Electrical Maintenance L1

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Electrical Maintenance

EE 8110

Course Tutor: Mr. Mlay J. J


Assistant Lecturer
(MSc: Power Engineering and Engineering Thermophysics)
[email protected]

Department of Electrical and Power Engineering (EPE)


College of Engineering and Technology (CET)
Mbeya University of Science and Technology (MUST)
Mbeya-Tanzania,
2021/2022
“ A stitch in time saves nine”.

“If you do not close/fill the crack you will build a wall”

if you sort out a problem immediately it may save a lot of extra work later.
Generally in electrical field we mainly practice

Design

Installation

Maintenance

Demolition
Maintenance

 The technical meaning of maintenance involves functional


checks, servicing, repairing or replacing of necessary devices,
equipment, machinery building infrastructure, and supporting
utilities in industrial, business, and residential installations. 

 Over time, this has come to include multiple wordings that


describe various cost-effective practices to keep equipment in
its operational condition.

 these activities occur either before or after a failure.


The need of maintenance

 The importance of an effective maintenance program cannot be overlooked


because it plays such an important role in the effectiveness of Lean
manufacturing.

 As in personal health care insurance, maintenance may be considered the


heath care of our manufacturing machines and equipment.

 It is required to effectively reduce waste and run an efficient,


continuous manufacturing operation, business, or service operation.

 The cost of regular maintenance is very small when it is compared to the


major breakdown at which time there is no production.
The need of maintenance,,,cont…

• Based on the actual or imminent fail.

• Ideally, maintenance is carried out to keep equipment


and systems running efficiently during at least its
usual life cycle.

As such, practical functioning of equipment is a function


based on time.
Purpose of Maintenance
• To ensure that all equipment required for production is operating at
maximum efficiency at all times.

Through short daily


• Inspections,
• Cleaning,
• Lubricating,
• Minor adjustments,

Minor problems can be detected and corrected before they become a major
problem that can shut down a production line.

A good maintenance program requires company-wide participation ranging


from the top executive to the shop floor personnel.
Breakdowns

 A machine’s breakdown true cost is sometimes difficult to measure.

A recent survey showed that the cost for a machine breakdown is


more than just the maintenance labor and materials to make the repair.

• The actual cost for a breakdown is between four to fifteen times


the maintenance costs.

When the breakdown causes production to stop, the costs are very high
because no parts are being produced.
Breakdowns,,,cont…
For years, maintenance has been treated as a
• Dirty,
• Boring,
• overlooked job,
• not recognized as a part of the operation that produces revenue.

The simple question is often,


"Why do we need to maintain things regularly?" The answer is, "To keep
things as reliable as possible."

But the real question is,


"How much change or wear has occurred since the last round of
maintenance?" Generally the answer is, "I do not know."
General Maintenance
• Machine conditions are monitored at the machine level, one machine at
a time.
• It is a "Fail and Fix approach."
• Troubleshooting is the primary purpose.

The challenge for reliability is dealing with data from the past. Whereby,

Failure is
• Modeled,
• Analyzed and,
• Predicted.

Prediction does not take into account users or working environment-


related restrictions, and often the results are not useful.
Alarm Bells
Today, machine field services depend on sensor-driven management systems that
provide
• Alerts,
• Alarms and
• Indicators.

 The moment the alarm sounds, it is already too late to prevent the failure.

 Most factory downtime is caused by these unexpected situations.

 There is no alert provided that looks at normal wear over time.

If it were possible to monitor the normal wear, then it would be possible to forecast
upcoming situations and perform maintenance tasks before breakdown occurs.
Autonomous Maintenance
The purpose of autonomous maintenance

(acting in accordance with one's moral duty rather than one's desires)

• To develop operators to be able to take care of small


maintenance jobs on the equipment they use.

• Skilled maintenance people can concentrate on value-added


activity and technical repairs.
Maintenance World of Tomorrow

With modern computing and information technologies, more


products and machines are equipped with

• Sensors on critical parts of machines

To warn of potential failures long before they may fail so


they can be corrected before they stop production.
Intelligent Maintenance Systems (IMS)
Intelligent maintenance systems (IMS)
• Predict and
• Forecast equipment performance

So "near-zero breakdown" status is possible.


 focuses on machine performance techniques to minimize failures.

Data comes from two sources:


 Sensors (mounted on the machines)
 The entire enterprise system (including quality data, past history and
trending).

