VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI-590018

An Internship Report On

“TO STUDY THE ROLE OF ELECTRICAL MAINTENANCE

DEPARTMENT & ELECTRICIAN IN THE INDUSTRY”
Submitted in the partial fulfilment of the requirements for the award of the Degree of
Bachelor of Engineering in Electrical and Electronics and Engineering

Submitted by
DIWAKAR M R 10X16EE405

Under the support and guidance of

Internal guide External guide

Smt. RESNA S R Mr. Prabhu Ram
Assistant Professor, Elec. Maintenance Engineer
Dept. of EEE, TOCE Alubee Die Casters, hosur

Department of Electrical and electronics and

Engineering the Oxford College of Engineering
Hosur Road, Bommanahalli, Bangalore-560068
(Approved by AICTE, New Delhi, Accredited by NBA, NAAC, New Delhi & Affiliated to VTU, Belagavi)
2020-2021
 DEPARTMENT OF COMPUTER SCIENCE AND ENGINEERING THE
OXFORD COLLEGE OF ENGINEERING
Hosur Road, Bommanahalli, Bangalore-560068
(Approved by AICTE, New Delhi, Accredited by NBA, NAAC, New Delhi & Affiliated to VTU, Belagavi)

CERTIFICATE

This is to Certify that the internship work entitled “TO STUDY THE ROLE OF ELECTRICAL
MAINTENANCE DEPARTMENT & ELECTRICIAN IN THE INDUSTRY” is a bona-fide
work carried out by Diwakar M R (10X16EE405) in partial fulfillment of internship in 8 th
semester, Bachelor of engineering in the course of electrical and electronics engineering at
The Oxford College of Engineering under Visvesvaraya Technological University, belagavi
for the year 2020-2021.it is certified that all correction and suggestions indicated for internal
assessment has been incorporated in the report. The internship report has been approved as it
satisfies the academic requirements for the award of bachelor of engineering degree.

INTERNAL GUIDE HOD PRICIPAL

Smt.RESNA S R Dr.V S BHARATH Dr. G.T RAJU
Assistant Professor Head of Department (EEE) Principal
Dept. Of EEE, TOCE Dept. of EEE, TOCE TOCE

SIGNATURE OF THE EXAMINERS:

1.

2.
DEPARTMENT OF ELECTICAL AND ELECTRONICS ENGINEERING
THE OXFORD COLLEGE OF ENGINEERING
Hosur Road, Bommanahalli, Bangalore-560068
(Approved by AICTE, New Delhi, Accredited by NBA, NAAC, New Delhi & Affiliated to VTU, Belagavi)

DECLARATION

We Diwakar M R students of Eighth semester B.E, at the Department of Electrical and

Electronics Engineering, The Oxford College of Engineering, Bangalore declare that the
Internship entitled “TO STUDY THE ROLE OF ELECTRICAL MAINTENANCE
DEPARTMENT & ELECTRICIAN IN THE INDUSTRY” has been presented by us and
submitted in partial fulfilment of course requirements for the award of degree in Bachelor of
Engineering in ELECTRICAL AND ELECTRONICS ENGINEERING discipline of
Visvesvaraya Technological University, Belagavi during the academic year 2020-2021.

NAME USN SIGNATURE

1. DIWAKAR M R 1OX16EE405

Place: Bangalore
Date:
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mention of the people who made it possible with continuous guidance
and encouragement and crowed our effort with success.

We have great pleasure in expressing our deep sense of gratitude to late SHRI. S. NARASA
RAJU, Founder chairman and we consider ourselves proud to be a part of the Oxford family
the institution that stood by our way in all our endeavors. So we express our gratitude to SHRI.
S. N. V. L. NARASIMHA RAJU, Chairman, the Oxford educational institution and Dr.
AMARNATH K, Director, The Oxford College of Engineering for providing all facilities for
our work to be a better one.

We would like to express our gratitude to Dr. G.T RAJU, Principal, The Oxford College of
Engineering for providing congenial environment surrounding to work in, we hearty thank to
our beloved HOD, Dr. V. S. BHARATH, Department of EEE for his encouragement and
support.

Words are inadequate in offering my thanks to Mr.PRABHU RAM, Maintenance Engineer

(Ele), Alubee Die Caster. Smt. RESNA S R, Assistant Professor Department of EEE and Smt.
NISHA C RANI, Associate Professor Department of EEE (Internship In-charges) with
profound gratefulness for a moral inspiration, encouragement and valuable guidance
throughout course of this work.

We also thank all the staff members of Electrical and Electronics department and all those who
have directly and indirectly helped us with their valuable suggestions in the successful
completion of this internship. Last but not the least we would thank our beloved parents for
their support and encouragement to successfully complete the task by meeting the entire
requirement.

NAME OF THE STUDENT USN

1. DIWAKAR M R 1OX16EE405
 Ⅰ
TABLE OF FIGURES

FIGURE NO NAME PAGE NO

1.1 Alubee Entrance 01

1.3.1 Die Casting Machines 02

1.3.2 Raw Aluminum 03

1.3.3 Metrology 04

1.3.4 Pressure Die-Casting Machine 04

1.3.5 Fettling-post-casting Process 05

1.3.6 Shot blasting process 05

1.3.7 CNC/VMC Machines 06

1.3.8 Post machining operations 07

1.3.9 Assembly 07

1.3.10 Final Inspection 08

1.3.11 Infrastructure 09

1.7 Clientele 10

2.1.3 Causes & percentage of cases 12

2.1.5 Advantages of Electrical Maintenance 13

2.1.7 Importance of Maintenance 15

2.1.10 Routine Maintenance 16

2.1.11 Predictive Maintenance 17

2.1.12 Breakdown Maintenance workflow 18

2.1.13 Corrective maintenance workflow 19

2.1.14 Preventive maintenance workflow 20

2.1.14 Preventive maintenance decreases 21

downtime
2.2.3 Types of maintenance workers 23
3.7 Electrical tools 29

3.8 Effects of electrical current in the human 31

body
3.9 Different wire gauges 31

3.9 American wire gauges 32

3.11 Electrical fire extinguishers 34

3.13 Step down transformer 35

LIST OF TABLES

FIGURE NO NAME PAGE NO

3.8 Typical effects on the human body based 30

on exposure

3.8 Effects of electrical current in the human 31

body

3.9 American wire gauges 32

Ⅱ
TABLE OF CONTENT

TITLE PAGE NO
Certification
Declaration
Acknowledgement Ⅰ
List of figures Ⅱ
List of tables Ⅱ

CHAPTER-1 1-10
ABOUT THE COMPANY 1
1.1 Alubee a glimpse 1
1.2 The journey 2
1.3 The Process 2
1.3.1 Introduction to die-casting 2
1.3.2 Raw materials for die-casting 3
1.3.3 Metrology 3
1.3.4 Pressure die-casting process-A glance 4
1.3.5 Fettling-post-casting process 5
1.3.6 Shot blasting process 5
1.3.7 CNC/VMC machining 6
1.3.8 Post machining operations 6
1.3.9 Assembly 7
1.3.10 Final inspection 8
1.3.11 Infrastructure 8
1.4 Vision statement 9
1.5 Mission statement 9
1.6 Marching towards 9
1.7 Clientele 10

CHAPTER-2 11-23
ABOUT THE DEPARTMENT 11
2.1 Introduction 11
2.1.1 History 11
2.1.2 What is Electrical Maintenance 12
2.1.3 Why do we need electrical maintenance 12
2.1.4 Benefits of electrical maintenance 13
2.1.5 What are the advantages of electrical maintenance 13
2.1.6 Why would you hire electrical maintenance serves 14
2.1.7 the importance of electrical maintenance & safety 15
2.1.8 concept of Maintenance 16
2.1.9 types of Maintenance 16
2.1.10 Routine maintenance 16
2.1.11 Predictive maintenance 17
2.1.12 Breakdown maintenance 18
2.1.13 Corrective Maintenance 19
2.1.14 Preventive Maintenance 20
2.2 Types of maintenance workers 21
2.2.1 Maintenance technicians 22
2.2.2 Maintenance Engineer 22
2.2.3 Maintenance planner 22
2.3 Program mission 23
2.4 Program description 23

