EPM – Electric Preventive Maintenance 2.

) Inspect and Service as Necessary (I&S)

Basic EPM Program: (WAITR) → Trad. but more progressive
→ Regular schedule of inspection
• Routine Inspections
→ Problems are mitigated before it becomes
• Routine Tests
catastrophic
• Repairs
→ Small to medium industrial plants
• Service of Elec. Apparatus
• Service of Control Wirings 3.) Time-based Maintenance (TBM)

Why do EPM? (MPMR) → More regular intervals/cycles

→ More cohesive routine
→ Minimize accidents and failures
→ Results are compared to industry standards
→ Reduce downtime and unplanned
→ More on individual equipment, does not
shutdowns
optimize the system
→ Prevent events detrimental to life and
→ Sophisticated industries
equipment
→ Minimize equipment failure or interruption 4.) Condition-based Maintenance (CBM)
of service
→ Predictive maintenance
Direct Benefits: → Non-intrusive testing
→ Includes performance history and
1. Reduce cost of repairs
maintenance data
2. Reduce downtime of equipment
3. Improved safety of personnel and property → Can be done while operating
→ Sophisticated industries
Indirect Benefits:
5.) Reliability Centered Maintenance (RCM)
4. Improved morale of employees
5. Better workmanship → Integrates equipment condition, criticality,
6. Increase in productivity performance history, life cycle cost
7. Early discovery of deficiencies in the → Re + Prev + Pred + Pro
system → Quantify risk without interrupting
operation
4 Rules for an effective EPM → Most expensive
• Dry and free from water → Requires expertise
• Clean surroundings Reactive Maintenance
• Cool temperature
• Airtight ➢ Failure prompts repair/replacement
➢ Small items, noncritical
5 Approach to EPM ➢ RCM, I&S
1.) Run-to-Failure (EPM) Preventive Maintenance
→ Traditional ➢ Regular inspection, cleaning, adjustments,
→ Repair when busted replacements, and repair
→ Less variable cost but more expensive in the ➢ Consumables, subject to wear, known
long run failure patterns
→ For small orgs with less manpower ➢ TBM
→ Case-to-case (Ex: light bulbs, fuse)
Predictive Maintenance Steps for when Failure Occur (CC-III-FDP)
➢ Non-intrusive techniques, historical data 1. Conduct a failure-cause analysis
analysis 2. Compare present failure to past
➢ Not subject to wear, random failure 3. If no root cause found, resume and monitor
patterns 4. If prob is endemic, inform the manufacturer
➢ CBM 5. If plant-specific, check plant design,
operational stats and envi factors
Proactive Maintenance
6. Further identify the specific deficiency
➢ Repair symptoms before illness 7. Determine the deficiencies in the problem
➢ Reduces recurrence of problems 8. Perform post-monitoring and testing
➢ Long-term solution
➢ A&E Design
➢ RCM
>Software trends data, CMMS
Steps for effective EPM (SCIDSu-DECR)
1. Set the short and long term objective
2. Collect data on equipment failure
3. Identify criticalities of equipment
4. Determine the risks to be permitted
5. Set up key performance indicators (KPIs)
6. Determine maintenance techniques
7. Employ most critical and fastest strat
8. Consolidate data
9. Repeat
Key Factors Affecting EPM Decisions
1. Safety impact
2. Productivity and profitability impact
3. Costs
4. Life expectancy of equipment
5. Failure predictability
6. Likelihood of damage
7. Technical support
8. Resource availability
Management Consideration Planning and Scheduling

• Policy making Benefits:

• Necessities of production
1. A reduction of 10% on emergency work
• Cost of loss of production 2. Improvement of productivity
• Maintenance priority areas 3. Upholds a safe working environment
• Human resources 4. Confidence in work and output quality
• Cost-benefit analysis 5. A reduction of up to 20% in maint. cost
• Organizational charts 6. Savings on time and materials
• Scheduling and work orders
• Record keeping Planned job includes:

Technical Considerations 1. All materials, tools, and testing devices

2. Description of tasks
1. Survey of Plant Equipment 3. Time of completion
• Flow Diagram Maintenance Checklist
• Block Diagram
1. Is the equipment number correct?
• Single line Diagram
2. Is there a comprehensive work order?
• Schematic Diagram
3. Do the problem and solution match?
• Wiring Diagram
4. Is the work location clearly identified?
• Interconnection Diagram
5. Which standard should be identified?
• Short Circuit Coordination Study 6. Are the steps clearly defined?
• System Diagram
Kinds of PM Inspections
2. Categorizing Based on Importance
- Requires high level of expertise 1. Can be done while in operation

3. Performing EPM Regularly 2. Can be done while shut down

- Predesignated frequency (by manufacturer) 3. Can be done in conjunction with corrective
- New cycle based on wear and tear period maintenance
-Factors:
Levels of PM Activities
o Environmental Condition
o Load/demand • Emergency – reactive planning
o Duty requirements • Complex – major overhaul, repair,
o Critical Nature of equipment turnaround, planned unit outage
• Breakdown Work – routine pump repair,
4. Development of Instructions and Procedures
filter change, heat exchanger cleaning
a. EPM and Testing • Simple – instrument calibration
b. Electrical Repairs
c. Analysis of Failures
d. Trending of Data
Types of Conductors Shielding prevents:

• Overhead Cable – stranded • Damage from corona

• Power Cable – single core, layers helix wire • Confinement of dielectric field
o Class B – 600V, 5kV, 15kV • Induced Voltages
o Class C&D – flexible
Electrical Constants
o Class G&H – for welding, portable
• Utility Cable – for specialized construction 1. +/- sequence resistance
o Compact Strand – manipis, light o Skin effect
o Annular – hollow center o Proximity effect
o Segmental – 4 parallel & stranded o Sheath current
o Concentric – inner & outer cond. 2. +/- sequence reactance
o Sector – circular multi-cond. 3. Insulation resistance
Cable Ratings 0.597𝐺𝑥106
𝑟1 = 𝑟2 =
𝑓𝐾𝑐𝑜𝑠𝜃
• Low-voltage cable (<2kV)
• Medium-voltage cable (2kV-35kV) Cable Ratings
• High-voltage cable (>35kV)
1. Continuous Current-Carrying Rating
Cable Types 2. Emergency Current-Carrying Rating
3. Voltage Rating
• Laminated – paper, varnished cambric
4. Short Circuit Rating
• Extruded – rubber, PE, XLPE
Insulation
1. Paper
-can be layered
-10kV and higher
2. Varnished Cambric
-weaved cotton or linen fabric
-outdoor application
-5kV at 85°C, 15kV at 77°C
3. Asbestos
-used in 50°C/60°C ambient temp
4. Rubber/rubber-like compounds
-easy to handle and splice
-flexible
-better elec & mech characteristics
5. Mineral Insulated
-magnesium oxide or copper tubing
-85 to 250°C
6. Teflon
-withstand high temp, moisture, chemicals
-temp rating up to 200°C
Visual Inspection – test before touch (with VOM)

• Wear and tear

• Bends
• Tension
• Oil leaks
• Insulation degradation
• Ground connection
• Corrosion
• Cracking
• Fireproofing
• Splices
• Water leakages
• Dirt
• Sheath deterioration
• Suspension system
Cable Failures
1. Mechanical Failure
2. Sheath Corrosion
3. Moisture Contamination
4. Heating
5. Fire and Lightning Exposure
6. Electrical Failure
7. Conductor Failure
Cable Testing
1. IR Test
𝐷
𝐼𝑅 = 𝐾 log10 𝑑