By looking at data from these sources (current and historical), it can predict
future performance.
Intelligent Maintenance Systems

The long-term view on intelligent maintenance is that we can use any means
- Including embedded (software)
- Remote technologies to monitor equipment performance.

Then, if wear starts to occur, there is enough time to service the item before
failure.

A machine can self-assess its health and trigger its own service request as
needed. If this model works,
• The product that can manage its own service performance and its own
warranty-based contracts.
• It also can alert us on ways to keep it running in a high-performance manner.
Focusing on the Bottom Line

Today, with industry so focused on the bottom line, the cost of downtime
has a big impact on profitability.

• If equipment starts to wear, it is possible to start producing parts with


unacceptable quality without knowing it for a long time. Eventually,
machine wear will seriously affect not only productivity but also
product quality.

• World-class companies already have taken a game-changing approach,


implementing a new service business model to change maintenance
systems into smart service and asset management solutions.
Focusing on the Bottom Line,,,cont….

• They reduce downtime and provide the ability to look ahead


at the quality of products before they ship by closely
watching equipment performance and machine wear.

• Rather than reactive maintenance - "Fail and Fix" -


companies can indeed move to "Predict and Prevent"
maintenance.
Contents

General View on Electrical Maintenance

Significance of Maintenance

Maintenance Management

Types Of Maintenance
General View on Maintenance

• Maintenance
The combination of all technical and administrative actions,
including supervision actions, intended to retain an item in,
or restore it to, a state in which it can perform a required
function.
Significance of Maintenance

Maintenance is carried out for the following reasons:

• To prevent danger
• To reduce unit cost and to keep a facility in operation
(reliability).
• To prevent pollution of the environment.
Significance – Prevent Danger

• Maintenance is done to prevent the dangers that might arise in


the event of failure
• This is done so as to ensure the safety of persons, livestock and
properties.
• Also is done to meet legal requirements, i.e. Electricity at Work
Regulations (EWR) requirements phrased:

‘ As may be necessary to prevent danger, all systems shall be


maintained so as to prevent, so far as is reasonably practicable,
such danger.’ (Regulation 4(2)).
Significance – Prevent Danger

• Generally, an equipment/system can not be kept in a


safe condition without being maintained.
• It is necessary to inspect and/or test a system to
determine if maintenance (including repairs) is
necessary.
• Keeping and analysis of records is also necessary to
monitor the effectiveness of maintenance.
Significance - Reliability

• The issues concern minimizing business costs and


maximizing income.
• Maintenance carried out to reduce the cost of an
enterprise would include action taken to reduce or avoid;

a. The cost of failure of plant or equipment - repair costs;


b. The cost of loss of production – revenue costs;
c. The cost of loss of service – revenue and goodwill.
Significance - Environment

• Maintenance is also done to protect the


environment.
• The legislations demands that the systems/plants
to abide with the Waste Electrical and Electronic
Equipment (WEEE) Directive, the Clean Air Act or
the Environmental Protection Act and associated
Regulations.
Maintenance Management

• The old idea was that, maintenance is the actions


associated with equipment repair after it is broken.

• But generally, maintenance should be actions taken


to prevent a device or component from failing or to
repair normal equipment degradation experienced
with the operation of the device to keep it in proper
working order.
Maintenance Activities

• Activities of maintenance function could be either repair or


replacement activities, which are necessary for an item to
reach its acceptable productivity condition and these
activities, should be carried out with a minimum possible
cost.
Maintenance Objectives

• Maintenance objectives should be consistent with and


subordinate to production goals.

• The relation between maintenance objectives and


production goals is reflected in the action of keeping
production machines and facilities in the best possible
operating condition.
Maintenance Objectives

i. Maximising production or increasing facilities availability


at the lowest cost and at the highest quality and safety
standards.
ii. Reducing breakdowns and emergency shutdowns.
iii. Optimising resources utilization.
iv. Reducing downtime.
v. Improving spares stock control.
Maintenance Objectives,,, cont..

vi. Improving equipment efficiency and reducing


scrap rate.
vii. Minimising energy usage.
viii.Optimising the useful life of equipment.
ix. Providing reliable cost and budgetary control.
x. Identifying and implementing cost reductions.
Elements Affecting

Elements affecting the performance of electrical


equipment and Installations
There are several elements that affects/influences the
performance of electrical installations, and which if not
taken into consideration might cause wearing down,
poor performance and even failure of the equipment.
Those elements include Moisture/Humidity, Dust and
Temperature.
Elements Affecting,,,cont…

i. Moisture
 Moisture is not acceptable in electrical and
electronic circuits or systems because it can cause
some parts to corrode and get damaged.
 Moisture can cause condensation in conduits at high
humidity
 It can also cause short circuit when equipment are in
operation and may cause insulating materials to lose
their properties.
ii. Dust

