GENERAL MAINTENANCE

What is Maintenance and why at all we require Maintenance ?

So, Maintenance is nothing but a process of keeping any equipment,

building or machine etc. in perfectly healthy condition by checking it, repairing it
regularly.

Maintenance is required for following purposes:-

■ Reliability of a System.
■ Enhancing Equipment Life.
■ Safety of the System and Work Force.
■ To get Optimum Output from the Equipment.
 TYPES OF MAINTENANCE
■ Preventive Maintenance - This type of Maintenance is also
called Plant Maintenance. This type of
Maintenance involved Preparation and
Adherence to the Maintenance
Schedule also known as Preventive
Maintenance Schedule or Annual
Maintenance Schedule. In Preventive
Maintenance prior information can be
send to consumer ahead of Planned
Shut-Down to carry out Maintenance
Work.
■ Predictive Maintenance - Predictive Maintenance is done if any
visible defects are seen in the
Equipment e.g. Leakage of Oil from
Transformer, Some Loose Connection
producing a Hot Spot etc. This type of
Maintenance is carried out only when
Preventive Maintenance is not done or
due to Un-reliable/Old Equipment
requiring frequent maintenance.
■ Break-Down Maintenance - As the name suggest this type of
Maintenance is carried out in the
event of failure of equipment. Non-
adherence to Preventive Maintenance
Schedule leads to Break-Down
Maintenance.
 CONT………….
• Maintenance Maintenance

technologies;-
Planned Maintenance Unplanned Maintenance

Scheduled Condition
Based Emergency
Maintenance

Preventive
Maintenance Corrective
Downtime
No Deferrable
downtime
Downtime
 CONT…….
• A well organized and implemented program minimizes
accidents, reduces unplanned shutdowns, and
lengthens the mean time between failures (MTBF) of
equipment.

• Benefits of Preventive Maintenance(PM) can be

categorized as direct and indirect.

• Direct benefits are derived from reduced cost of repairs,

reduced downtime of equipment, and improved safety of
personnel and property.

• Indirect benefits can be related to improved morale of

employees, better workmanship, increased productivity,
and the discovery of deficiencies in the system that were
either designed into the original system or by later
changes made in the system.
 CRITERIA FOR EFFECTIVE PM
 Program should have provisions to take effective
advantage of actual experience accumulated both
in the plant and elsewhere

 Should have provisions for failure analysis,

correction and recurrence control

 Should maintain a data base of all PM activities

 Should be performed by qualified personnel

Management should continuously monitor ,
reevaluate and make appropriate changes in response
to identified problems and advances in maintenance technologies
PREVENTIVE MAINTENANCE OF
ISOLATORS
Maintenance of Operating Mechanism:-
■ Cleaning of Auxiliary Switch Contacts.
■ Tightening of wires
■ Lubrication of Operating Mechanism, Hinges, Bearing etc.
■ Checking of Mounting Bolts for tightness.

Main Contacts :-
■ Cleaning & Lubrication of Main Contacts.
■ Alignment.
■ Main Contact Resistance Measurement.
■ Tightness of Nut-Bolts.
■ Cleaning of Support Insulators.
■ Checking of any visible cracks.
 Checklist for Isolators
SR.NO. NATURE OF WORK OK / NOT OK ACTION TAKEN
1 Cleaning of support insulators
2 Physical inspection of support insulators
3 Cleaning of fixed contacts
4 Cleaning of moving contacts
5 Cleaning of ground isolator fixed & moving contact
( in case isolator with Earth blade)
6 Checking tightness of power connections
7 Checking tightness of all nut bolts of foundation
and operating mechanism

8 Lubricate operating mechanism

9 Cleaning of operating mechanism box
10 Cleaning of Aux switch and tightness of its wiring
11 Check alignment by trial operations of main
and earth isolator
12 Check for rusty parts if any ,touch or paint.
13 Any other observations
PREVENTIVE MAINTENANCE OF EARTH
SWITCHES
■ Checking and Alignment of Earth Blades.
■ Cleaning of Contacts.
■ Contact Resistance.
■ Operation of Earth Switch.
■ Checking of Aluminum, Copper Flexible Conductor.
■ Checking of Earth Connection.
PREVENTIVE MAINTENANCE OF SURGE
ARRESTORS

■ Checking of Leakage Current.