CHAPTER-3 24-42
TASK PERFORMED 24
3.1 Introduction 24
3.2 Electrical safety equipment 24
3.3 Electrical Equipment 25
3.4 Lifesaving kits, rescue hooks& operations rods 25
3.4.1 Insulated gloves 25
3.4.2 Insulated matting 25
3.4.3 Earthing & short circuiting 25
3.4.4 Arc flash 25
3.5 Personal protective equipment 26
3.5.1 Protective Employees from 26
3.5.2 Examples of PPE 26
3.5.3 Eye Protection 27
3.5.4 Safety spectacles 27
3.5.5 Goggles 27
3.5.6 Face shields 27
3.5.7 Head protection 28
3.5.8 Hearing protection 28
3.5.9 Safety shoes 28
3.6 Summary 28
3.7 What are electrical tools 29
3.8 How much electrical is dangerous 30
3.9 Control inadequate wiring hazards 31
3.10 Controlling Hazards 32
3.11 Electrical fires 33
3.12 First aid facts sheet 34
3.13 Transformer 35
3.13.1 Transformer maintenance checks on a monthly basis 35
3.13.2 Daily basis maintenance testing & checking 36
3.14.3 Annual transformer maintenance schedule 36
3.15.4 Transformer maintenance on a half yearly basis 36
3.15 Maintenance of earthing equipment, visual inspection 37
3.16 Diesel generator 38
3.16.1 Routine general inspection 39
3.16.2 Lubrication services 39
3.16.3 Cooling system 39
3.16.4 Fuel system 39
3.16.5 Testing batteries 39
3.16.6 Routine engine exercise 39
3.16.7 Keep your generator clean 40
3.17 lighting operations & maintenance 40
3.17.1 Operations manuals 40
3.17.2 Schedules 40
3.17.3 Flexibility 40
3.17.4 Cleaning 40
3.17.5 Replacement 41
3.17.6 Operation of control system 41
3.18 The best wire maintenance checklist for industry usage 41
3.18.1 Choose right 41
3.18.2 Preventions of damage 41
3.18.3 Repairs on time 42
3.18.4 Always maintain records 42
3.18.5 Loose wire connections at switches & outlets 42
3.18.6 Wire connections made with electrical tape 42
3.18.7 Two or More wires under one screw terminals 42
3.18.8 Exposed wires 42

CHAPTER-4 43-45
REFLECTIONS 43
4.1 Introductions 43
4.2 Technical outcomes 43
4.3 Non-technical outcomes 44
4.4 Electric shock & its managements 44
4.4.1 Causes of electrical shock 44
4.4.2 Symptoms of electrical shock 45
4.5 key learning 45

CHAPTER 5 46-47
CONCLUSION 46
REFERENCES 48

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CHAPTER 1

ABOUT THE COMPANY

1.1 ALUBEE A GLIMPSE

Alubee has its state-of-the-art manufacturing facility in the industrial suburb of Hosur. Alubee is a
pioneer in the high-pressure aluminum die-casting industry. Alubee successfully reached the
prestigious silver jubilee year and is currently marching towards the golden period. The name
“Alubee” is derived from the fact that “Alubeans” work with Aluminum alloys with high energy
levels, intellect and purity like the bees. Alubee produces components ranging from 10 grams to 2.0
kgs. Alubee caters to various types of industrial needs in India and abroad. The service is catered in
domains and sectors like automotive, electrical, and textile, power tools, solar, etc. The mantra that
Alubee follows is: “Always yes to the customer.” This is the attitude of every “Alubean,” who strives
with a dedicated interest in satisfying the customers (both internal & external).

Fig 1.1 Alubee Entrance

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1.2 THE JOURNEY

Over 25 years of rich expertise in Die-Casting has propelled us to deliver world-class components to
our customers. The journey began in the mid of the year 1991 as a specialized tool room for making
prototype molds, miniature molds, and job works. Produce regular production molds.

 During the year 1995-2000, the tool room was expanded, added with reputed CNC machines.
 During the years 2001-2005, the Die-casting plant came into existence.
 During the years 2006-2010, facilities for post-casting activities and post-machining activities
were introduced.
 Today Alubee stands as the most attractive solution for any high-pressure die casting needs.
 Alubee is a typical gurukul where not only the alloys are molded, but also tuning the being of
the employees and making they perfect for being and doing.

1.3 THE PROCESS

1.3.1 INTRODUCTION TO DIE-CASTING

Die casting in itself is a unique process. Since the technology consists of mechanical, electrical,
electronics, thermodynamics, hydraulics, and metallurgy, the success of die casting purely depends
on process control. The soundness of casting depends on how the process is controlled during die
casting.Alubee is having its state-of-the-art Die Casting facility equipped with a range of machines
starting from 125 tons, 250 tons, and up to 350 tons capacity. Also, the progressive plan is to add
higher tonnage machines to cater to a wide range of customers and varieties of products.

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Fig 1.3.1 Die casting machines

1.3.2 RAW MATERIALS FOR DIE-CASTING

Aluminium ingots will be procured from reputed and authorized source on and around Bangalore and
Chennai. Based on the customer requirements, the ingots also will be imported from Thailand. All
the raw materials will be subjected to rigorous incoming inspection as per the customer standard, and
all the related testing and measuring facilities are available in-house at alubee. Incoming quality
inspection is performed for colour code, weight, and cut section. The ingots are also subject to
verification for porosity and chemical composition.

Fig 1.3.2 Raw Aluminium

1.3.3 METROLOGY

At Alubee, the advanced state of art metrology department takes care of the dimensional verification
activities for setting parts and all the development components. They are tested to ensure the
accuracy, reliability, and precision of these components. The metrology lab follows the standards that
are required by the customers and also the statutory norms required by the registered authorities for
testing and verification.

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Fig 1.3.3 Metrology

1.3.4 PRESSURE DIE- CASTING PROCESS – A GLANCE

Fully automated high-pressure die casting is set-up. Die casting is the first and foremost process. The
output of subsequent processes depends on this process. Once the ingot is received, it is melted in the
mother furnace. Once the melting set temperature is attained, the alloy is cleaned with drossing
chemicals. After the cleaning process, the molten alloy is ready for use. This molten alloy is
transferred to the holding furnaces using the transfer ladles. After the molten aluminium is transferred
on to the holding furnaces, Nitrogen degassing is performed, and the density index is verified. Only if
the density index less is than two; the alloy is used for casting production.

Fig 1.3.4 Pressure Die-casting machines

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1.3.5 FETTLING – POST-CASTING PROCESS

Once castings are produced, they are moved to the fettling process. Fettling is a post-casting
operation. This post-casting operation includes linishing, trimming, filing, shot blasting, and Vibro
finishing. After the gates are finished, the components are moved for the trimming operation. After
trimming, the minor burrs are removed manually and sent to shot blasting operations. Based on the
customer and the process requirement, either shot blasting or Vibro or both of these operations are
carried out.

Fig 1.3.5 Fettling -Post-casting process

1.3.6 SHOT BLASTING PROCESS
To improve the aesthetic of the component, shot blasting is performed. Stainless steel shots are used
to achieve the desired finishing. Castings are moved to the machining processes after shot blasting is
done.

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Fig 1.3.6 shot blasting process

1.3.7 CNC / VMC MACHINING

The performance of any product majorly depends on the dimensional accuracy of the components.
The accuracy of the components further depends on the accuracy of the machining process.
Computerized numerically controlled machining canters and vertical milling machining centres help
Alubee to produce high precision components.

Alubee has a state-of-the-art CNC machine shop, which consists of CNC machines and VMC
machines. The HASS model VMC canters are imported from the United States and ensure high
accuracy and productivity. The consistency and repeatability of these machines are excellent. LMW
CNC lathes ensure the customer requirements are met 100%.

