MAINTENANCE PRACTICES
&
FEEDBACK

COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM

FEATURES

EQUIPMENT MANAGEMENTWORK MANAGEMENTBREAKDOWN MAINTENANCEPREVENTIVE MAINTENANCEPREDICTIVE MAINTENANCEOVERALL EQUIPMENT EFFECTIVENESSDOCUMENT MANAGEMENTMIS REPORTSPROJECT MANAGEMENTEXECUTIVE INFORMATION SYSTEMCALIBRATION & TOOLS MANAGEMENT SYSTEMINSPECTION MANAGEMENT SYSTEMKNOWLEDGE BASED SYSTEMFAILURE ANALYSISMATERIAL MANAGEMENT SYSTEMPROCESS AUTOMATION INTEGRATIONINTEGRATION WITH MOBILE DEVICES

DATABASE CREATION

ANNUAL MAINTENANCE DATATEST / MEASUREMENT VALUES

DISSOLVED GAS ANALYSIS

VIBRATION ANALYSIS

TEMPERATURE TRENDING ETC.,

HISTORY SHEETS BREAKDOWNREPORTS RESTORATION & ANALYSIS REPORTSINVENTORYSPARES SEGREGATION

REPORTING A FAILURE

ACKNOWLEDGE ALL ALARMSRECORD ALARMS AND RESETANALYZE & LOCATE FAULTINFORM RLDC ABOUT FAULT & CHANGE SCHEDULETAKE IR VALUE OF SUSPECTED EQUIPMENT (GEN, MOTOR)SYNCHRONIZE IF NORMALELSE CALL MAINTENANCE DIVISIONPREPARE TRIP REPORT AFTER RECTIFICATION PREPARE RESTORATION & ANALYSIS REPORTPREPARE HISTORY REPORT FOR RECORD

DISTURBANCE RECORDER

DR IS A TOOL FOR ANALYZING PERFORMANCE OF POWER SYSTEM AND RELATED EQUIPMENT DURING AND AFTER MAJOR DISTURBANCES.RECORDING OF MONITORED INPUT IS INITIATED BY A POWER SYSTEM DISTURBANCE E.G. A RELAY PROTECTION TRIP.

Pre fault recording time=0.02-0.98s in steps of 0.02s

Post fault recording time = 0.1-5s in steps of 0.1 s

BLOCK TRANSFORMER FAILURE

URI POWER STATION,

U-PH OF UNIT-3 ON 04/06/99

ALARMS:

BLOCK OVERALL DIFFERENTIAL TRIPPEDBUCHHOLTZ TRIPPEDNEGATIVE SEQUENCE STARTEDREVERSE POWER RELAY START

REASONS:

INTERTURN SHORT CIRCUIT IN HV WINDING

EVENT LOGGER PRINTOUT

DISTURBANCE RECORDER PRINT OUT

DIAGRAM TO HELP ANALYSIS OF INTERTURN FAULT

a2

a1

b2

b1

c2

c1

C1

C2

B1

B2

A1

A2

ANALYSIS

Ratio test shows 1 or 2 % of turns of HV winding short circuited.No big change in line current of U-ph as compared to other phasesPeak value of current before CB trip

U-ph:7273 A

V-ph:7162 A

W-ph:7537 A

shows negative sequence protection start.

Reverse power start

DAILY MAINTENANCE SHEETUNIT No. GENERATOR1.Stator & Rotor ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)Sound and odour inside barrelVibration LevelCondensation on pipes and coolers in barrelLeakage from water pipelines ,coolers etcReverse water flow2.BEARINGSThrust Bearing oil levelUGB oil levelLGB oil levelCooling water flow to bearings3.EXCITATION SYSTEMIndicationsExcitor cooling fan operationCarbon brush -sparking/chattering etc.4.UAT &UCBAbnormal noise and odourIndications