■ Testing of Counters.
■ Cleaning of LA Insulators.
■ Measurement of Capacitance and Tan Delta.
 PREVENTIVE MAINTENANCE OF
BREAKERS

■ Checking of SF6 Gas Pressure.

■ Checking of SF6 Gas Leakage.
■ CB Operation Timing.
■ CB Static Contact Resistance.
■ CB Dynamic Contact Resistance.
■ Checking of all Operational Lock-outs.
■ Checking of all Inter-locks.
■ Checking of Gas & Air Pressure Settings.
■ Checking of Breaker, Interruptor & Support Insulators.
■ Checking of Close/Trip Coils.
■ Checking of Breaker, Clamps for tightness.
■ Checking of Space Heaters.
 Checklist for Breakers
SR.NO. NATURE OF WORK OK / NOT OK ACTION TAKEN
1 Cleaning of breaker cubical
2 Cleaning of support insulators
3 Physical inspection of support insulators
4 Checking of power connections
5 Checking of CT primary and secondary connections
6 Checking of rack in / out mechanism & breaker
mechanism lubrication (Refer OEM Instructions)
7 Checking tightness of breaker control and relay wiring
8 Checking panel grounding connections
9 Checking I.R.for Control cables ( once in a year)
10 Checking tightness of all Nut bolt connections
11 Checking Close/Trip coil connections
12 Checking healthiness of space heaters
13 Checking of indicating lamps
14 checking of annunciations ( SF6 pressure low,
Oil press & spring not charged)
15 Checking of Oil BDV in case of oil circuit breakers
16 Breaker timing ( once in a year)
17 Contact resistance ( once in a year)
18 Breaker trial tripping in isolated condition
 MAINTENANCE OF INSTRUMENT
TRANSFORMERS

■ Inspect Porcelain for Chipping, Cracks & Leakage of Oil.

■ Oil Sampling to be kept Barest Minimum.
■ Checking Primary & Secondary Connections for Tightness.
 CONDITION MONITORING
Condition monitoring of power
transformers include
 Generator transformer
 Transmission transformers
 Converter transformer
Insulation includes;---

 Paper insulation
Oil insulation
 Stresses acting
Mechanical Stress: Between conductors,
leads & windings due to over currents or
fault currents, mainly due to system short
circuits.
Thermal stress: Due to local heating , over
load currents & leakage flux or due to
malfunctioning of cooling system.
Dielectric stress: System over voltage,
transient impulse conditions or due to
internal resonance within a winding.
• Final stage of failure is due to dielectric
failure.
 Degrading factors

Moisture level, Local over stressing

Voids conducting
particles
wet fibers
gas bubbles
sharp conductors Increased Dielectric Losses
Tracking

Oxidation of paper and oil

Chemical decomposition
Partial Discharges
of oil and paper
 Insulation Deterioration

•Function of temperature and time

• Moisture
• Oxygen Content
 Objective of Diagnostic Tests:

• To predict state and condition of the equipment

• To determine suitability of transformers for service
• To detect extent & type of deterioration
• To suggest appropriate remedial measures to
avoid forced outages.
 DIAGNOSTIC TESTS
Tests Information Provided

Insulation Resistance Indicate the Dryness and Cleanliness of Winding

Polarization Index Direct Measure of Dryness of Winding

Capacitance and Tan Delta Indicate Dielectric Loss in Insulation

Furan Analysis Test Indicate Deterioration of Paper Insulation

DC Resistance Test Loose Connection in the Winding or OLTC

Ratio Test and Phase Angle Error Test Indicate Connection of Tapping Leads, Turn Short
within the Winding

Floating Neutral Point Measurement Indicate Connection of Common Point

Magnetic Balance Test To check the imbalance in Magnetic Circuit.