Fig 1.3.7 CNC/VMC Machine

1.3.8 POST MACHINING OPERATIONS

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Once the CNC and VMC operations are done, the components are moved to post-machining
operations known as secondary operations. In the secondary department, operations like drilling,
tapping, burnishing, multi-head drilling, multi-head tapping, and impregnations are carried out.
Milling, grooving, and bush pressing and other groove cuttings are some of the additional secondary
operations done at Alubee. Post machining operation saves the cost. Instead of performing every
operation in VMC, several operations are carried out in conventional drilling machines, tapping
machines, and burnishing machines. This is to prove the concept of “Think global and work locally.”
Once secondary operations are done, the components are moved to subassembly or moved directly
for the final inspection.

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Fig 1.3.8 Post machining Operations

1.3.9 ASSEMBLY
The vacuum pump assembly is one of the challenging assignments Alubee has undertaken. Safety is
a prime factor since the component is part of the brake assembly system. The vacuum pump
assembly consists of the pump housing, pump plat, the rotor, and the O-ring. The electronic leak
tester ensures the pump does not have any leak. The auto-confirmation mark after the assembly
ensures that the leak is appropriately tested and passed. Alubee has the capacity of assembling around
2000 assemblies per shift.

Fig 1.3.9 Assembly

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1.3.10 FINAL INSPECTION

The final inspection ensures the supply of the right quality of components produced at Alubee to the
customers. This is known as the zero-error station. Most important functional parameters are checked
in the semi-automatic inspection machines. After the auto MFD, the components are moved for the
packing. The quality is taken care of during the entire production process itself; the final inspection
serves as a firewall.

The final inspection is made practical and reliable via inspection through automatic gauges, receiving
gauges, and plug gauges. Varieties of packing available at Alubee includes carton packing, reusable
bin-packing, plastic crates packing & export pallet packing.

Fig 1.3.10 Final Inspection

1.3.11 INFRASTRUCTURE

 Fully automated Japanese high-pressure die casting machines.

 World-class CNC shop equipped with HASS, RoboDrills, and CNC lathes.

 Innovative post-casting and machining setups.

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 Unique precision metrology equipment is operational with CMM, SpectroMax, profile

projectors & Surtronic.

Fig 1.3.11 Infrastructure

1.4 VISION STATEMENT

Alubee is committed to becoming the number one in every segment; we operate in. Alubee strives to
bring pride & joy to all its stakeholders and ensure the holistic growth of “Alubeans” by enhancing
their proficiency.

1.5 MISSION STATEMENT

Alubee strives to provide world-class & innovative products and provide organizational excellence in
every aspect to help fellow “Alubeans,” explore their potential by providing a happy environment.

1.6 MARCHING TOWARDS

 Zero PPM at Customer end

 99 PPM targets for machining

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 Less than 10,000 PPM target for castings.

1.7 CLIENTELE

Fig 1.7 Clientele

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CHAPTER 2

ABOUT THE DEPARTMENT

2.1 INTRODUCTION

2.1.1 HISTORY

The Board of Directors of the National Fire Protection Association in the fall of 1967 authorized the
formation of an Ad Hoc Committee on Electrical Equipment Maintenance to determine the need for
the development of a suitable document on this subject. The purpose of the document would be to
give recommendations on the maintenance of various types of electrical installations, apparatus, and
equipment usually found in industrial and large commercial type installations.

Various highly diversified interests and organizations were invited to participate. At a meeting of the
Ad Hoc Committee held January 10, 1968, in New York, with 31 representatives attending, it was
pointed out that several requests had been made to the National Electrical Code Committee to include
maintenance recommendations in the NEC.

It was noted that electrical safety information breaks down logically into four main subdivisions: (1)
design or product standards; (2) installation standards (as covered by the National Electrical Code
and the National Electrical Safety Code; (3) maintenance recommendations; and (4) use instructions.
The problem was to explore whether something more should be done in the interest of electrical
safety on the maintenance of electrical equipment and what form activity in this field should take. It
was recognized that much has been done to enunciate maintenance needs for specific types of

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equipment by the equipment manufacturers, and that guidance is available on the general subject
from a number of sources. However, it was also felt desirable to bring together some of the general
guidelines in a single document under the NFPA procedure. The stature of the document would also
be enhanced if it could in some way become associated with the National Electrical Code. To this
end, a tentative scope was drafted for presentation to the Board of Directors of the National Fire
Protection Association with a recommendation that an NFPA Committee on Electrical Equipment
Maintenance be authorized.

2.1.2 WHAT IS ELECTRICAL MAINTENANCE

It revolves around maintaining and repairing electronic equipment used in large facilities .Facets of
the work include testing, fixing and replacing equipment in buildings owned by corporations,
government entities and modern industrial plants. One essential ingredient is knowledge of the
National Electric Code, in addition to familiarity with local codes. OSHA (Occupational Safety and
Health Administration) and NFPA (National Fire Protection Association) states that equipment
deterioration is normal, but equipment failure is not inevitable. An effective electrical preventive
maintenance program can reduce accidents, save lives, and minimize costly breakdowns and
unplanned shutdowns of production equipment.

2.1.3 WHY DO WE NEED ELECTRICAL MAINTENANCE

Many lives and properties are lost due to fires and electrocution. Just because electrical appliances
and equipment appears to be functioning does not guarantee that there are no problems. It is often
only during electrical maintenance work that hidden problems become apparent. Most of these fires
and incidents of electrocution are attributed to “faulty electrical wiring” and “lack of maintenance.
Economic losses brought about by fires contribute to reduced productivity and therefore affect the
economy of the country.

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Fig 2.1.3 causes and percentage of cases

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2.1.4 BENEFITS OF ELECTRICAL MAINTENANCE

 Electrical Maintenance Can Save Lives.

 Electrical Maintenance Protects Expensive Equipment.

 Electrical Maintenance Reduce Energy Costs.

 It can save lives, businesses/property because it may prevent electrical problems deteriorating

to such an extent that they cause damage.

2.1.5 WHAT ARE THE ADVANTAGES OF ELECTRICAL MAINTENANCE

You can face some electrical problems in your house or office anytime and you need to call an
electrician to fix the issue. But, to maintain all the electrical components and systems, you need to
hire a professional electrical maintenance service because they can test and inspect your electrical
system on regular intervals, to avoid any complication. They are registered with some associations
which are governed by the government, and they always maintain the safety measurements of your
property. If you have a commercial property that is open to the public then you need some
certifications from a competent authority regarding your commercial electrical system. You must
maintain all regulations implemented by the local authority in this regard. However, electrical
systems in domestic properties are always being neglected and people tend to hire electricians when
they face some emergency issues.

Fig 2.1.5 Advantages of Electrical maintenance

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 There are some certifications like NICEIC certifications for electrical contractors and such
certifications can ensure the quality of such electrical contractors.
 . You can hire such certified contractors for electrical maintenance and they can conduct a
periodical inspection on your property. They can identify the potential issue of your electrical
system and solve them at an initial stage.

 There might be some hidden problems in your electrical systems such as earthing problems
and high resistance connections, and you cannot identify such issues with your DIY tools.
These are dangerous and your employees, family members or customers can get affected by
such problems. Even fatal accidents can occur anytime inside your property and you need to
bear the loss afterward. In this case, you need to maintain your electrical systems by certified
contractors and they can conduct regular tests to ensure the safety measurements of your
property.

 Electrical contractors can provide round the clock services and most of them offer 24×7 call-
out services. So you can call them anytime and you do not need to wait longer during an
emergency issue. It is better to make an annual maintenance contract with such contractors to
maintain the electrical systems of your property.