DAILY MAINTENANCE SHEETGENERATOR1.Stator & Rotor ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)5.TEMPERATURE ANALYSIS (PAST 24 HRS.)Stator windingStator coreThrust Bearing oil Thrust Bearing metalUpper Guide bearing oilUpper Guide bearing metalLower Guide bearing oilLower Guide bearing metalField temperatureExcitation transformer6 BRAKE, JACK,HP LUBRICATIONIndicationsBrake pressure in the panelOil/air leakageHP pump operation during start stop

FORT NIGHTLY MAINTENANCE SHEET ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)FIRE FIGHTING SYSTEMAIR COMPRESSOR AUTOMATIC START/STOP AND RUNNING TESTAUTOMATIC DELUGE VALVES ALARM AND TRIPPING TEST (TRANSFORMERS, CVT ZONES AND, SHUNT REACTORS)ILLUMINATIONCHECKING OF ILLUMINATION AND REPLACEMENT WHEREVER NECESSARY

MONTHLY MAINTENANCE SHEETGENERATORUnit No1.Stator & Rotor ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)THE EXTERNAL PARTS-FRAME,JOINTS,RADIAL SUPPORT OF THE STATORWORKING OF RTD AND TSDCHECK FOR EXCESSIVE AMOUNT OF CARBON DEBRIS\CONTAINMANTAIR PASSAGE IN STATORCLEAN/REPLACE AIR FILTERSWORKING OF BARREL HEATERSOVERHANG PORTION OF STATOR WINDINGSTATOR FOUNDATION AND CRACKS IN CIVIL STRUCTURECONDITION OF THE WINDINGSTRIPPING& ALARM CONTACTS FOR PROPER FOCTIONINGCLEAN THE BRAKING RINGVISUAL INSPECTION OF ROTOR FASTENERS & OTHER PATRSCONDITION OF THE WINDING2.BEARINGSFUCTIONING OF THERMOSIGNALLING & TEMPERATURE MEASURING DEVICEREPLACEMENT OF HP OIL FILTEROIL LEVEL

MONTHLY MAINTENANCE SHEETGENERATOR1.Stator & Rotor ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)3.EXCITATION SYSTEMCLEAN EXCITATION SYSTEM,COMMUTATOR,SLIPRING,BRUSHES,BRUSH BOXCHECK LENGTH OF THE BRUSHESCHECK AND TIGHT ALL CONECTIONS IN FIELD BREAKER CUBICLESCHECK THYRISTER RECTIFIER OPERATIONCLEAN INLET AIR FILTERCHECK OPERATION OF COOLING FAN4 BRAKE, JACK,HP LUBRICATIONINSPECT BRAKE AND JACK FOR ANY ABNORMALITYOPERATION OF AC/DC HP LUBRICATION PUMPCLEAN THE BRAKES/LINERS ETC TO REMOVE TRACES OF OIL ETCCLEAN HP OIL FILTER/STRAINER

QUARTERLY MAINTENANCE SHEET ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)GENERATORFILTERATION AND CENTRIFUGING OF UPPER GUIDE BEARING OILFILTERATION AND CENTRIFUGING OF COMBINATION BEARING OIL

HALF YEARLY MAINTENANCE SHEETUNIT-NO-GENERATOR ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)CHECK COLLECTOR RING HOUSING AIR FILTERS FOR CLEANLINESSCLEAN THE COLLECTOR AND COLLECTOR INSULATORCHECK THAT HIGH/LOW LEVEL SWITCHES OF ALL THE BEARINGS ARE WORKING PROPERLY.CHECK THE STATOR AND FRAME FOR TIGHTNESS OF BOLTS AND NUTS