Frequency Response Analyzer (FRA) FRA is used to detect condition of Core and
Winding based on previous references, which is
created as a Data Base.
Dielectric Strength Indicate the suitability of oil to withstand electric
stress
Interfacial Tension Indicates presence of sludge and pollar
contaminants from cellulose material
Neutralization number Indicate Acidic Contents in the Oil
Moisture Content Indicate total dissolved water in the oil
Flash Point Indicate presence of some of lower
Hydro Carbons
Sludge Indicate presence of Fibrous particles,
dust, contaminants etc.
Dielectric Dissipation Factor Indicate contents of contaminants like
Varnish, Raisins etc.
Dissolved Gas Analysis
Methane
Ethane It is Powerful Diagnostic Preventive
Ethylene Maintenance Technique for monitoring
internal condition of Transformer
Acetylene
CO2
CO
Hydrogen
Capacitance and Tan Delta of Indicate healthiness of Bushing
Bushing
Partial discharge test Detection of incipient faults
CONDITION MONITORING OF
TRANSFORMER OIL
Transformer oil functions
Transformer oil perform at least
four functions for the transformer. Oil
provides insulation, provides cooling and
helps extinguishing arcs. Oil also dissolves
gases generated by oil degradation,
moisture and gas from cellulose insulation
and gases and moisture from whatever
atmosphere the oil is exposed to. Close
observation of dissolved gases in oil and
other oil properties, provides the most
valuable information about transformer
health.
Cont…..
A four condition DGA guide to classify risks to transformers with no
previous problems has been developed by IEEE. The guide uses
combination of individual gases and total combustible gas concentration.
This guide is used as a one of the tool to evaluate transformers and is
given below:-
Condition 1 ;-Total dissolved combustible gases(TDCG) below this level
indicates the T/F is operating satisfactorily. Any individual combustible
gas exceeding levels in table should have additional investigation.
Condition 2 ;- TDCG within this range indicate greater than normal
combustible gas level. A fault may be present. Take DGA samples often
enough to calculate the amount of gas generation per day for each gas.
Condition 3 ;- TDCG within this range indicate a high level of
decomposition of cellulose insulation and/or oil. Any individual gas
exceeding specified limits may have additional investigation. A fault or
faults are probably present . Take DGA samples to calculate amount of
gas generation per day for each gas.
Condition 4 ;- TDCG within this range indicate excessive decomposition of
cellulose insulation and/or oil. Continued use can result in failure of T/F.
These figures taken are extremely conservative. We have
T/Fs that have operated safely with condition 4 gases with no problem;
however they are stable and gases are not increasing or are increasing
very slowly. If TDCG and individual gases are increasing significantly
(more than 30 ppm/day ) the fault is active and the T/F SHOULD BE DE-
ENERGISED when condition 4 levels are reached.
 Cont………..
• Dissolved Key Gases Concentration Limits in
ppm
Status H2 CH4 C2H2 C2H4 C2H6 CO CO2 TDCG

Con 1 120 35 50 65 350 2500 720

100

101-700 121-400 36-50 51- 66- 351- 2500- 721-

Con 2
100 100 570 4000 1920

51-80 101- 101- 571- 4001- 1921-

Con 3 701-1800 401-1000
200 150 1400 10000 4630

Con 4 Above Above Above Above Above Above Above Above

1800 1000 80 200 150 1400 10000 4630
 Parameters for condition monitoring of oil service
Two ways are available to an operating engineer
1. To make periodic oil tests to establish trends and classify
them.
2. To conduct dissolved gas analysis to assess the internal
condition of transformers
PARAMETERS TO BE CHECKED ARE:
1. FLASH POINT
2. DIELECTRIC DISSIPATION FACTOR
3. SPECIFIC RESISTANCE
4. NEUTRALISATION.
5. MOISTURE CONTENT
6. SLUDGE %
7. BREAK DOWN VOLTAGE
8. D.G.A.
 PHYSICAL CONTAMINATION
1. Dust, fiber, metallic, particles, other solid impurities.
2. Dissolution of varnish.
3. Free and dissolved water.