2.1.6 WHY WOULD YOU HIRE ELECTRICAL MAINTENANCE SERVICES

If you are living in an old building then your home and other utilities accommodate are prone to
exposure, wear and rust. They become harmful and they can damage the electrical wiring of your
building. Similarly, if you want to move to a new home or office then you need to inspect the
property and its electrical layout to ensure your safety. Even you need some qualified electrical
engineers to sketch the layout for a new installation of your electrical system, and they can install
your electrical components with all safety measurements. On the other part, climatic disorders like,
flood, storms and heavy rains can damage your electrical components, and you need to replace them
immediately. If you have a plan for renovation then also you need some electricians to install new
electrical system in your house.

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In those cases, you can hire the best electrical maintenance services and they can provide the above
services at a nominal cost.

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2.1.7 THE IMPORTANCE OF ELECTRICAL MAINTENANCE AND SAFETY

Fig 2.1.7 Importance of maintenance

 Electricity is a very necessary and useful part of our daily lives, its safety precautions should not be
taken for granted. Not only is it vitally important to know how dangerous electricity can be, but
special attention about how poor maintenance on electrical systems can lead to electrical failure in
equipment, or worse, catastrophic fires should also be noted. Although it may seem insignificant,
basic electrical maintenance can go a long way in preventing electrical fires or electrical surges
which can damage property. Below are a few basic tips you can do at your home or business to help
ensure your electrical systems are performing as they should.

 Keep electrical panels free of excessive dust and dirt.

 Do not store items within three feet of electrical panels.

 Keep panels dry and free from potential sources of water.

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 Wipe down panels with lint-free rags and solvents as needed.

 Minimize heat build-up in rooms with electrical panels.

 Inspect panels for any signs of corrosion, loose wires/breakers, and signs of excess heat.

2.1.8 CONCEPT OF MAINTENANCE

Maintenance is the process of maintaining any equipment or machinery in a proper and efficient
conduction. Maintenance can be defined as, the activities required to keep the equipment in operating
condition so that it continue to meet specifications. Thus, maintenance ensures that the production
plant or equipment is available for use at minimum cost for scheduled hours.

2.1.9 TYPES OF MAINTENANCE

 Routine maintenance

 Predictive maintenance

 Breakdown maintenance or corrective maintenance.

 Corrective Maintenance

 Preventive maintenance

2.1.10 ROUTINE MAINTENANCE

WHAT IS ROUTINE MAINTENANCE

Routine maintenance are maintenance activities such as regular inspections or machine servicing.
Routine maintenance is done on a regular basis, whether that be daily, weekly, monthly, or yearly.
Routine maintenance is an important part of keeping systems up to date and functional.

ROUTINE MAINTENANCE WORKFLOW

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Fig 2.1.10 routine maintenance

2.1.11 PREDICTIVE MAINTENANCE

WHAT IS PREDICTIVE MAINTENANCE?

Predictive maintenance (PdM) is a type of condition-based maintenance that monitors the condition
of assets using sensor devices. These sensor devices supply data in real-time, which is used to predict
when the asset will require maintenance and prevent equipment failure.

PREDICTIVE MAINTENANCE WORKFLOW

The graphic below outlines the predictive maintenance workflow from start to finish. The ultimate
goal with predictive maintenance is to catch breakdowns before they happen by monitoring
equipment conditions.

Fig 2.1.11 predictive maintenance

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THE BENEFITS OF PREDICTIVE MAINTENANCE

Predictive maintenance stands to improve your maintenance and reliability program as a whole. By
using technology and best practices to streamline processes and increase productivity. A few of
the top benefits of predictive maintenance are:
 Increasing asset uptime by 30% and reducing unexpected failures by 55%.
 Streamlining maintenance costs through reduced labor, equipment, and inventory costs.
 Improving safety.

2.1.12 BREAKDOWN MAINTENANCE OR CORRECTIVE

MAINTENANCE

WORKFLOW

Fig 2.1.12 Breakdown maintenance

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2 TYPES OF BREAKDOWN MAINTENANCE

PLANNED MAINTENANCE

Planned maintenance means that the organization is prepared for a breakdown and even expects it to
happen. The equipment runs until it breaks, which initiates a run to failure (RTF) trigger. While RTF
triggers can be unplanned, breakdown-maintenance plans use RTF as a way of lowering the cost of
maintenance.
This kind of plan needs to be rigorously documented and controlled. Employees should be clear on
exactly which parts will break down and which parts will be maintained normally via preventive
maintenance. Without these checks, a breakdown maintenance plan can be exploited or run awry.

UNPLANNED BREAKDOWN MAINTENANCE

Unplanned breakdown maintenance, on the other hand, occurs when a piece of equipment fails or
breaks unexpectedly—also called an unplanned downtime event. While some facilities may not
utilize a planned maintenance plan, nearly every facility needs resources in place for
unplanned maintenance. After all, every piece of equipment will break or fault at some
point in its life.

2.1.13 CORRECTIVE MAINTENANCE

WHAT IS CORRECTIVE MAINTENANCE?

Corrective maintenance (also called breakdown maintenance) are tasks that are performed in order to
rectify and repair faulty systems and equipment. The purpose is to restore broken down systems.

CORRECTIVE MAINTENANCE WORKFLOW

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Fig 2.1.13 corrective maintenance workflow

2.1.14 PREVENTIVE MAINTENANCE

What is preventive maintenance?

Preventive maintenance is a type of proactive maintenance that includes adjustments, cleaning,

lubrication, repairs, and parts replacements. PM keeps assets in good order and reduces unscheduled
downtime and major repairs.

PREVENTIVE MAINTENANCE WORKFLOW

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Fig 2.1.14 Preventive maintenance workflow

HOW PREVENTIVE MAINTENANCE DECREASES DOWNTIME

Think about it in simple terms such as with your car. Oil changes and regular servicing are part of a
preventive maintenance schedule that ensures your car runs properly and without unexpected failure.
If you ignore that maintenance schedule and Miss Service intervals, your car will depreciate in value
and utility. The same goes for machinery in manufacturing plants and equipment in facilities.

With a PM schedule in place, maintenance managers can decrease downtime. This schedule is
usually automated with a CMMS that comes with PM scheduling software. However, managers are
always cautious of over-maintaining assets. There’s a point where preventive maintenance starts
costing too much in relation to the amount of downtime it prevents.

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Fig 2.1.14 Preventive maintenance decreases downtime

2.2 TYPES OF MAINTENANCE WORKERS

A maintenance worker is responsible for the upkeep of a facility and the assets within that facility.
But not every maintenance worker uses the same tools and tactics to achieve this. Different types of
maintenance workers collaborate as a team. Some teammates strategize and plan using maintenance
software (e.g. maintenance planners); others get their hands dirty by executing repairs and
inspections (e.g. maintenance technicians).
Delegating responsibilities among different types of workers strengthens an organization’s ability to
schedule more maintenance, improve schedule compliance, increase uptime, execute repairs faster,
and retain good talent. It’s tempting for organizations to save money by giving a worker the
responsibilities of several job titles, but this is not an effective approach. For larger organizations that
need to hit production quotas, uptime SLAs, or certain levels of customer satisfaction, it’s essential to
hire a team of maintenance workers with different skills.

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The type of maintenance worker you need to employ depends on the type of workers you already
employ, your goals, and your industry (manufacturing, property management, etc). For instance, if
you manage a manufacturing plant and have enough technicians but want to increase your percentage
of planned work, you need to hire a maintenance planner. And if you manage a small property that
contracts out repairs and want to decrease turnaround times for work requests, you need to hire a
maintenance technician.

2.2.1 MAINTENANCE TECHNICIAN

A maintenance technician is the maintenance worker that performs the most hands-on work. They
perform preventive maintenance tasks (e.g. lubrication), emergency repairs (e.g. parts replacements),
and inspections.

In some facilities, the maintenance technician is a “jack of all trades” and works on many different
types of equipment. However, they do not perform major repairs and rebuilds. This work is either
contracted out or assigned to a maintenance engineer.

