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Topics
Definition of Preventive Maintenance (PM) Reasons for the increased need of PM Advantages of a PM system Risks of running a PM system When to use a PM system The law of PM Guide to a successful PM system Execution process

Conclusion
Readings

What is Preventive Maintenance?

Preventive maintenance is a schedule of planned maintenance actions aimed at the prevention of breakdowns and failures. The primary goal of preventive maintenance is to prevent the failure of equipment before it actually occurs. It is designed to preserve and enhance equipment reliability by replacing worn components before they actually fail.

Reasons for the need of a PM system

Increased Automation

Business loss due to production delays

Production of a higher quality product

Just-in-time manufacturing
Need for a more organized, planned environment

Advantages of a PM system
Reduced production downtime, resulting in fewer machine breakdowns. Better conservation of assets and increased life expectancy of assets, thereby eliminating premature replacement of machinery and equipment. Timely, routine repairs circumvent fewer large-scale repairs.

Continued Reduced cost of repairs by reducing secondary failures. When parts fail in service, they usually damage other parts. Better quality products

Identification of equipment with excessive maintenance costs

Improved safety and quality conditions.

Brainstorming Exercise

Are there any risks of running a PM system?

If there are risks when would it be a good time to use PM?

Potential errors or damage of a PM system

Damage to an adjacent equipment during a PM task.

Reintroducing equipment mortality by installing new parts or materials. Damage due to an error in reinstalling equipment into its original location.

When Does Preventive Maintenance Make Sense

This is a logical choice that considers two conditions
- #1. The component in question has an increasing failure rate. - #2. The overall cost of the preventive maintenance action must be less than the overall cost of a corrective action. If both of these conditions are met PM would make sense

The Law of PM Higher the value of the plant assets and equipment per square foot of plant, the greater will be the return on a PM program.
E.g. - downtime in an automobile plant assembly line at one time cost $10,000 per minute. Relating this to lost production time an automobile manufacturer reported that the establishment of a PM program in their 16 assembly plants reduced downtime from 300 hours per year to 25 hours per year. With results such as this no well-managed plant can
afford not to develop a PM program.

How to determine the optimum age of replacement?

How to determine the optimum age of replacement?

A more technical approach.

Where: R(t) = reliability at time t. CP = cost of planned replacement. CU = cost of unplanned replacement CPUT(t) = The optimum replacement time

The key for a successful PM system Scheduling Should be automated to the maximum extent possible Execution Should be done before the actual break down occurs.

Execution
The Bath Tub Model Three stages of new parts
1. Infant morality stage 2. A fairly long run stage 3. Wear out stage

Traditional View according to Bath Tub Model Replace components just before they entered wear out stage

Execution
Traditional view says
Wear out stage = Increased rate of failure. Point to Ponder Since, wear out stage represents increased rate of failure, wouldnt it be plausible to execute the PM program at this stage?

What really should PM focus on? Cleaning Lubrication And correcting deficiencies Found through testing and inspection

Predetermined parts replacement should be minimal and done only where statistical evidence clearly indicates wear-out characteristics

In the absence of data

Age exploration programs Statistical analysis

Cost shouldnt be a primary factor in deciding against data collection for a PM

Motivating Preventive Maintenance Workers

Training programs most effective
Establish inspection and preventive maintenance as a recognized, important part of the overall maintenance program. Assign competent, responsible people to the preventive maintenance program.

Continued Follow-up to assure quality performance and to show everyone that management does care. Provide training in precision maintenance practices and training in the right techniques and procedures for preventive maintenance on specific equipment. Set high standards. Publicize reduced costs with improved up-time and revenues, which are the result of effective preventive maintenance

Summary PM is not difficult to achieve.

It is an essential part for cost reduction

There is an element of risk involved in PM Careful planning and execution will reduce the risk of PM

The biggest benefits of a PM program occur through painting, lubrication, cleaning and adjusting, and minor component replacement to extend the life of equipment and facilities.

