Preventive Maintenance
of HT & LT Motors,
Power transformers
By
Rubanprabu
Date:28-01-2025
importance Preventive maintenance
?
Enhance equipment life span
Minimize downtime
Ensure safety
Preventive maintenance of ht < motors
visual inspections
cleaning
cable and terminal checks
test
mechanical maintenance
Regular Maintenance:
Just like we need self-care, motors and transformers need
regular maintenance too! Schedule routine check-ups to clean, lubricate, and
inspect. This simple step can prevent major issues and keep your
equipment happy and healthy for years to come!
Visual inspection for electric engine
external appearance
cooling systems
electrical connections
bearings
coupling and alignment
mounting and foundation
name plate and identification
insulation and cables
seals and gaskets
grounding
noise and vibrations ( during operation enclosure integrity)
Motor Cleaning
exterior surface dust and dirt removal
cleaning cooling vents and fan
cleaning the terminals and connection
cleaning bearing and lubrication
post cleaning inspection
required materials( crc, ctc, blower, brush, cloths )
CABLE AND TERMINAL CHECKS
physical damage
burn marks
aging
moisture
tightness of connection
cable routing
terminal lugs and connectors
heat and overload signs
cable glands and entries
insulation test and continuity
Common Electrical Tests of motors
Insulation resistance test (megger test) :
To check the condition of insulation between motor windings and the ground.
minimum IR value- UV(KV)+1
Value should come in Mega ohm, Giga ohm, infinity.
Winding Resistance Test:
To check the continuity and resistance of motor windings and identify issues like
open circuit or unequal resistance.
Resistance should be balanced across all phases within a small tolerance.
Value should come in mill ohm or ohm.
Inductance test of motors :
To check the health of the motor and windings .
The inductance value should be approximately equal for a balanced motor
Test detects short turns, open circuit, uneven air gap, phase imbalance
Mechanical Maintenance for motors
Bearings and lubrication
check for signs of wear, noise or over heating.
clean old grease from nipples and apply fresh grease as per specification
Shaft and couplings
check for straightness and signs of wear, scoring or corrosion
replace worn-out or damaged coupling components
verify proper alignment use of dial indicator or laser alignment tool
Cooling systems
inspect air vents (radiator & fan cover) cleaning and fan blades damage and unbalance.
Mounting and alignment
ensure the motor is securely bolted to its base
inspect for loose or damaged mounting bolts and base
check foundation status
Vibration and noise analysis
Use vibration meter to check for abnormal vibrations, which could indicate misalignment,
bearing issues, or unbalanced components
PREVENTIVE MAINTENANCE OF
TRANSFORMER
INTRODUCTION:
Preventive maintenance of power transformers is essential to
ensure their efficient operation, Extend lifespan and prevent failures.
DAILY CHECKS:
Visual inspection for oil leaks and unusual noises.
Monitor oil and winding temperatures.
Verify load current and voltage Levels.
Monitor cooling fan and pump status. Inspect radiator fins.
Check oil level in conservator tank and Buchholz relay
(Level should be in above minimum Level)
Inspect and Regenerate silica gel and oil cup level in the breather.
Inspect on load tap changer(OLTC)
Pre-Shutdown Preparation
Planning:
Schedule the maintenance during low demand periods to minimize operational
disruption
Inform all relevant personnel about the shutdown plan.
Safety Measures:
Isolate the transformer from the power supply
Ensure proper grounding and locking-out/tagging-out (LOTO) Procedures.
Discharge stored charges in the transformer windings to prevent accidents.
Tools and Equipment:
Ensure the availability of necessary tools, test equipment, and spare parts.
INSPECTION
External inspection:
Check for physical damage, corrosion or oil leaks.
Inspect bushings, gaskets, and External connections.
Cooling System:
Examine radiators, fans, and Pumps for cleanliness and functionality.
Conservator and Breather:
Inspect the oil level in the conservator tank
Check the silica gel in the breather and replace it if needed.
Cleaning:
Radiators and cooling fins:
Use a soft brush or air compressor to remove dust and debris.
For oil stains, use of cleaning solvent.
Avoid using high pressure water jets directly on the transformer.
Bushing and Insulators:
Wipe of dirt with a lint free cloth.
Use a non conductive cleaning agent for stubborn stains or grease.
Inspect for cracks or signs of flashover
Tank and conservator:
Remove dust and oil from the tank surface with a damp cloth or vacuum cleaner.
Clean the conservator and breather,
Cooling system:
Check and clean oil pumps, fans and filters.
Marshalling panel and Terminal Box:
Clean the marshalling panel and terminal box of primary and secondary winding.
Servicing:
Oil Maintenance:
Filter or replace the transformer oil to maintain its insulating properties.
Clean the oil conservator and tank.
Mechanical Maintenance:
Tighten bolts, Clamps, Electrical connections and Mounting Bolts.
Replace worn-out gaskets and seals.
Tap changer Maintenance:
Inspect and clean the On-Load tap changer (OLTC)
Replace or top up oil in the OLTC compartment if necessary.
KEY Testing:
Insulation Resistance Test (Megger Test):
Measures the insulation resistance of windings and checks for any deterioration or moisture ingress
Winding Resistance Test using CRM:
Inject a test current through the winding using the CRM. Record the voltage drop across the winding terminals.
The CRM automatically calculates and displays the winding resistance value.
CRM checks for any loose connection or contact issue, oxidation, corrosion at joints, unequal winding damage
or short circuits between turns.
Turns Ratio Test (TTR):
Verifies the correct turns ratio between primary and Secondary windings.
Ensures the proper voltage transformation.
OTI, WTI, Buchholz, Surge, PRV, Oil Level Trip and Alarm Test
NIFPS Panel Maintenance and test
Magnetising balance Test
Oil Analysis:
Perform Dissolved Gas Analysis (DGA) to detect internal faults ( over heating, arcing, insulation Breakdown)
Transformer Tests:
Pre-Commissioning Tests:
Insulation Resistance test (Megger Test)
Turns Ratio Test (TTR)
Winding Resistance Test
Polarity and phase Relationship Test
Vector Group Test
Routine Tests:
Dissolved Gas Analysis (DGA)
Oil Dielectric Strength Test
Temperature rise Test
Load Test
Earth Resistance Test
Open circuit test
Special Tests:
FRA (Frequency response analysis)
Partial Discharge Test (PD) Test:
Impulse Test
Short circuit test
Tan Delta Test
Magnetic Balance Test
Magnetic Current Test
Post-Maintenance Activities
Reassembly:
Reassemble all parts and ensure proper sealing.
Testing Before Energization:
Perform insulation resistance and continuity checks.
Verify that all protective relays and control circuits are functional.
System Energization:
Energize the transformer and monitor it for abnormal behaviour.
Check for temperature rise, oil levels, and unusual sounds.
Rubanprabu
