TRAINING FOR TRAINERS

HOW TO BECOME GLOBAL PLAYER?

• Global size
• Cost competitiveness
• Perfect Delivery system
• Adopt best management practices

WHAT IS IMPORTANT FOR US TO

CONTRIBUTE TOWARDS OUR VISION?
• Asset management
• Maintenance Management of Asset is one of
the important functions that we do !!!
Maintenance Management :
Change of Concept !!!!

Maintenance earlier remained a ‘Cost Center’

now it is a ‘Profit Center’

• How to achieve that role?

• What role we will have to play?
 What should be the aim of
Maintenance Management?
• Focus on Availability of equipment.

• Focus on Reliability of equipment

• Frequency of breakdown should be reduced

to ZERO

• Adopt benchmark practices for each shop

floor and equipment.
MAINTENANCE CONCEPTS
EVOLUTION OF MAINTENANCE
• First Generation
– Fix it when it breaks (old concepts)
• 2nd Generation
– Higher plant availability
– Longer equipment life
– Lower equipment cost
• 3rd Generation (Modern Concepts)
– High plant Availability and Reliability
– Greater Safety
– Better Product Quality
– Longer Equipment Life
– Greater Cost Effectiveness (Life Cycle Cost becomes
important)
 CONCEPTS & TERMINOLOGIES OF
MAINTENANCE
• Top down maintenance approach is old concept –
it’s an example of fire-fighting
• Bottom up approach is more scientific
– FMEA (Failure Mode Effect Analysis)
– FMECA (Failure Mode Effect Criticality Analysis)
• Focus should be on Predictive Maintenance &
Condition Monitoring for more reliability of the
equipment – i.e. to aim for Reliability Centered
Maintenance (RCM)
• Measure maintenance effectiveness by MTBF,
MTTR, MDT etc.
 FMEA & FMECA
• FMEA
– Identifies cause of failure modes and traces it
forward to its effect.
– Find eqpt. Functions, functional failures, failure
modes, effect of failure and design action plan
for proposed tasks to prevent the same.
• FMECA
– Assess maintenance activity by identifying
critical items of systems
– Assign criticality factor to each component of
system
 KEY ASPECTS OF
MAINTENANCE
• What are the functions and associated
performance standards of equipment
• What way does it fails to fulfill its functions
• What causes functional failures
• What happens when each failure happens
• What can be done to predict & prevent failure
• What action to take if suitable proactive task is not
available
TYPES & ASPECTS
OF EQUIPMENT
 TYPES OF EQUIPMENT
(ELECTRICAL)
• Generations
• Transmission / Rectification (Transformers, Rectifiers etc.)
• Utilization
– Motors
– Heaters
– Compressors
– Illumination system
– Welding
• Measurement
– Calibration (Meters, Gauges, Calibration)
– Testing
• Control
– Relays, Contactors
– Drives
– Measuring Instruments
 Important aspects of equipments
• Functions of equipments
• How to specify equipment / rating
• Basic Principle of operation
• Important constructional feature
• Performance / parameters
• Common problems / failures of equipment
• Maintenance aspect of equipment (preventive, predictive,
condition monitoring, capital O/H)
• Safety aspects of equipment
• Standards and Statutory provisions applicable
• Standard Operating Procedures
• Special Features if any.
KEY POINTS OF EQUIPMENT
DETAILS TO COVER IN AN
EQUIPMENT, AN EXAMPLE
OF TRANSFORMER
 TRANSFORMER

• Function of equipment
• Basic principle of operation – Principle of
transformation, basic equation
• Types of transformers
– Step up/ step down/ isolation
– Core type / shell type
– Power / distribution / rectifier / welding
– Types of cooling etc.
 TRANSFORMER Cont’d...
• Rating (Voltage, MVA, %Z, Cooling, Vector
Group, Insulation level)
• Constructional Features
– Core & winding
– Cooling system
– Accessories (Conservators, Buchholz relay, WTI, OTI,
Breathers, PRV, Bushings, Tap changers etc.
• Performances / parameters
– Losses
– Efficiencies
– What is voltage regulation
– Temperature rise.
 TRANSFORMER Cont’d...

• Common Problems
– Winding failure
– Over heating
– Partial discharge
– Arcing
– Deterioration of insulation failure
– Problems in accessories like cooling system,
tap changers etc.
 TRANSFORMER Cont’d...
• Maintenance
– Inspection (Routine)
• Voltage / Current, OTI, WTI readings
• Oil level, Oil leakages
• Cleanliness
– Preventive Maintenance (Frequency to decided based
on usages, criticality, type of loading etc.)
• Tightness of all connection
• Prevention leakages if any
• IR values
• BR, OTI, WTI checking
• Protection circuit checking
• Tap changer maintenance
 TRANSFORMER Cont’d...
• Condition monitoring / Predictive Maintenance
– Oil testing ( BDV, PPM, Dissolved gas
analysis, resistivity, Tan delta, acidity, sludge,
flash point
– Furan Analysis
– Transformer Tan Delta capacitances
– Winding Resistance
– Core Balance
– PI value
– Recovery Voltage
 TRANSFORMER Cont’d...
• Safety aspects
– Shut down procedures (Ex. Power isolation
required for both Pri / Sec)
– Checking of earth pit resistance, earthing
system, body earthing, neutral earthing
– PRV, BR (Safety devices functionality to be
checked)
– Safety aspects related to paralleling
 TRANSFORMER Cont’d...
• Standards
– IS:2026 (I, II, III, IV – General)
– IS:335 (Oil)
– IS:1866 (Oil)
– I.E. Rule