Example for Breaker Maintenance

Why and what has to be maintained on breakers ?

Case

Mechanism
Arc chute Main contacts Control unit Connection systems Auxiliary Devices Communication system

Maintenance of case
Function of case :
- isolate the main contacts and protect from arcing effects - support the mechanism, tripping device, auxiliary devices, terminals - Must withstand the stresses during short circuit

Damaged case is the consequence of

shocks, moisture, high short circuit, overheating ( loose connection)

Preventive maintenance includes :

- visual inspection of dust, dirt, grease, moisture, cracks, soot, - cleaning, ( dust, dirt, soot,) with dry cloth, brush or vacuum cleaner - replacement in case of cracks

Maintenance of the mechanism

Breaker mechanism
- Spring energy on Masterpact - Tumbler on Compact NS - operate the contacts to establish and interrupt the circuit

Chassis mechanism
- to rack in and out the breaker, test the breaker

Maintenance of the mechanism Contd.

Jammed mechanism is the consequence of : dust : shocks : bending of mechanical part corrosive atmosphere : rust and corrosion of metallic part No operation for a long time Preventive maintenance includes : dust removal : vacuum cleaner recommended cleaning : dry cloth, brush, solvent prohibited greasing : only Schneider recommended greases, in small quantity operation of breaker / chassis : to give the spring charged energy and the mechanism their original characteristics

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Maintenance of the arc chute (Power breaker only)

Function of arc chute :
- splitters : extinguish the arc and absorb the energy under normal condition and electric fault - filter : blow the pressured gas out , cool down the gas

Arc chute deteriorates

- under In : the insulation material of the arc chamber can perforate - under Icc : the metal part is vaporised

Maintenance of main contacts

Arc chute in bad condition may result in a non interruption of the arc, decrease of the isolating function and ultimately destruction in case of high short circuit current. Filters : avoid compound (made of dust + grease) covering the filter Preventive maintenance includes : periodic inspection after a fault : splitters should not present holes and be too thin, plastic part should not have holes ( decrease of insulation level) replacement cleaning of filter

(Power breaker only)

Contd.

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Maintenance of main contacts

Function of main contacts :
- To make or break the circuit under normal ( In) or fault conditions (overload and Shortcircuit )

(Power breaker only)

Contacts get worn during each mechanical and electrical open / close operation and after short circuit ( maxi 2 cycles at Icu) Worn contacts will result in :
- over heating of the breaker ( increase of contact resistance) - decrease of life expectancy - measurement of individual pole resistance - replacement

Preventive maintenance includes : periodic visual check, control of the mechanical contact wear indicator and electronic wear indicator on Micrologic P & H Worn contacts will result in : over heating of the breaker ( increase of contact resistance) decrease of life expectancy Preventive maintenance includes : periodic visual check, control of the mechanical contact wear indicator and electronic wear indicator on Micrologic P & H measurement of individual pole resistance replacement

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Maintenance of electronic control unit

Function of control unit :
- permanently analyse the phase current compare it to the protection set and in case of fault trips the breaker

Control unit is sensitive to :

- environment : ambient temperature, humidity, corrosive atmosphere, - operating conditions : vibration, electro-magnetic field,

A malfunctioning of the trip unit will result in :

- a non interruption of the fault current
- damage of equipment and breaker

Preventive maintenance includes :

- periodic push to trip test or trip test

- control of the complete tripping channel

- curve adjustment - saving of log event, settings ( Micrologic P & H)

Maintenance of thermal-magnetic trip unit

Function of thermal-magnetic trip unit :
- Connected permanently in series with the phase currents - based on the bending of a bimetal for overload and the movement of a magnet in a strong magnetic field

Thermal -magnetic trip unit is sensitive to :

- ambient temperature, corrosive atmosphere

A malfunctioning of the trip unit will result in :

- a non interruption of the fault current - damage of equipment and breaker

Preventive maintenance includes :

- primary injection test to trip the breaker

Maintenance of connection systems

Function of connection systems :
- Link together various types of devices by mean of electrical distribution systems (bus bars, cables, auxiliary wires, ).

