Heavy machinery used in manufacturing requires continual maintenance in order to keep it running at peak efficiency.  Poorly maintained machinery will run poorly and breakdowns cost money not only for repairs but also in downtime.  When machinery is not maintained, safety is compromised. 

Professional Tips for Maintaining Machinery and Electrical in Manufacturing

• Keep Up to Date with Operator Training

Most large scaled machinery will have multiple operators.  Manufacturing facilities running three shifts will have operators on each shift as well as others to fill in when necessary.  When using any tracking software for machine maintenance it is important that operator training for equipment is part of the checklist. Correct machine operation is critical in maintain machinery. 

Operators should be trained in visual inspection as well.  When a piece of equipment is first introduced into a manufacturing facility it should be thoroughly inspected by the operators who will be using the machine. This is also a good time to provide critical operator training and to put in place a training schedule.  When machinery is updated all operators need to be included in additional training. Not only is there employee turnover to account for, but overtime operators will become relaxed which will lead to breakdowns in proper techniques. On going training helps to eliminate this. 

Equipment manuals should be kept up to date and revised as needed.  These manuals should be kept within the vicinity of the equipment so that operators have access to them when needed.  A shorter manual can be used for ease of reference on common everyday operations. 

• Apply Lubricants Liberally and Frequently

Manufacturing components move all the time.  Lubricants can reduce the friction that is caused from all of these moving parts.  A regular maintenance schedule involving lubrication not only extends the machines lifespan and the longevity of the electrical components and parts working within the machine.

Lubrication is one of the most importance aspects in machine maintenance and should be checked on a regular basis.  It is critical that signs of excess oil and grease build-up are tracked as well as cracks in oil seals and leaks.

Using the correct lubricant for the machine and the components within is important.  Be sure to use the oil and grease that is recommended by manufacturers when lubing up electrical components. Checking lubricants helps in the diagnosis of problems in large machinery.  Experts can analyze the particles in used oil.  The makeup of the contaminants can indicate the part of the machine that is suffering from excess wear and breakdown.

• Examine Machinery for Signs of Wear

Machinery in manufacturing facilities often operates at high temperatures, with vibration, shock, and friction that contribute to the overall breakdown and wear of heavy machinery and electrical components and parts within.

• Machine vibrations come from belts and gears that are not in alignment.
• Shock comes from accidents and poor operation techniques.
• Increased temperatures come from extensive use, friction, improper lubrication, and worn our parts.
• The age of key machine components can cause deterioration. Belts can warp, seals can crack and dry out, bolts loosen and stretch.  The age of large scaled machinery needs to be tracked and monitored to avoid a compromise to the safety of your machine.   

When you notice that moving parts in your heavy machinery is beginning to wear and tear it is important to perform necessary maintenance as soon as possible.  The replacement of worn parts is essential to the health of your equipment.

• Keep the Facility Clean and Maintain Clean Equipment

Heavy machinery and the facility that contains it should be kept free of contaminants and as clean as possible.  Seals and filters should be examined to ensure they are in good order.  It is crucial that manufacturing equipment and the components within are kept tidy.

• Maintain a Record of Maintenance and Repairs

Record keeping of repairs and maintenance on equipment is beneficial for so many reasons.  Over time patterns will emerge and you will be able to anticipate when components will fail.  Detailed records of preventive maintenance such as checking fluids, electrical systems, and components within.  Moving parts are especially important in maintenance. 

• Moving components create friction.  These items need to be inspected for wear and replaced on a regular basis. 
• Gears need to be lubricated often. 

Following these steps will extend the lifespan of manufacturing equipment and heavy machinery.  With the exuberant costs associated with large scaled equipment and machines, increasing your ROI with regular maintenance and replacement of electrical components you can extend the usable time of these pieces. 

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

As we promised in our last installment, we will continue the discussion on equipment failure.  We will continue to dive into various electrical components and how they work, their longevity, usage, and testing. 

Transformers

Transformers are large scaled pieces of equipment that are used to either reduce or increase the voltage produced by a current.  Liquid filled transformers are most often installed outdoors on a concrete slab, under a canopy to protect against the elements.  The liquid serves two purposes, it cools the transformer coils and provides insulation between the coils and the grounded tank. 

Older transformers use insulating mineral oils where as newer transformers use either a silicon based, fluorinated hydrocarbon, or combustion resistant vegetable oil based dielectric fluid or synthetic esters.  These insulating fluids break down first due to the entrance of moisture, impurities, and intermittent periods of heating and cooling.  Liquid transformers can deliver consistent service for more than 30 years with regular maintenance, fluid replacement, testing, and repairs.

Low Voltage Circuit Breakers

LV distribution systems commonly use molded case circuit breakers.  These systems contain two elements that deteriorate when used, a spring-loaded operating mechanism and copper contacts.  These two components will wear out from abrasion while closing and arching when the breaker is opened.  Larger breakers can be replaced. 