2.2.2 MAINTENANCE ENGINEER

A maintenance engineer is certified to perform repairs and rebuilds on specific types of equipment.
They also diagnose failures when equipment breaks down and help create preventive maintenance
schedules. This combination of hands-on maintenance and maintenance strategy requires them to
work with both technicians and planners.

2.2.3 MAINTENANCE PLANNER

A maintenance planner makes sure technicians and engineers have everything they need—tools,
parts, documentation, etc—to perform scheduled work as efficiently as possible. They coordinate
with parts managers, maintenance managers, and other teammates to make this happen. They also
coordinate with managers from other departments like production to plan for site-wide shutdowns.
Depending on how large a facility is, there is either a separate maintenance scheduler and

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maintenance planner, or a single maintenance worker that performs both planning and scheduling
functions.

Fig 2.2.3 Types of Maintenance Workers

2.3 PROGRAM MISSION

The Electrical Installation & Maintenance Technology program's mission is to serve the community
as a learning-canters, open door program that provides technical training to meet the demands of the
electrical industry and the needs of the individual. An open-exit option allows the students to identify
their career objectives and participate in program exploration.

2.4 PROGRAM DESCRIPTION

The curriculum is designed to prepare students with entry level knowledge and manipulative skills
for employment in the electrical industry. The program combines theory with laboratory activities as
an effective means of developing the skills essential to the electrical trade. The student begins with
the fundamentals of electricity and wiring of simple circuits, then progresses to residential interior
wiring, three phase alternating current power, and wiring of more complex circuits and equipment.
Safety is stressed as an integral part of each shop task. Emphasis is placed on wiring in accordance
with the provisions contained in the National Electrical Code.

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CHAPTER 3

TASK PERFORMED

3.1 INTRODUCTION

Your facilities depend on efficient and reliable management of your electric power, distribution,
control, security, communications and heating/lighting systems. A well-trained electrical
maintenance staff, coupled with the performance of regular industrial electrical maintenance tests, is
critical to ensuring safe, reliable operation. Use the Electrical Maintenance training to raise
awareness of potential hidden problems in your electrical systems before they grow to become
disasters. Electrical maintenance covers all aspects of testing, monitoring, fixing, and replacing
elements of an electrical system. Usually performed by a licensed professional with a complete
knowledge of the National Electric Code and local regulations, electrical maintenance covers areas as
diverse as: – Digital communication.

3.2 ELECTRICAL SAFETY EQUIPMENT

 Insulated Gloves
 Insulated Matting
 Insulated Ladders
 Rescue Rods
 Life Saving Kits
 Earthing & Short Circuit Kits
 Earthing Clamps & Fittings
 Operating Rods
 Voltage Detectors
 Warning Signs & Tapes
 Partial Discharge Detectors
 Gas Detection Equipment

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3.3 ELECTRICAL SAFETY EQUIPMENT

Your employees are your company’s most important asset, and you want to ensure that they stay safe
when doing any type of electrical testing, repair work, installation or maintenance.
At PowerPoint Engineering, we understand how important workplace safety is for you. We
understand the protection you require and as such we only work with the best manufacturers in our
industry, providing quality and innovative products and solutions. We supply the complete range of
electrical safety equipment and we are market leaders in the supply of insulating gloves, insulating
matting, earthing & short-circuiting kits, Arc Flash PPE or rescue hooks, sticks and kits.

3.4 LIFE SAVING KITS, RESCUE HOOKS & OPERATING RODS

3.4.1 INSULATED GLOVES

Choose from SOFAMEL Insulated Gloves, Regeltex Insulated Gloves (Class 00 – 4), Linesman
Leather Over gloves, Cotton Inner Mittens, Pneumatic LV Glove Testers and Plastic Glove Storage
Boxes.

3.4.2 INSULATED MATTING

With our wide selection of insulated matting, you can find the right solution for use at switchboards
and transformers and in other high voltage areas of your facilities. Email us for assistance selecting
the right matting for your needs.

3.4.3 EARTHING & SHORT CIRCUITING

we supply SOFAMEL earthing & short-circuiting kits, as well as customised earthing kits that are
tailored to your exact requirements.

3.4.4 ARCFLASH
Choose from Arc Flash gloves, Arc flash face shields, Arc flash coveralls, Arc Flash protective hoods
& Jackets from leading brands program.

 Insulated Gloves – Insulated gloves will prevent electricity from traveling into your hands
should there be an exposed wire, short circuit, or other issue.

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 Insulated Matting – Insulated matting will put a protective layer between the employee and
the floor. This is helpful when working at switchboards, transformers, and other high-voltage
areas. It can help prevent electricity from traveling up from the floor into the person’s body,
as well as eliminating a path for electricity to travel through the body and out to the floor.
 Insulated Ladders – Insulated ladders won’t transmit electricity into the person who is using
it. If a normal metal ladder accidentally touches a live electrical wire, it can be devastating.
With the insulated ladder, this isn’t an electrical concern.
 Rescue Rods – In the event that someone is being electrocuted, people will be tempted to
rush in to save them. Unfortunately, this will only lead to them becoming electrocuted as
well. Having a rescue rod present will allow those in the areas to pull the victim to safety, or
push the source of the electricity away.
 Voltage Detectors – Even after a power source has been removed, there can still be
electricity in a system because of capacitors. A voltage detector will show the level of
electricity in a given system at the current time, so employees won’t mistakenly begin
working on a system until all power has been eliminated.

3.5 PERSONAL PROTECTIVE EQUIPMENT (PPE)

3.5.1 PROTECTING EMPLOYEES FROM

 Workplace Hazards Workplace Hazards

 Employers must protect employees from workplace hazards such as machines, work
procedures, and hazardous substances that can cause injury
 Employers must: ¾ Use all feasible engineering and work practice controls to
eliminate and reduce hazards ¾ then use appropriate PPE if these controls do not
eliminate the hazards.
 Remember, PPE is the last level of support!

3.5.2 EXAMPLES OF PPE

• Eye - safety glasses, goggles

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• Face - face shields

• Head - hard hats
• Feet - safety shoes
• Hands and arms - gloves
• Bodies - vests
• Hearing - earplugs, earmuffs

3.5.3 EYE PROTECTION

• Dust and other flying particles, such as metal shavings or sawdust

• Molten metal that might splash

• Acids and other caustic liquid chemicals that might splash

• Blood and other potentially infectious body fluids that might splash, spray, or splatter

• Intense light such as that created by welding and lasers

3.5.4 SAFETY SPECTACLES

• Made with metal/plastic safety frames
• Most operations require side shields
• Used for moderate impact from particles produced by such jobs as carpentry,
woodworking, grinding, and scaling

3.5.5 GOGGLES

• Protect eyes, eye sockets, and the facial area immediately surrounding the eyes from
impact, dust, and splashes
• Some goggles fit over corrective lenses

3.5.6 FACE SHIELDS

• Protect the face from nuisance dusts and potential splashes or sprays of hazardous
liquids

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• Do not protect employees from impact hazards

3.5.7 HEAD PROTECTION

What are some of the causes of head injuries?
• Falling objects
• Bumping head against fixed objects, such as exposed pipes or beams
• Contact with exposed electrical conductors
3.5.8 HEARING PROTECTION
What are some of the causes of foot injuries?
• Heavy objects such as barrels or tools that might roll onto or fall on employees’ feet
• Sharp objects such as nails or spikes that might pierce the soles or uppers of ordinary
shoes
• Molten metal that might splash on feet
• Hot or wet surfaces
• Slippery surfaces

3.5.9 SAFETY SHOES

• Have impact-resistant toes and heat-resistant soles that protect against hot surfaces
common in roofing, paving, and hot metal industries
• Some have metal insoles to protect against puncture wounds
• May be designed to be electrically conductive for use in explosive atmospheres, or
nonconductive to protect from workplace electrical hazards

3.6 SUMMARY
Employers must implement a PPE program where they:
• Assess the workplace for hazards
• Use engineering and work practice controls to eliminate or reduce hazards before
using PPE
• Select appropriate PPE to protect employees from hazards that cannot be eliminated

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• Inform employees why the PPE is necessary and when it must be worn
• Train employees how to use and care for their PPE and how to recognize deterioration
and failure

3.7 WHAT ARE ELECTRICAL TOOLS

Electrical tools are used to do the electrical work like electrical wiring installations by using
this tool we can do the installation of electrical wire properly and quickly. We must be able to
choose the right equipment or tools to do the electrical work then only the quality of our work
will improve. By using electrical tools we could do the electrical tasks effortlessly.

