Maintenance Programs


Electrical equipment failures account for millions of dollars in damage and lost business every year. This problem is only going to worsen unless active steps are taken to counter the trend.  Ironically, more than two-thirds of electrical system failures can be prevented by a routine preventive maintenance program.

The failure rate of electrical equipment is three times higher for components that are not part of a scheduled preventive maintenance program as compared with those that are. In addition, a planned program allows the equipment owner to schedule the system outage at a time of their choosing rather than having to correct major problems resulting from an always untimely failure.

The purpose of our programs are to provide the business owner with recommended practices and frequencies that would form the core of a regularly scheduled electrical preventive maintenance program.

 

 

Recommended  Maintenance Practices

At Electrotec Solutions we can conduct an agreed upon program to suit your requirements, this can be done at a fixed yearly rate which can be paid in instalments. This will go a long way toward preventing any major disruptions to your production.

The following sections are segmented by equipment type. For each component, a recommended minimum practice for preventive maintenance is provided. Any or all of the following can be included in your program.

Conductors

Examine insulation for signs of deterioration, cracking, flaking, or \overheating. Examine all connections for signs of overheating, cracked or broken connectors, and signs of tracking or arcing. Ensure that conductors are clean and dry.
Examine and clean all connections, and torque to manufacturer’s recommendations.

Contacts

Ensure that all contacts are clean, smooth, and in proper alignment. Ensure that spring pressures are maintained according to manufacturer’s specifications. Vent openings cleaned of all dust and dirt accumulations.

Insulators, Supports, and Connectors

Inspect insulators and conductor supports for signs of cracking, broken pieces, and other physical damage or deterioration. Clean all loose dirt with lint free rags. For contaminates that will not remove easily, solvents approved by the manufacturer may be used.

Enclosures

Ensure that all enclosure panels, doors, and structures are well-maintained in accordance with the manufacturer’s specifications. During de-energized maintenance, enclosures are to be vacuum cleaned of all loose dirt and debris Any buildup of dirt or other contaminates that will not come off with vacuuming cleaned with lint free rags using cleaning solvents

Auxiliary Devices

Inspect operating devices for proper operation and general condition.
Ensure all indicating devices are fully functional and properly set.
Protective relays and circuit breaker trip devices inspected and tested according to manufacturers’ specifications and applicable industry standards.

Operating Mechanism

Inspect for loose, broken, worn, or missing parts. Examine for excessive wear of moving parts. Observe that operating mechanisms function properly without binding, hanging, or without delayed action.

Chargers

Clean all dust and/or dirt accumulation from charger. Clean all vent openings and ensure that they are free from obstructions. Check terminals and connections for tightness. Check all relays, lights, and other indicating devices for proper operation.
If all cells consistently read low, check charger for proper operation. If electrolyte levels are low, check charger rate settings against the manufacturer’s specifications.

Molded-Case Circuit Breakers

Molded-case circuit breakers should be kept clean for proper ventilation of the breakers. These types of breakers are usually tripped by a thermal element that senses an increase in temperature due to excessive current draw. However, if dirt accumulates on the surrounding of the breaker, the heat build-up may not be permitted to dissipate properly and result in nuisance tripping.

Clean the breaker housing and inspect it for cracks or signs of overheating. Tighten all connections. Exercise the breaker several times to ensure the mechanism has freedom of movement and to allow contact wiping.

In addition, larger duty circuit breakers (225 amps or above) electrically trip tested to ensure proper operation of the trip elements and trip linkages.

Surge Arrestors

Clean and inspect porcelain for signs of damage or deterioration. Repair or replace as necessary. Examine arrestor leads for damage and/or deterioration, evidence of overheating, corrosion, arcing, or other forms of deterioration. All loose or dirty connections cleaned and properly torqued —

Transformers

Transformer data (such as, voltage, current, and temperature readings) recorded on a regular basis in order to determine operating conditions of the transformer. Peak, or redline, indicators recorded and reset.

