EE 81 Course Pack PDF - University of the Philippines Los Baños

University of the Philippines Los Baños College of Engineering and Agro-industrial Technology Department of Electrical Engineering EE 81 Course Pack Maintenance of Electrical Equipment and Devices First Semester A.Y. 2024-2025 Prepared by: GYR Garcia & G...

University of the Philippines Los Baños College of Engineering and Agro-industrial Technology Department of Electrical Engineering EE 81 Course Pack Maintenance of Electrical Equipment and Devices First Semester A.Y. 2024-2025 Prepared by: GYR Garcia & GMM Gonzal  MODULE 2 Welcome back to EE81. In our last module, we learned about the Overview of Electrical Maintenance Strategies and the background on Electric Preventive Maintenance (EPM). In this module, we will try to discuss more about the EPM Procedures and Results Oriented Reliability and Maintenance (RORM). We learned from module 1 the background of EPM. We established that managerial, and technical factors affect the development of an effective EPM program. Now we’ll delve even more into these ideas in this module. Management Considerations A maintenance program always has a direct cost of the final product. It serves a management’s insurance policy. However, it is usually challenging to convince the managerial side of things to accept the importance of an EPM since it doesn’t always have a direct payback to the company. Thus, on the managerial side, cost effectiveness, time schedules, and record keeping systems are considered. Managerial factors include: Policy making Cost-benefit analysis Necessities of production Organizational charts Cost of lost production Scheduling and Work Orders Maintenance priority areas Record keeping Human resources Technical Considerations Technical requirements can be divided into four subcategories. A. Survey of Plant Equipment EPMs usually begin with an inventory of data of the entire power system. The identification of diagram symbols, device designations and electrical symbols is also included. The types of diagrams that are needed for a plant survey include: 1. Flow diagram – pictorial representation of subsystems connections 2. Block diagram – interconnected blocks of devices or subsystems EE 81 Course Pack First Semester A.Y. 2024-2025 3. Single line diagram – diagram of electrical power flow 4. Schematic diagram – includes all circuits and devices 5. Wiring diagram – locates and determines devices, terminals, and wiring 6. Interconnection diagram – only shows controller connections EE 81 Course Pack First Semester A.Y. 2024-2025  7. Short circuit coordination study – data on relays, coordination, and protection; done on construction and commissioning phase of the facility 8. System diagrams – includes monitoring system, lighting controls, ventilation, heating and cooling facilities, and emergency system. B. Categorizing of Equipment based on Importance Assigning a criticality value and importance of an equipment varies from one facility to another. Thus, this requires high level of expertise and knowledge from maintenance personnel. Each system and subsystem must be well represented on the EPM team in order to collect a cohesive set of data. C. Performing EPM on a Regular Basis The service manuals of equipment provided by manufacturers usually have a pre-designated frequency to conduct maintenance activities. However, new EPM cycles must be established throughout the use and ‘wear and tear’ period of the equipment. Some of the factors to be considered on the frequency of EPM are: Environmental conditions Duty requirements Load/demand Critical nature of equipment D. Development of Instructions and Procedures This part ensures the continuity of operations within the facility. The procedures include the development of shutdown plans, safeguards, interlocking of equipment, alarms, and data recording. EPM and Testing Program Framework EPM and testing Analysis of failures Electrical repairs Trending of data EE 81 Course Pack First Semester A.Y. 2024-2025 EPM and testing Inspection, cleaning, and calibration to ensure operations until the next cycle Allows prediction of unanticipated failures of a part/s of an equipment to prevent more serious damage Electrical repairs Should be conducted efficiently, at the earliest possible time and economically Spare parts should always be available during electrical repairs Should ensure continuity of operation Prioritize safety of personnel due to live parts Analysis of failures Identify causes of failures Usually caused by lack of attention from maintenance team Trending of data Guide for staff on the degradation status of equipment Early corrective actions for mitigation of problems We now go to the next part of the module on RORM. The key processes and sub processes in RORM are shown on the diagram below. RORM Root Cause Preventive Facilities, Planning and Prolem Maintenanc tools & Scheduling Elimination e workshops Balancing Maintenance Work Planning Test Selection Operating request Scheduling Procedures Cleanliness Prioritization Execution Filtration Lubrication Backlog Recording Condition Alignment Monitoring EE 81 Course Pack First Semester A.Y. 2024-2025 Maintenance Costs are usually considered just the tip of the iceberg. Management usually fails to see the other costs of poor equipment reliability at the bottom of the iceberg. Something Before you move into the next section, what do you think are the to ponder effects to the system of poor equipment reliability and maintenance? on: Effects of poor reliability and maintenance to direct costs: 1. Production losses 2. Loss of customer confidence 3. Increased working capital 4. Shorter Plant Life 5. High Energy Cost 6. High Production Cost In your own words, can you expound on these effects? You may use Something everyday life instances as examples to relate to the list above. We to ponder may discuss this during our online meeting so better be prepared. J on: Planning and Scheduling Included in the RORM framework is the planning and scheduling key processes. So, what are the benefits of incorporating them in you EPM? 1. A reduction of 10% on emergency work 2. Improvement in productivity 3. Upholds a safe working environment 4. Confidence in work and output quality 5. A reduction of up to 20% in maintenance costs 6. Savings on time and materials A planned job includes: 1. All materials, tools, and testing devices 2. Description of tasks 3. Time of completion EE 81 Course Pack First Semester A.Y. 2024-2025  Now it might be useful to have this Maintenance Checklist with you before you conduct any EPM Testing and Procedure: 1 Is the equipment number correct? Is there a comprehensive work order? 2 Do the "problem" and "solution" 3 match? 4 Is the work location clearly identified? Which standard should be attained? 5 Are the steps clearly defined? 6 Seatwork: Assess the job shown below. Is it effective? Which elements could be improved more? EE 81 Course Pack First Semester A.Y. 2024-2025 Kinds of PM Inspections 1. Activities that can be done routinely while the equipment is in operation. 2. Activities that can be done routinely only when the equipment is shut down. 3. Activities that can be done in conjunction with corrective maintenance in an effort to prevent the recurrence of the issue. Some of the levels of these activities include the following: DETAIL LEVEL JOB TYPE Emergency Reactive planning or “planning on the run” Complex Major overhaul, repair, turnaround, planned unit outage Breakdown Work Routine pump repair, filter change, heat exchanger cleaning, etc. Simple Instrument calibration Final Note: The relationship between manufacturers and maintenance personnel is an important factor in any EPM. A strong partnership between the two should be required to attain the same level of interests. This is also because about half of all maintenance costs are spent on materials or spare parts of equipment. Good job! You’ve finished Module 2. See you next week for the next module which will be about the Electrical Cables. Padayon! --End of Module 2-- EE 81 Course Pack First Semester A.Y. 2024-2025  "Exclusively for First Semester A.Y. 2024-2025 students use only. 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