INTRODUCTION

(EE603: Testing, Commissioning and Maintenance

of Electrical Equipments)

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 Contents
 Course code, name, credits, CLO
 Weightage for different components
 Introduction to testing

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 Introduction
 Deterioration of electrical equipment is normal, and
this process begins as soon as the equipment is installed.
 If it is unchecked, it leads to electrical failures and
malfunctions.
 Electrical Preventive Maintenance and Testing
Program (EPM)
 EPM program should consist of conducting routine
inspection, tests, repairs and service.
 EPM will minimize the hazards to life, reduces
downtime (Stoppage/lost time).
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 Why maintain and test?
 A well organized EPM minimizes accidents, reduces
unplanned shutdowns, lengthens MTBF (“Mean
time between failures”) .
 Direct benefits of EPM are reduced cost of repairs,
reduced down time, improved personnel &
equipment safety.
 Indirect benefits of EPM are improved morale of
employees, better workmanship, increased productivity,
discovery of deficiencies (shortages).

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 Overview of EPM
 Effective EPM can be summarized,
Keep it dry
Keep it cool
Keep it clean
Keep it tight
 There are basic four approaches to EPM.
Run to failure
Inspect and service as Necessary
Scheduled Preventive Maintenance (SPM)
Reliability-Centered Maintenance
(RCM)
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  Run to Failure
 Here EPM is not performed at all.
 Degraded equipment is only repaired or replaced
when effect of degradation becomes unacceptable.
 Mostly it leads to catastrophic failure*.
 Small organizations which lack dedicated maintenance
staffs often utilize this approach by default.
 Large and more sophisticated organizations in the
manufacturing sector apply it to noncritical equipment
and systems.

* A catastrophic failure is a sudden and total failure from which

recovery is impossible.
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  Inspect and Service as Necessary

 Advanced beyond “run to failure”

 Inspection on a more or less regular schedule.
 Incipient (initial) failures are usually corrected
before they become catastrophic.
 Many follow this approach and find it satisfactory.

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  Scheduled Preventive Maintenance (SPM)

 EPM performed at fixed intervals of operating

calendar time, operating hours or operating cycles.
 This is done based on manufacturer’s recommendations or
industry standards.
 It does not necessarily prioritize EPM according to
safety or productivity significance, nor does it
optimize the application of limited EPM resources.
 Scheduled EPM is the predominant approach among
relatively sophisticated operators of plants where
productivity and safety is a serious concern.

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  Reliability Centered Maintenance
 RCM involves specifying and scheduling EPM activities in
accordance with statistical failure rate, life expectancy of the
equipment, its criticality and productivity and continually
updating EPM procedures and schedules.
 RCM is the most cost effective of the alternative approaches
because it improves plant safety, reliability, availability while
reducing maintenance cost by concentrating on items which are
the most important.
 It reduces maintenance of less significant items.
 It also includes failure root cause investigation,
correction, performance monitoring to predict
failures.
 RCM is used extensively in military and is gaining acceptance
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 Key factors in EPM optimization
 Safety impact of equipment failure
 Productivity and profitability impact of equipment
failure
 Cost of preventive maintenance (PM)
 Failure rate and/or anticipated life of equipment
 Predictability of failure
 Probability of inducing equipment damage during
maintenance and testing
 Technical knowledge of plant maintenance staff
 Availability of equipment information to support RCM

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 Qualifications of EPM Personnel
 The fundamentals of electrical power technology
 General electrical maintenance techniques
 Electrical safety methods and practices
 Design and operation of equipment/system to be
maintained
 Maintenance and testing procedures
 For critical tasks, engineers’ experience should include
preferably in an operating environment

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 Systematic Failure Analysis Approach
 Use a failure cause analysis to determine the proximate
cause of the failure.
 Compare the proximate cause to past failures or
conditions on the same equipment to determine if the
problem has a systematic root cause.
 If there is no systematic root cause, correct the failure,
resume operation, continue performance monitoring.
 If there is apparent root cause, initiate analysis.
 If the problem is generic (general), contact other affected
plants to determine if they have taken any corrective
action.
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 Cont…
 If the problem is plant specific, determine if it is
attributable to a unique system design, or
environmental factors or to operational factors
such as maintenance, testing.
 If the problem is related to system design, equipment
application, or environment, determine specific
deficiency.
 If the problem is related to faulty operation, identify and
correct the specific procedure.
 Determine whether the root cause of the problem is a
programmatic deficiency, e.g. in procedure writing,
training, supervision etc., make appropriate corrections.
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 Post Maintenance Testing
 It provides best assurance that maintenance action were
accomplished correctly and equipment/system is
functional.
 It is heavily emphasized in the better performing plants.
 Scope of the testing is broad.
 All systems, subsystems, components are tested if
engineering analysis emphasized them as significant for
maintenance.

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 Engineering Support
 Maintenance engineering
 System engineering
 Design engineering
 Training
 Spare parts and materials management
 Quality Assurance
 Quality Control

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 Planning an EPM program
 Maintenance Management Considerations
 Technical Requirements
 What should be included in the EPM program?

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 Maintenance Management Considerations
 Responsibilities
 Inspection
 Scheduling
 Work orders
 Record keeping

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 Technical Requirements
 Survey of plant equipments
 Listing of plant equipments in order of critical
importance
 A plan to perform EPM on regular frequency
 Development of instruction and procedures for the EPM
program

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 What should be included in the EPM
Program?
 Electrical preventive maintenance and testing
 Electrical repairs
 Analysis of failures
 Trending of maintenance and testing data

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 Different Standards
ICEA Insulated Cable Engineering Association
NFPA National Fire Protection Association
IEEE Institute of Electrical and Electronics Engineers
ANSI American National Standard Institute
NEMA National Electrical Manufacturer’s Association
NEC National Electric Code
IS Indian Standards
BS British Standards
IEC International Electro technical Commission
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 Overview of Testing and Test Methods
 Manufacturer conducts electrical tests on equipment
before it leaves the factory  Factory Tests
 Field tests are conducted to see whether newly installed
equipment has been damaged, to indicate whether any
corrective maintenance or replacement is necessary on
existing equipments.
 Electrical Testing divided into the following:
 Types of tests
 Types of testing methods

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 Types of Tests
Acceptance Test
 These tests are known as start up tests.
 Performed on new equipment, usually after installation
and prior to energization.
 It is required to check,
 Equipment is in compliance with specifications
 Benchmark for future tests
 To check equipment installed without damage
 To verify equipment meets in its design intent and
limit

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 Types of Tests
Routine Maintenance Tests
 Performed at regular intervals over the service life.
 Concurrently with preventive maintenance and at 60%
of final factory test voltage.
1. As found tests
2. As left tests

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 Types of Tests
 As-found tests
 These tests are performed on equipment on receipt
(acceptance) or after it has been taken out of service
for maintenance, but before maintenance work is
done.
 As-left tests
 These tests are performed after maintenance, just
before energization.
 Indicates degree of improvement and service as a
benchmark for comparison for future tests.

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 Types of Tests
Special Maintenance Tests
 These tests are performed on equipment that is known
to be defective or has been subjected to adverse
conditions that may affect its operating
characteristics.
Ex: Fault interruption by a circuit breaker:
 This requires inspection, maintenance and test
before it can be put back into service.

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 Types of Tests
Type test:
It is conducted on first prototype of product to confirm the
design specifications.
This test is not repeated on other products of same type. e.g.
temp rise test
Routine test:
It is conducted on each product manufactured to confirm
proper manufacturing of each and every units.
This test is essential to be performed on each unit before
dispatching the product to site.
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