Aerial Cables

Check supports for excessive wear or deterioration, check cables for wear at support points, inspect for mechanical damage from vibration. At dead-ends, check cable for worn insulation, sharp bends, or cracks.

Relays

Inspect relays for physical damage and deterioration. Inspect gaskets and covers for damage and/or excessive wear. Examine and clean the relay and enclosure of foreign materials, such as dust, dirt, and moisture contamination. Examine the condition of the spiral spring, disc clearances, contacts, and case shorting contacts (if present). Check mechanism for freedom of movement, proper travel and alignment, and tightness of mounting hardware and plugs.

UPS Systems

Clean interior and exterior of cabinets and enclosures, ensuring that any areas of corrosion and/or deterioration are repaired as necessary. Clean all vent and air circulation openings and ensure freedom from obstructions. If installed, clean cooling fan blades and motor housings. Ensure that motor bearings are properly lubricated and that fan blades are properly secured to drive shafts. Examine for signs of moisture contamination and correct if necessary. Clean and examine all electrical connections for signs of corrosion or deterioration.
Ensure all connections are tightened according to manufacturer’s specifications. As applicable, clean and test all breakers, disconnects, and relays.Check all system alarms and indicating lights for proper operation.

Electric Motors

Inspect for damage caused by dirt, loose parts, or foreign objects. Verification that air inlets are not blocked. Evidence of moisture and/or dirt build-up.Unusual noises, leaking oil seals, or high vibration Oil level gages (if present) checked. Evidence of degradation of foundation, bed plates, anchor bolts. Evidence of oil rings turning (if applicable). Evidence of leaking oil and water piping and connections.

Record bearing temperatures and stator temperature using thermographic imaging. The record monitoring completed at similar motor loading and ambient temperature to allow for accurate trending.
Record and trend vibration levels.
Look at overall conditions and check for foreign matter, additive depletion, varnish precursors and
metallic elements. Record and trend all three phase currents and verify the currents are balanced and do not exceed nameplate rating.Perform IR check between motor leads and ground. This
determines condition of the ground insulation. Record, temperature correct and trend

Measure the trueness of the shaft extension.

Infrared Inspection

An infrared, or thermographic, inspection should be performed at least once every three years on all switchgear, distribution panels, cable and bus connections, motor control centers and starters, and other critical equipment. Infrared inspections are extremely beneficial in reducing electrical failures by identifying potentially dangerous conditions; such as, loose or dirty connections, overloaded or imbalanced circuits, or improperly installed equipment. By measuring the heat imbalance relative to the environment and to surrounding equipment, abnormal or adverse conditions can be uncovered that if left unattended would worsen to the point of failure.

Record Keeping

The electrical preventive maintenance program should be well-documented as to scope and frequency of maintenance. Record all routine maintenance activities and
the results of routine testing for trending purposes. Document all repair and/or replacement of electrical components. When changes are made to the electrical distribution system, update all applicable drawings and maintenance schedules to reflect the changes. Ensure that spare parts inventories are updated for any new equipment added based on the manufacturer’s recommendations.

Felix has been a shining light among tradesmen that we have encountered in the Dandenong South and wider Melbourne area. During a very trying Christmas period, Felix attended our site on a number of occasions, sometimes in the middle of the night (2am) to try and get us up and running given our production deadlines. In addition to his positive attitude, Felix also is well connected and if he is unable to fix a problem that is outside of scope will recommend high quality trades people of high repute. Be it stand alone or working alongside other trades, his work is of a high standard and he conducts himself in a professional manner, efficient, honest, well priced and full of integrity, I would highly recommend Felix to anyone looking for electrical work to be undertaken” “Thank you, thank you, thank you!!! I cannot express our gratitude sufficiently. What a life saver you and of course the 2 workmen are, We had dreadingly thought that another 2 weeks would pass and we would have had to disappoint our customers by staying closed for renovations. Thank you for coming to our rescue, the renovations would not have been completed without your professional help.”