2. DC Overpotential/Hi-Pot Test
3. Go, No-go Overpotential Test
– accept if no sudden rise in current
- not recommended
4. ECAD System
- fully automated
- for trending and monitoring measured variables
5. Cable Indentor – age is determined through the
depth of indent made by poked anvil
6. BIS Prognostic
Transformer Nameplate Rating (>500 kVA Rating) 2. Sizzle Test – 35ppm acceptable

• Name of Manufacturer kV Max ppm

• Serial number 5 30
• Year of manufacture
15 30
• Number of phases
• kVA or MVA rating 35 25
• Frequency 69 20
• Voltage rating >138 15
• Tap Voltages
• Connection diagram
• Cooling class 3. Color Test – accept 3.5 below
• Rated temperature in °C
Test Satisfactory
• Polarity (single phase)
Acidity <= 0.4
• Phasor/vector diagram (3-phase) IFT >= 40
• Percent Impedance Color <= 3.5
• Approximate mass/weight Dielectric Strength >= 23 kV
• Type of insulating liquid Power Factor <= 0.5%
• Conductor material for each winding
• Oil volume (per container)
4. DGA
Types of Transformers
Key Gases Interpretation
A. Based on Cooling N + <5% O2 Normal Operation
N, CO, CO2 Winding insulation
• Dry Type
overheated
• Oil Immersed
N, CH4, C2H4, some C2H6 Oil overheating, minor
B. Based on Application fault causing oil BD
N, H, some C2H4 C2H6 Corona discharge in oil
• Power Transformer N, H, some C2H4 C2H6, Corona involving paper
• Instrument Transformer CO, CO2 insulation
o Potential N, high H, C2H2, minor High-energy arcing
o Current CH4 C2H4
• Distribution Transformer N, high H, C2H2, minor High-energy arcing
CH4 C2H4, CO, CO2 involves paper
Tests for Oil
1. Oil Dielectric Breakdown Voltage Test Tests for Transformer Windings
V Rating New Old Fair 1. TTR Test – accept 0.5% deviation
72.5 kV >55 kV >40 kV 30-40 kV
72.5-170 kV >60 kV >50 kV 40-50 kV 2. DC WR Test
>170 kV >60 kV >60kV 50-60 kV 𝐶𝐹 + 𝐶𝑇
𝑅𝐶 = 𝑅𝑀 ( )
𝐶𝐹 + 𝑊𝑇
CF = 234.5 (copper)
CF = 225 (aluminum)
3. Tap Changer Test – mechanical 2. Infrared Temp Analysis – energized
4. IPF Test 3. Visual Inspection

Double MEU: %𝑃𝐹 = 𝑚𝑉𝐴 × 100

𝑚𝑊
• Cracks
• Dirty Bushing
𝑊
Double M2H: %𝑃𝐹 = 𝑚𝐴 × 10 • Loss of oil
- PF < 0.5% • Short-circuited
- PF < 1% for old • Wet or deteriorated bushing or tap
- PF < 2% for really old insulation
• Dirty tap insulation
5. High Voltage EC Test
• Corona in bushing insulating system
- Y: 2H, 1L
- Δ: 2L, 1H
6. SCI Test – Short circuit impedance
7. AC Hi-Pot Test
- Stress insulation
- IR immediately after
- not exceed 75% factory test values
Test for Cable and Winding Insulation
1. IR Test
𝐶𝐸
𝐼𝑅 = , C=30 at 20°C
√𝑘𝑉𝐴

Dry:
V Rating Test V Min IR
0-600 1000 500
600-5000 2500 5000
5000 5000 25000

Liquid-Filled:
V Rating Test V Min IR
0-600 1000 100
600-5000 2500 1000
5000 5000 5000

10 𝑚𝑖𝑛
2. PI Test – 1 𝑚𝑖𝑛 ≥ 2
60𝑠
3. DA Test – 30𝑠

Test for Bushing Insulation

1. BHC Test
- GST: current measured from collar to ground
-UST: measured from collar to center conductor