Fig 3.7 Electrical tools

 Hammer
 Torpedo level
 Flashlight
 Utility knife
 Tape measure
 Needle-nose pliers
 Philips screwdrivers
 Straight-blade screwdrivers
 Allen wrench set (hex set)
 Tongue-and-groove pliers

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 Non-contact voltage tester

 Wire strippers
 Linesman pliers
 Diagonal cutting pliers
 Fish tape
 Voltmeter or multimeter
 Wire crimpers

3.8 HOW MUCH ELECTRICITY IS DANGEROUS?

How Much Electricity is Dangerous Current through the body, even at levels as low as 3
milliamperes, can also cause injuries of an indirect or secondary nature in which involuntary
muscular reaction from the electric shock can cause bruises, bone fractures and even death
resulting from collisions or falls (i.e. fall from a ladder after receiving a small shock).

Fig 3.8 Typical effects on the human body based on exposure

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Fig 3.8 Effects of electrical current in the human body

3.9 CONTROL INADEQUATE WIRING HAZARDS

Electrical hazards result from using the wrong size or type of wire. You must control such
hazards to create a safe work environment. You must choose the right size wire for the
amount of current expected in a circuit. The wire must be able to handle the current safely.
The wire’s insulation must be appropriate for the voltage and tough enough for the
environment. Connections need to be reliable and protected

 Use the right gauge and type of wire. ❚

 AWG—American Wire Gauge— a measure of wire size

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Fig 3.9 Different wire gauges

Use the right extension cord the gauge of wire in an extension cord must be compatible with the
amount of current the cord will be expected to carry. The amount of current depends on the
equipment plugged into the extension cord. Current ratings (how much current a device needs to
operate) are often printed on the nameplate. If a power rating is given, it is necessary to divide the
power rating in watts by the voltage to find the current rating. For example, a 1,000-watt heater
plugged into a 120-volt circuit will need almost 10 amps of current. Let’s look at another example:
A 1-horsepower electric motor uses electrical energy at the rate of almost 750 watts, so it will need
a minimum of about 7 amps of current on a 120-volt circuit. But electric motors need additional
current as they startup or if they stall, requiring up to 200% of the nameplate current rating.
Therefore, the motor would need 14 amps. Add to find the total current needed to operate all the
appliances supplied by the cord. Choose a wire gauge that can handle the total current.

Fig 3.9 American Wire Gauges

3.10 CONTROLLING HAZARDS: SAFE WORK ENVIRONMENT

When You Must Work on or Near Live Circuits Working on live circuits means actually
touching energized parts. Working near live circuits means working close enough to
energized parts to put you at risk even though you may be working on de-energized parts.
Common tasks where you need to work on or near live circuits include:

 Taking voltage and current measurements,

 Opening and closing disconnects and circuit breakers,

 Racking circuit breakers on and off the bus,

 Removing panels and dead fronts

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For other situations where you might need to work on or near live circuits, your employer
should institute a written live-work permit system, which must be authorized by a qualified
supervisor. Live-work permit system a live-work permit should, at least, contain this
information:

 A description of the circuit and equipment to be worked on and the location,

 Explanation why the work must be done “live”,
 Date and time covered by the permit,
 A description of the safe work practices to be used,
 Results of shock hazard analysis and determination of shock protection boundaries,
 Results of flash hazard analysis and determination of the flash protection boundary,
 PPE needed to safely perform the job, who will do the work and how unqualified
persons will be kept away, and evidence of completion of job briefing, including
discussion of job-specific hazards.
 Energized-work approval signatures (authorizing or approving management, safety
officer, owner, etc.). To work on or near live parts, you must do the following:
 Have a written live-work permit for the work to be done.
 Wear the right PPE to protect against electric shock and arc flash. Never wear clothing
made from synthetic materials, such as acetate, nylon, polyester, polypropylene, or
rayon – alone or combined with cotton. Such clothing is dangerous because it can
burn and melt into your skin. The PPE that’s needed depends on the type of electric
work being done. The minimum PPE required would be an untreated natural fiber
long-sleeve shirt and long pants plus safety glasses with side shields. Depending on
the voltage and the electric task to be done, different types of PPE are required. Fire-
resistant protective clothing can include multi-layer flash suit jacket and pants,
wraparound face shield, double-layer switching hood, voltage-rated gloves with
leather protectors, electrically rated hard hats, and so forth.

3.11 ELECTRICAL FIRES

Electricity is one of the most common causes of fires and thermal burns in homes and

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workplaces. Defective or misused electrical equipment is a major cause of electrical fires. If

there is a small electrical fire, be sure to use only a Class C or multipurpose (ABC) fire
extinguisher, or you might make the problem worse. All fire extinguishers are marked with
letter(s) that tell you the kinds of fires they can put out. Some extinguishers contain symbols,
too. The letters and symbols are explained below (including suggestions on how to remember
them).

Fig 3.11 Electrical fires

Fig 3.11 Electrical fire extinguishers

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3.12 FIRST AID FACT SHEET

The electrical current if the victim is still in contact with the energized circuit. While you do
this, have someone else call for help. If you cannot get to the switchgear quickly, pry the
victim from the circuit with something that does not conduct electricity such as dry wood. Do
not touch the victim yourself if he or she is still in contact with an electrical circuit! You do
not want to be a victim, too! Do not leave the victim unless there is absolutely no other
option. You should stay with the victim while emergency medical services (EMS) are
contacted. The caller should come back to you afterwards to verify that the call was made. If
the victim is not breathing, does not have a heartbeat, or is badly injured, quick response by a
team of emergency medical technicians (EMTs) or paramedics gives the best chance for
survival.

Fig 3.12 First aid fact sheet

3.13 TRANSFORMER

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Fig 3.13 Step down Transformer

Electrical transformers are an expensive and important part of any machinery. So for getting optimal
performance and increased product life, it is best to conduct regular maintenance check-ups on your
machinery.

There are basically two types of transformer maintenance. One is done on a regular basis and the
other is done at the time of urgency. If maintenance check-ups are done on a routine basis then you
may not have to undergo breakdown maintenance and hence save downtime.

There are a lot of different types of maintenance checks to be conducted on a power transformer.

Here are some of the main transformer maintenance actions that have to be performed:

3.13.1 Transformer Maintenance Checks on a Monthly Basis

1. Oil level in the oil cap must be checked on a monthly basis so that it doesn’t drop below a
fixed limit and hence avoid damage due to it.

2. Keep the breathing holes in the silica gel breather clean to ensure proper breathing action at
all times.
3. If your electrical transformer has oil filling bushing, make sure that the oil is filled up to the
correct level. 

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3.13.2 Daily Basis Maintenance Testing and Checking

Here are 3 maintenance tests you should run on your transformer on a daily basis:

1. Oil levels of MOG (Magnetic Oil Gauge) of the main tank and conservator tank. Always
maintain to keep oil filled up to the desired level in MOG.

2. Replace the silica gel if its colour changes to pink.

3. If any leakage is detected seal it.

3.14.3 Annual Transformer Maintenance Schedule

The air fans, oil pumps along with other items that are used to cool down a transformer and control
circuit must be inspected annually.