Bad connection ( too tight or too loose) will result in :

- Thermal effect leading to destruction of devices - short circuit or fire

Preventive maintenance includes :

- For fixed connectors : No need of control if done with Schneider recommendation . otherwise : check temperature rise, if loose, dismantle and tighten with new screws, bolts & washers - For sliding connectors : (mainly chassis)

- periodic cleaning and greasing with Schneider recommended grease - if corrosive atmosphere ( SO2 / H2S) : clean with special solution ( Thioure) and re grease
- Wires : check tightening and the insulation material

Maintenance of auxiliary devices

Function of auxiliary devices :
- Shunt trip release, under voltage release, OF contacts, SD/SDE alarm contacts , electrical motor MCH

Malfunctioning of the auxiliary device will result in a wrong operation of the breaker the consequences can be :
- no safety operation ( emergency) - wrong operation in the circuit

Preventive maintenance includes :

- functional test of auxiliary device at nominal voltage
- replacement

PPM Schedule For Township(Metering Panel)

Sl No Name of the Cluster Name of the block Date of PPM to PPM start time be carried out PPM end time Activity to be carried out
All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel ) cleanning & all Basbas & cable conection check & tightness Electrical Panel Cleaning & all busbar & cable connection check & tightness All eletrical panel( Metering Panel, Utility Panel) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel) cleanning & all Basbas & cable conection check & tightness All eletrical panel( Metering Panel, Utility Panel) cleanning & all Basbas & cable conection check & tightness Electrical Panel Cleaning & all busbar & cable connection check & tightness 1 A&B 11/5/2012 9:00 15:00

C&D

11/6/2012

9:00

15:00

E&F

11/7/2012

9:00

15:00

Sankha
4 G&H 11/8/2012 9:00 15:00

J ,K & L

11/9/2012

9:00

15:00

M&N

11/10/2012

9:00

15:00

7 8

O&P Aminety

11/12/2012 11/15/2012

9:00 9:00

15:00 15:00

A&B

11/16/2012

9:00

15:00

10

C,D&E

11/17/2012

9:00

15:00

Koel
11 F&G 11/19/2012 9:00 15:00

12 13

J&K Aminety

11/20/2012 11/21/2012

9:00 9:00

15:00 15:00

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PPM Schedule For Township(Substations)

Name of the Sl No Cluster Name of the block Date of PPM to be carried out PPM start time PPM end time Activity to be carried out Efected Area Eletrical Feeder panel cleanning , Breaker Rackout,Rackin SA/SB,SC/SD,WTP,PROJECT check, Breaker Contact check. All Busbar & cable conection OFFICE,KA/KB,KC/KD/KE, check & tightness KF/KG,KH/KJ,KF/KG Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection SE/SF,SG/SH,SJ/SK/SL, check & tightness SM/SN,SO/SP,COMMERCIAL Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection check & tightness SPARE Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection STUDIO/MA/MB,MC/MD/ME, check & tightness MF/MG Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection MAINGATE/BANGALOW/ check & tightness HOSTEL Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection HATI BLOCK/COMMUNITY check & tightness CENTER,TEMPLE,APPOLO Eletrical Feeder panel cleanning , Breaker Rackout,Rackin check, Breaker Contact check. All Busbar & cable conection check & tightness BRAHMANI BLOCK

Substation # 3

LT Panel # 6

1-Mar-13

9:00

15:00

LT Panel # 7

2-Mar-13

9:00

15:00

LT Panel # 5 Substation # 2 3 LT Panel # 3

3-Mar-13

9:00

15:00

4-Mar-13

9:00

15:00

LT Panel # 4

5-Mar-13

9:00

15:00

Substation # 1

LT Panel # 1

6-Mar-13

9:00

15:00

LT Panel # 2

7-Mar-13

9:00

15:00

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THANK YOU

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