A film of dust/dirty reduces the reflecting part of all exposed


surface of lamps, fittings so it is necessary to clean those
surfaces It may also damage electronic equipment.
 
iii. Temperature
 High temperature weakens the insulating materials like
plastic (PVC).
 Plastic conduits also soften at high temperatures, so it loses
its strength (mechanical strength)
 Low temperature causes hardening (making stiff/brittle) of
plastic (PVC) materials.
 Some lamps (e.g. fluorescent lamps) may fail to operate or
may delay lighting at a temperature less than 5oC
 Motor windings can also be damaged if allowed to operate
at high temperatures.
Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE


MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL - CONDITION - DEFERRED REMEDIAL


ENGINEERING DESIGN - OUT
BASED BASED
SERVICES

WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN


NITY PREVENTIVE IMPROVEMENT CORRECTIVE
Types of Maintenance

• There are generally five types of maintenance.

1. Run to Failure Maintenance (RTF)


2. Preventive Maintenance (PM)
3. Corrective Maintenance (CM)
4. Improvement Maintenance (IM)
5. Predictive Maintenance (PDM)
6. Total productive maintenance (TPM)
1. Run to Failure Maintenance (RTF)

• The required repair, replacement, or restore action


performed on a machine or a facility after the
occurrence of a failure in order to bring this machine
or facility to at least its minimum acceptable
condition.

• It is the oldest type of maintenance.


Run to Failure Maintenance (RTF),, cont..

• It is subdivided into two types:

• Emergency maintenance: it is carried out as fast as


possible in order to bring a failed machine or facility to a
safe and operationally efficient condition.

• Breakdown maintenance: it is performed after the


occurrence of an advanced considered failure for which
advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.
Run to Failure Maintenance (RTF),, cont..

Disadvantages:

1. Its activities are expensive in terms of both direct and indirect


cost.

2. Using this type of maintenance, the occurrence of a failure in a


component can cause failures in other components in the same
equipment, which leads to low production availability.
3. Its activities are very difficult to plan and schedule in advance.
Run to Failure Maintenance (RTF),, cont..
This type of maintenance is useful in the following situations:

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities is


lower than performing other activities of other types of
maintenance.

3. The equipment failure priority is too low in order to include the


activities of preventing it within the planned maintenance
budget.
2. Preventive Maintenance (PM)

• It is a set of activities that are performed on plant equipment,


machinery, and systems before the occurrence of a failure in
order to protect them and to prevent or eliminate any
degradation in their operating conditions.

• This maintenance is carried out at predetermined intervals or


according to prescribed criteria and intended to reduce the
probability of failure or the degradation of the functioning and
the effects limited.
Advantage Preventive Maintenance (PM)

• The advantage of applying preventive maintenance activities


is to satisfy most of maintenance objectives.

• It is good for those machines and facilities which their


failure would cause serious production losses.
• Its aim is to maintain machines and facilities in such a
condition that breakdowns and emergency repairs are
minimised.
• Its activities include replacements, adjustments, major
overhauls, inspections and lubrications.
Preventive Maintenance (PM),,,,cont
• factors affecting the efficiency of this type of maintenance:

i. The need for an adequate number of staff in the maintenance


department to perform this maintenance.
ii. The required staff qualifications and skills, which can be gained
through training.
iii. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the workload
of this environment.
iv. The support and commitment from executive management to the PM
programme.
v. The proper planning and scheduling of PM programme.
vi. The ability to properly apply the PM programme.
Preventive Maintenance (PM),,,,cont
Researchers subdivided preventive maintenance into
different kinds according to the nature of its activities:

i. Routine maintenance which includes those maintenance


activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.

ii. Running maintenance which includes those maintenance


activities that are carried out while the machine or
equipment is running and they represent those activities
that are performed before the actual preventive
maintenance activities take place. Eg. checking,
lubricating, Periodic inspection
Preventive Maintenance (PM),,,,cont
iii. Opportunity maintenance, which is a set of maintenance
activities that are performed on a machine or a facility when an
unplanned opportunity exists during the period of performing
planned maintenance activities to other machines or facilities.

iv. Window maintenance, which is a set of activities that are


carried out when a machine or equipment is not required for a
definite period of time.

v. Shutdown preventive maintenance, which is a set of preventive


maintenance activities that are carried out when the production
line is in total stoppage situation.
3. Corrective Maintenance (CM)

• In this type, actions such as repair, replacement, or restore will


be carried out after the occurrence of a failure in order to
eliminate the source of this failure or reduce the frequency of
its occurrence.