1. Make sure that you clean all the bushings of your electrical transformer with only soft cotton
cloth annually.

2. Oil condition of OLTC should be carefully examined on an annual basis. For that take an oil
sample from drain valve and test it for moisture content (PPM) and dielectric strength (BDV).
If the BDV value is found low and the PPM value high, then the oil needs to be replaced.
3. Make sure to clean out the inside of all of the marshalling boxes annually. Check proper
functioning of the space and illumination heaters. All of the terminal connections of control
and relay wiring need to be tightened at least once a year.
4. All the control switches, alarms and relays along with their circuits, Remote Tap Changer
Control Panel and Relay and Control Panel have to be cleaned with a proper cleaning agent.
5. Examine all the pockets for the Winding Temperature Indicator and Oil Temperature
Indicator if they have the necessary level of oil and make sure to top it up if required.
6. The proper function of Buchholz and Press Release Device relay need to be checked on a
yearly basis.
7. Make sure to measure the resistive value of the earth connection should be measured annually
with a clamp on the earth resistance meter. 

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3.15.4 Transformer Maintenance on a Half Yearly Basis

Your electrical transformer needs to be checked every 6 months for IFT, DDA, flash point, sludge
content, acidity, water content and dielectric strength along with how resistant it is to transformer oil.

3.15 MAINTENANCE OF EARTHING EQUIPMENT, VISUAL

INSPECTION
 

The correct handling and maintenance of the equipment contributes towards upholding the product’s
protective capacity. Tools should be kept clean and dry as well as protected against damage during
use, transport and storage. Earthling and short-circuiting equipment shall be handled with great care
and be thoroughly inspected before each application.

Earthling equipment must be checked regularly according to the checklist below to ensure that the
tools work safely and reliably. Damage of cable insulation or exposure of bare cable conductor shall
be regarded as a serious fault and disposal should be considered.
A more extensive inspection, a so called “recurring test” shall be carried out by an authorized
inspector and should be executed annually or perhaps with a shorter interval for equipment exposed
to great wear and tear, see “Services” alternatively “Products - Maintenance of earthling equipment”.

NOTE: A device that has been exposed to short-circuit current shall be disposed of unless it is
proved by thorough investigation, calculation and inspection, that the exposure has been too
moderate to give any negative mechanical or thermal effects. If there is any doubt as to the perfect
condition of the device, it shall be disposed of.

1.  Corrosion damage  
Check for signs of corrosive damage to contact surfaces on
Line clamps/Earth clamps. If defected, the surfaces must
be cleaned. If heavy corrosion is detected the clamps
should be replaced.
Insure that the clamping screw can be easily fully drawn.  

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2.  Cable lug connection

Check the cable lug’s connection to the clamp - the screw
must be firmly tightened and the cable lug firmly attached.
Check for breaks on cable lugs. Damaged cable lugs have
to be replaced.
    
Twisted (not broken) cable lugs can be adjusted to the
correct position. After this, check for breaks and check the
tightening torque. If the screw must be tightened, the
spring washer must be replaced as it has lost some of its
locking capacity.
3.  Damaged cable connection
The most common damage on an earthing device can be  
found on the cable connection. Check that no cable strands
are damaged. If a strand is damage the cable should be re-
pressed. When the wires are intact, insulation damage can
be temporarily repaired using vulcanized tape or similar
material.
4.  Damaged Cable
 
Check for any damage on the cables. A damaged cable
(strand breakage) must be replaced. Insulation damage can
be temporarily repaired using vulcanized tape or similar
material.
5.  Dirty insulating poles
Insulating poles must be free of moisture and  
contamination. The poles should be cleaned with acetone
or industrial alcohol in a well ventilated space. The poles
should then be treated with silicone. Silicone of type DC
200 100 cSt is applied with a clean cloth.
6.  Damaged Pole  
Inspect for damaged poles. If damage is severe, replace the

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pole.

7.  Damaged Connection Fitting  

Inspect the connection fitting for damage. If damaged,
replace with new fitting.

3.16 DIESEL GENERATOR

   

A diesel generator is the combination of a diesel engine with an electric generator (often an
alternator) to generate electrical energy. This is a specific case of engine-generator. A diesel
compression-ignition engine often is designed to run on fuel oil, but some types are adapted for other
liquid fuels or natural gas.

3.16.1 Routine General Inspection

During the running of the diesel generator, the exhaust system, fuel system, DC electrical system and
engine require close monitoring for any leaks that can cause hazardous occurrences.

3.16.2 Lubrication Service

The engine oil must be checked while shutting down the generator at regular intervals using a
dipstick. Allow the oil in the upper portions of the engine to drain back into the crankcase and follow
the engine manufacturer’s recommendations for API oil classification and oil viscosity..

3.16.3 Cooling System

Check the coolant level during shutdown periods at the specified interval. Remove the radiator cap
after allowing the engine to cool, and, if necessary, add coolant until the level is about 3/4 in. Heavy-
duty diesel engines require a balanced coolant mixture of water, antifreeze, and coolant additives..

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3.16.4 Fuel System

Diesel is subject to contamination and corrosion within a period of one year, and therefore regular
generator set exercise is highly recommended to use up stored fuel before it degrades. The fuel filters
should be drained at the designated intervals due to the water vapor that accumulates and condenses
in the fuel tank.

3.16.5 Testing Batteries

Weak or undercharged starting batteries are a common cause of standby power system failures. The
battery must be kept fully charged and well-maintained to avoid dwindling by regular testing and
inspection to know the current status of the battery and avoid any start-up hitches of the generator.
They must also be cleaned; and the specific gravity and electrolyte levels of the battery checked
frequently.

3.16.6 Routine Engine Exercise

Regular exercising keeps the engine parts lubricated and thwart oxidation of electrical contacts, uses
up fuel before it deteriorate, and helps to provide reliable engine starting. Engine exercise is
recommended to be executed at least once a month for a minimum of 30 min. loaded to no less than
one-third of the nameplate rating.

3.16.7 Keep your Generator Clean

Oil drips and other issues are easy to spot and take care of when the engine is nice and clean. Visual
inspection can guarantee that hoses and belts are in good condition. Frequent checks can keep wasps
and other nuisances from nesting in your equipment.
The more a generator is used and relied on, the more it needs to be taken care of. However, a
generator set that is rarely used might not need a lot of care.

3.17 LIGHTING OPERATIONS & MAINTENANCE

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Lighting operations and maintenance ("O&M") are the practices that keep lighting systems working
at peak performance during the life of the building. As a designer, your choices can make it easy or
hard to maintain your lighting system.

3.17.1 Operations Manuals

Good design process can help ensure good operations and maintenance routines. The lighting
designer should create a manual for operations staff that makes the lighting design intent clear, lists
maintenance and replacement schedules, and makes it clear what parameters should be measured
during commissioning, as well as how often such measurements should be done.

3.17.2 Schedules
An important part of the O&M manual is schedules for cleaning fixtures, replacing bulbs, and
measuring energy use and lighting levels. Performance measurements should be done monthly or at
least quarterly, to provide operators with enough data to tell when systems are beginning to perform
poorly.

3.17.3 Flexibility
When building occupants bring in their own lights, it may be an indication that the lighting system is
not working as designed, or was not designed to meet the current users' needs. Have the flexibility to
work with users to meet their needs while ensuring energy efficiency. This may mean changes to the
original design, or helping occupants choose efficient products for their personal use.

3.17.4 Cleaning
Keeping lamps and fixtures clean may be the most important factor in keeping their performance
high. However, it is often neglected. Walls, ceilings, and other lit surfaces should also be kept clean,
as their reflection of light is sometimes as important as the fixtures themselves.
Clean bulbs and fixtures with soft moist cotton cloth, soft-bristled anti-static brush, or low-power
vacuum cleaner.

3.17.5 Replacement

Bulbs should be replaced not only when they break, but on a schedule according to how the
brightness of the lamp decays over time. Some bulbs lose over a third of their initial brightness over a
few years.

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3.17.6 Operation of Control Systems

lighting control systems are often run by timers. Such timers should be set to match the activity
schedules of different spaces. These schedules change over the years as building use changes.