CHEMICAL DETERIORATION
Oxidation resulting in acids sludges and polar
impurities.
CONTAMINATION OF GASES
a) Dissolved air from atm. Nitrogen, co2
b) Generated in oil, methane, ethane, acetylene,
ethylene etc.Before the oil is put in
the transformer, its properties
should be fully ensured.
Possible causes of gases
generation
Transformers are so complex that it
is impossible to put all symptoms and
causes into a chart. But some problems
are listed below;-
Partial discharge (Corona ) - Hydrogen H2
High Temp. Heating – Methane C H 4 ,
Ethane C2H 4, Ethylene C 2H 6
Arcing - Acetylene C2H 2
Cellulose involved - CO , CO 2
 SERVICE OIL TESTS
The service oil tests to be conducted are furnished below:
Service oil tests as per IS: 1866 – 2000
INFORMATION PROVIDED BY
Sl. No. TESTS
TESTS
1
Interfacial Tension Sludge present in the oil.

2
Neutralisation Number Acid present in the oil

3 Moisture content Reveals total water content or

(ppm) cellulosic deterioration.

Sudden drop in flash point indicates of

4
Flash point unsatisfactory working condition of
transformer.

5 Sludge Indicated deterioration

 Reveals presence of moisture, resins,
Dielectric Dissipation
6 varnishes or their products of oxidation
Factor
in oil

Conductive contaminants and moisture

7 Dielectric strength
present in the oil.

8 Resistivity Indicative of conducting impurities.

Reveals ppm of combustible gases

9 Dissolved Gas Analysis dissolved in the oil to assess the internal
condition of the transformer.
Cont……..
• Overheating = Degradation of key insulating
components
• Oil
• Insulating paper
Acetylene Very high temp. Arcing
Hydrogen High Temp. PD
Ethylene High temp. O/H
Ethane High temp. O/H
Methane High temp. Ageing
Carbon-Monoxide Paper decomposition
Carbon Dioxide Paper decomposition
TAKING AN OIL SAMPLE
• It is important to get a representative sample of the
oil inside the transformer. Use a clean glass sampling
bottle, free of dirt and moisture. Amber colored glass
is often used since sunlight will deteriorate the oil
sample. Use the following procedure to take the oil
sample for standard oil tests.
 From a bottom drain valve ,half fill the sample bottle .Cap
the bottle and swirl oil around. Pour out oil in a waste can.

 Refill and dump two more times.

 Refill the bottle to the neck,
leaving a small air space and cap tightly
Purpose of this test procedure is to get
a sample that is not contaminated by the debris of
the bottom of the tank or from the sample jar.
 Checklist for Batteries

SR.NO. NATURE OF WORK OK / NOT OK

ACTION TAKEN
1 Checking battery terminals for sulphation
2 Cleaning of battery cells and its terminals
3 Checking tightness of connectors nut bolts.

4 Checking battery stand condition.

5 Checking sp. Gravity and Voltage of each cell

6 Applying jelly to battery terminals

7 Checking exhaust fan working
8 Cleaning of battery room.
Checklist FOR Equipments-CAPACITORS

SR.NO. NATURE OF WORK OK / NOT OKACTION TAKEN

1 Cleaning of cap units and cap. Room
2 Check balancing of cap units
3 Checking tightness of power connections
4 Check units for compound leak
5 Checking tightness of all nut bolts.
6 Cleaning of reactors and NCT
7 Checking oil leak if any ( Oil reactors)
8 Check condition of silica gel ( Oil reactors)
9 Checking cable terminations
10 Check condition of fencing ( Out door cap bank)
11 Check for rusty parts if any. Paint or Touch up