• It is the maintenance carried out after recognition, and intended


to put an item into a state in which it can perform a required
function.
Corrective Maintenance (CM),,,cont…
This type of maintenance is subdivided into three types:

i. Remedial maintenance, which is a set of activities that are


performed to eliminate the source of failure without
interrupting the continuity of the production process.

The way to carry out this type of corrective maintenance is


by taking the item to be corrected out of the production
line and replacing it with reconditioned item or transferring
its workload to its redundancy.
Corrective Maintenance (CM),,, cont…

ii. Deferred maintenance, a set of corrective maintenance


activities that are not immediately initiated after the
occurrence of a failure but are delayed in such a way that
will not affect the production process. Eg. Changing
filters, painting, glazing windows, masonry repairs

iii. Shutdown corrective maintenance, a set of corrective


maintenance activities that are performed when the
production line is in total stoppage situation.
Corrective Maintenance (CM),,, cont…
• The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant systems, the
elimination of breakdowns, the elimination of unnecessary repair,
and the reduction of the deviations from optimum operating
conditions.

• The difference between corrective maintenance and preventive


maintenance is that for the corrective maintenance, the failure
should occur before any corrective action is taken.

• Corrective maintenance is different from run to failure maintenance


in that its activities are planned and regularly taken out to keep
plant’s machines and equipment in optimum operating condition.
Corrective Maintenance (CM),,, cont…
• The way to perform corrective maintenance activities is by
conducting four important steps:

 Fault detection.
 Fault isolation.
 Fault elimination.
 Verification of fault elimination.

In the fault elimination step several actions could be taken such as


adjusting, aligning, calibrating, reworking, removing, replacing
or renovation.
Corrective Maintenance (CM),,, cont…
• Corrective maintenance has several pre-requisites in order to be carried
out effectively:

i. Effective planning which depends on the skills of the planners, the


ii. Availability of well developed maintenance database about standard
time to repair,
iii. The required labour skills,
iv. Accurate identification of incipient problems.
v. A complete and proper repair procedures,
vi. Adequate time to repair.
vii. specific tools, parts and equipment.
viii. Verification of repair.
4. Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.

This type of maintenance is subdivided into three types as follows:

1. Design-out maintenance which is a set of activities that are


used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance by
redesigning those machines and facilities which are vulnerable to
frequent occurrence of failure and their long term repair or
replacement cost is very expensive.
Improvement Maintenance (IM),,,cont..

2. Engineering services which includes construction and


construction modification, removal and installation, and
rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of


improvement maintenance activities that are performed
while the production line is in a complete stoppage
situation.
5. Predictive Maintenance (PM)
• Is a set of activities that detect changes in the physical
condition of equipment (signs of failure) in order to carry out
the appropriate maintenance work for maximising the service
life of equipment without increasing the risk of failure.

• It is classified into two kinds according to the methods of


detecting the signs of failure:
• Condition-based predictive maintenance
• Statistical-based predictive maintenance
Predictive Maintenance (PM),,,cont…
• Condition-based predictive maintenance depends on continuous
or periodic condition monitoring equipment to detect the signs of
failure.

• Statistical-based predictive maintenance depends on statistical


data from the meticulous recording of the stoppages of the in-
plant items and components in order to develop models for
predicting failures.
Predictive Maintenance (PM),,,cont…
• The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.

• Some researchers classified predictive maintenance as a type of


preventive maintenance.

• The main difference between preventive maintenance and


predictive maintenance is that predictive maintenance
monitoring the condition of machines or equipment to determine
the actual mean time to failure whereas preventive maintenance
depends on industrial average life statistics.
6. Total productive maintenance (TPM):

• Is a maintenance activity that involves production operators


in maintaining equipment / machinery in addition to
activities carried out by maintenance operators.

• Examples are cleaning, lubricating, tightening nuts & bolts,


daily checking (checking equipment / machine state),
simple repairs (replacing leaking hoses, welding tips) etc.
Total productive maintenance (TPM),,,cont….

The objectives of the TPM are:

• Develop operators that are able to detect damage signals


as early as possible. Because it is the production operator
that really knows the state of the equipment to even the
most detailed part.

• Creating a neat, clean workplace so that any irregularities


can be detected as early as possible

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