics
Distortion
2. Minimized heat cause by Harmonics
Correction
3. High ambient will reduce the life of
capacitor by a factor of 2 for every 5
degree. Higher than the normal rated
temperature.
4. Longer Capacitor Life.
1. Depends on Load
Classification.
2. Depends on harmonics limits
imposition by the utility
company.
3. Depends on Load
Requirement.
4. Depends on target harmonics
limit by the user.
 Less equipment breakdown.
 Less maintenance cost
 Lower electric consumption
 Savings on capacitor
 Better voltage regulation
 Reduced line losses
 Better transformer capacity
 Longer life of equipment and protective
devices.