ANNUAL MAINTENANCE SHEETUnit No.GENERATOR ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)STATOR INSPECT WINDINGS THOROUGHLY CHECK a)STATOR WINDING BOLTSb) STATOR STAMPINGS HOLDING DOWN BOLTS c) VENTILATING DUCTSd) SLOTS , SLOT WEDGES & PAINT CHECK AIR GAP BETWEEN STATOR & ROTOR. CHECK FOR ANY DAMAGED INSULATION . CLEAN GENERATOR HOUSING. CLEAN OVERHANG PORTION OF WINDINGS. CHECK STATIC STATOR VIBRATION CHECK FOR OVERHEATING/TIGHTNESS AND CLEAN a) Y POINTSb) MAIN CT TERMINALS c) MAIN & NEUTRAL CONNECTIONS OF STATORd) NEUTRAL GROUNDING TRANSFORMER CHECK IR VALUE OF WINDINGS CHECK DC RESISTANCE OF WINDINGS CHECK TRIPPING AND ALARM CONTACTS CHECK EARTHING OF STATOR BODY.

ANNUAL MAINTENANCE SHEETUnit No.GENERATOR ACTIVITYOKNOT OKTYPE OF FAULT (If not ok)ACTION TAKEN (If not ok)ROTORCHECK/CLEAN/PAINT( WITH WELDING TACKS)a) POLE CONNECTIONS b) JOINTS/FIXING OF ROTOR ARMS,PINS,BOLTS,NUTSc) SPIDER RIM KEYSd) TOP AND BOTTOM FAN BLADESe) TOP AND BOTTOM POLE DAMPERSf) BRAKE TRACKg) ROTOR STAMPING HOLDING DOWN BOLTS/DOWELSh) VENTILATING SPACE AND COIL SURFACESi) FIXING AND LOCATION OF JOINTS OF AIR BAFFLES.j) POLE WINDINGS FOR TIGHTNESS.k) ROTOR & ROTOR POLES l) POLE WEDGES, POLE KEYS & KEY RETAINER.CHECK IR OF ROTOR WINDING INCLUDING CURRENT CARRYING LEADSCHECK DC RESISTANCE CHECK CONNECTIONS FROM ROTOR TO SLIP RINGS.CHECK SPLASH GUARD CLEARANCESMEASURE VOLTAGE DROP PER POLE.MEASURE THE HEIGHT OF WEDGES AT BOTH ENDS OF UGB & LGB PADS.CHECK & TIGHTEN/LOCKING OF BOLTS OF ALL BEARINGS. CHECK DAMPER WINDING FOR LOOSE,BROKEN BARSCHECK ROTOR LEVEL

THANKS

EQUIPMENT MANAGEMENT

Hierarchical structure of equipmentGraphical representation of entire facilityAttachment of OEM & Safety doc. With equipmentDefining specifications, properties, technical requirement, failure code & characteristics of equipmentEasy retrieval of equipment informationDefines spare part of the equipmentDefine measurement point & parameter for condition monitoring

WORK MANAGEMENT

Generate work order for maintenance jobStandardise work procedureMaintain resource required for taskTrack claims & warrantiesProvides technical doc, drawing with work order

OVERALL EQUIPMENT EFFECTIVENESS

ANALYSIS OF SYSTEM WITH THE FOLLOWING PARAMETER:

AVAILABILITY

PERFORMANCE

TOTAL RUNNING TIME

INTERNAL & EXTERNAL STOPPAGE TIME

FAILURE TIME

TOTAL PRODUCTION

MTTR & MTBF

PROJECT MANAGEMENT

Organize project, subproject, and work order structure with unlimited complexityEstimate labor costsReserve and requisition materials, tools, equipment, and other resourcesCreate a master work order templateGenerate purchase orders based on projectsPlan for shutdown

EXECUTIVE INFORMATION SYSTEM

THE BUILT IN KEY PERFORMANCE INDICATORS FOR ASSESSMENT OF PERFORMANCE OF THE MAINTENANCE SYSTEM. FUNCTIONALITY OF BALANCE SCORECARD TO ANALYZE THE PERFORMANCE OF OPERATION AND MAINTENANCE SYSTEM BOTH FROM FINANCIAL AND NON-FINANCIAL PERSPECTIVE.