3.18 THE BEST WIRE MAINTENANCE CHECKLIST FOR

INDUSTRIAL USAGE

Cables and wires are the elements of support system of most industrial applications. They have to be
maintained well, or the entire working system comes to a standstill. Even a slight interruption or
breakdown can lead to a drop in an industry’s profit margin. Following some basic guidelines and
right maintenance will increase the lifespan of your wires.

3.18.1 Choose Right

Choose the most appropriate cable which is suitable for your industrial usage by acquiring enough
knowledge about different kinds of cables that are available in the market. Choose the appropriate
cable size recommended for your industry. Also, one should train and educate the staff on periodic
maintenance so as to identify the signs if any failure occurs.

3.18.2 Prevention of Damage

Keep a close watch when the wires are being installed. Wires should be laid as straight as possible to
avoid any mechanical stress on the conductors. Avoid twisting of wires or making a knot of the cable
bunch, while laying the wire at any application, which shall improve the performance of the cable.
Prevent any impact, puncture or crushing that could damage the wire jacket. Consult a professional
for recommendations on the industrial setting system. 

3.18.3 Repairs on time

Check your wires and cables regularly to avoid any major mishaps in the future. Perform repairs
immediately if any wires or cables are damaged or found to be on the verge of getting damaged.
Crushed and damaged cables should be removed before they can lead to an unsafe condition.

3.18.4 Always maintain records

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It is always advisable to maintain repository of the cables and wires installed in your industry.
Installation date of the wires and cables gives an idea about the lifespan of their working. Also, have
a record of the cable laying procedure for all future reference

3.18.5 Loose Wire Connections at Switches and Outlets

By far the most common problem is when screw terminal connections at wall switches and outlets
become loose. Because these fixtures get the most use within an electrical system, these are the
places to look first if you suspect wire connection problems.

3.18.6 Wire Connections Made With Electrical Tape

A classic wire connection error is when wires are joined together with electrical tape rather than a
wire nut or other sanctioned connector

3.18.7 Two or More Wires Under One Screw Terminal

Another common wire connection problem is when you find two or more wires held under a single
screw terminal on a switch or outlet. This is a clear sign of amateur work and a distinct fire hazard.

3.18.8 Exposed Wires

It is quite common, especially with amateur electrical work, to see a screw terminal connection or
wire nut connection where it has too much (or too little) exposed copper wire showing at the wires.

CHAPTER 4

REFLECTIONS
4.1 INTRODUCTION

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Internship at Alubee Die Casters Limited was started from 29.09.2020 for a period of one month.
Electrical maintenance engineer is very knowledgeable person with immense of experience in the
industry. Personnel Officer assigned topic, which is Study on the role of Electrical maintenance
department & Electrician in the industry.

During the internship period we had the opportunity to interact with several employees, a task
which further enabled us to access their knowledge and experience in technical and non-technical
aspects. The experience gained is vast and they are briefed in points below.

We came to know about how the practical knowledge playing an important role of an Electrical
Engineer. We now have an idea about the Industrial equipment that are used and how it can be
handled.

➢ Overseeing the planning, operation and interdepartmental function that contributes to the smooth
functioning of the organization.

➢ interacting with various staffs for gaining their experience and increasing the Practical skills of
real time working in an organization.

➢ Strategic planning of production that helps in achieving the monthly and yearly targets with less
discrepancy.

4.2 TECHNICAL OUTCOMES:

➢ Learnt about the safety precautions to be followed while performing each and every task and
completing it without causing damage to life and property.

➢ Learnt about safety procedure like first aid to be followed in case of emergency.

➢ increased our knowledge on transformers practically.

4.3 NON-TECHNICAL OUTCOMES:

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➢A vast improvement is happened for good future career. Few improvements were made in, verbal
and non-verbal communications skill and also in soft skill. Overall improvements will help for
professional life career.

➢Handling the work alone have taught us to be punctual and competing the tasks on right time.

➢After completion of the internship in overall confidence was boosted.

➢Learnt how to manage a store and track the usage of materials and how to economically use the
materials available.

➢Learnt the working of commercial department, as to how they produce the materials and how they
choose the best vendor.

➢Learnt the functioning of Admin and HR department and gathered information about how they
train the new employee.

➢ Handling the work alone did learn to be punctual and competing the tasks on right time.

4.4 ELECTRIC SHOCK AND ITS MANAGEMENT:

The human body conducts electricity. If any part of the body receives an electric shock, the
electricity will flow through the tissues with little obstruction.

Depending on the length and severity of the shock, injuries can include:

➢ Burns to the skin

➢ Burns to internal tissues

➢ Electrical interference or damage (or both) to the heart to stop or beat erratically. Always
disconnect the power supply before trying to help a victim of electric shock.

4.4.1 CAUSES OF ELECTRIC SHOCK:

➢ Insulation failure

➢ Faulty appliances

➢ Damaged or frayed cords or extension leads

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➢ Electrical appliances coming in contact with water

➢ Incorrect or deteriorated household wiring

➢ Downed power lines

➢ Lightning strike

4.4.2 SYMPTOMS OF ELECTRIC SHOCK:

The typical symptoms of an electric shock include:-

➢ Unconsciousness

➢ Difficulties in breathing or no breathing at all

➢A weak, erratic pulse or no pulse at all

➢ burns, particularly entrance and exit burns (where the electricity entered and left the body)

➢Sudden onset of cardiac arrest. Sometime victims of electric shock may appear to be unhurt, but
they should still be treated as a victim of electric shock.

4.5 KEY LEARNING:

➢ The Company’s strict policy of adherence to quality standards.

➢ Sampling process done for inspection of the quality of the procured materials whether they fall
within the prescribed limits of quality dimension or not. This approved and checked by various
departments like procurement, quality, control and production to ensure the quality.

➢The maintenance plan which is done monthly, based on the schedule of maintenance and the w

➢ All the workers skilled in performing all the types of maintenance seen. Work rotation is being
done efficiently workers allotted to each operation so maintenance process is optimized.

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CHAPTER 5

CONCLUSION

Electrical maintenance forms an important link between two transmission networks or between the
transmission lines for industrial equipment’s. It has vital influence on reliability of service. Apart
from ensuring efficient transmission and distribution of power, the MNT dept. configuration should
be such that it enables easy maintenance of equipment and minimum interruption in power supply.

From the internship we have observed the maintenance done in a regular basis to ensure proper
functioning of the equipment. Since any major damage can cause a lot of loss, maintenance is very
important to avoid it. Maintenance department which is required to provide a continuous reliable
supply takes care of the equipment thoroughly, failing to do so, leads to major damage and loss.

We are made aware of how the safety of equipment’s are done. We too came to know about various
parts of industrial equipment’s. The three wings of electrical system viz. primitive maintenance,
predictive maintenance, and routine maintenance are connected to each other and that too perfectly.

Thus, for the effective maintenance must have:

➢ Ensure steady state and transient stability.

➢ Effective voltage control.

➢ Prevention of loss synchronism.

➢ Reliable supply by feeding the network at various parts.

➢ Fault analysis and improvement in respective fields.

➢ Establishment of economic load distribution.

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The personnel over there all actively perform the maintenance to achieve this. We have learnt the
task being carried out, as daily, weekly, and monthly routine checking of equipment for efficient
running on a daily basis. We got a chance to learn about the maintenance of the equipment’s of
substation. Hence we have carefully studied about the maintenance department how it is carried out
on the basis of daily, monthly, periodic, yearly and half yearly so that the all the equipment works
smoothly and efficiently and power supply should be continuous, we sincerely thank our
Maintenance engineer Mr. Prabhu Ram of Alubee die Caster in guiding us the complete knowledge
about maintenance of Electrical department

By seeing the above Scenario we can finally conclude that the Alubee Die Casters which is found to
be one of the most important leading company.

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REFERENCES

The information taken in this internship report is from:

1. www.electrical4u.com

2. www.tnelectric.org

3. www.quora.com

4. www.Alueediecasters.com

5. www.electricityforum.com

6. Handbook on maintenance of electrical general services of industry

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