As these systems age the mechanisms that operate will start to slow down which delays clearing times.  The springs operating the mechanism are strong and hardly ever need to be fixed or repaired.  Lubrication however will deteriorate and need to be replenished to avoid the slower clearing times.  When a breaker operates above the normal trip rate it should be replaced.  These systems often last upwards of 20 years.  After 20 years replacement is most often recommended whether or not you are seeing slower clearing times during testing.

Low Voltage and Medium Voltage Cables

For most of us cables are quiet simple consisting of a stranded aluminum or copper conductor that is wrapped in insulation as well as a jacket that is resilient to the weather.  The manufacturing of electrical power and control cables sounds fairly simple however this industry is one that is in fact highly specialized.

Assessing the integrity of electrical cabling and its remaining longevity is important however can be quite complicated.  Cables can quickly lose electrical integrity while it is in use because of air pockets, gas pockets, and the voids found in the insulation.  This occurs due to thermal expansion and contraction.  If cables are in water their deterioration will occur at a faster rate.  Testing and analysis on these voids will offer up an estimate on the life that remains for the cable. J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

When dealing with electrical equipment and components it is inevitable that they will fail, and you will have to deal with the consequences.  The minute electrical equipment is put into place, from transformers to circuit breakers and panel switches and tap boxes, they start to decline.  Deterioration of electrical products happens for a number of reasons including:

• Moisture Absorption
• Differing Temperature Cycles
• Dust and Particles Settling
• Condensation Buildup
• Fragile Operating Springs
• Insulation Material Breakdown
• Rusted Out Switchgear Enclosures
• Dried Out Capacitors

When electrical components within distribution systems age vulnerabilities start to appear. With automation being what it is today, electrical technology can often run unassisted, without issue for years. Because of this maintenance on these systems tend to be ignored which can lead to unpredicted failures which lead to catastrophic failures; the most common being fire.  Thus, in order to keep electrical components operating at their peak and delivering consistent power renovations and maintenance are critical.

The two biggest nemeses of electrical equipment and the components within are moisture, condensation, dust, and loose particles. When equipment is installed outdoors or in spaces that offer no type of temperature or humidity control deterioration occurs more rapidly then in spaces where there are controls, just at a slower, more gradual pace. 

Based on the quality, maintenance schedule, and environment of electrical equipment and components that are installed the deterioration rate varies.  When planning for maintenance, upkeep, and refurbishment of electric components and equipment it is important to establish the age and overall condition of each piece. 

Electrical Equipment and Component Insulation

Components within each piece of equipment must be inspected individually.  Insulation is the component of electrical equipment that degrades the quickest.  Paper and solid synthetic insulation is used throughout equipment around motors, capacitors, cables, transformers, circuit breaker trip coils, operating coils of contractors, and reactors.  The breakdown of insulation depends a great deal on the temperatures that it is exposed to.  To increase longevity of equipment and decrease the breakdown of insulation it is important for equipment not to be operated above optimal temperature ratings.

Capacitors in Electrical Equipment

There are various types of capacitors used in both low and medium voltage distribution systems including:

• Surge Capacitors
• Power Factor Correcting Capacitors
• Commutating Capacitors
• Capacitors in Active and Passive Filters
• Pole-Mounted Capacitors

The most common capacitor to use in ratings up to several hundred kVAR is power factor correction.  They are sealed in airtight, insulated units for protection.  The insulating material that is used is a metalized polypropylene film that is compressed in a thermal setting resin.  In the event of internal failure, pressure sensitive interrupters are used to disconnect the capacitor. Capacitors are always fused externally because their failure is most often due to circuit shorts.

There is a nonstop loss of power internally because of lag thus causing the insulating resin to dry.  This often goes unnoticed.  Most capacitors have an average life expectancy of about seventeen years when in continuous operation. This of course decreases depending on the environment in which it operates.  Many systems have a decrease in this average life expectancy due to being exposed to over use and variation in frequency.  To check measurements for capacitors, use clamp-on ammeter to test and detect disparity over time.  

In our next installment we will dive deeper into more electrical components and how they work, their longevity, usage, and testing.  Such components we will inspect will include transformers, circuit breakers, reactors, cables, relays, and more.

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

Just as molded case circuit breakers, MCCB, air circuit breakers, ACB, is device that is in place to provide protection from an electrical surge or short-circuit.  The main difference is the amps they protect; ACB can withstand higher short circuit currents and mechanical stress because of the arc extinguisher element then MCCB can.  There are a variety of air circuit breakers and switching gears available to purchase.  Air circuit breakers have replaced oil circuit breakers because of their resiliency, performance, ease of installation, and low maintenance level. 

Three Types of Air Break Circuit Breaker

The three main types of air break circuit breakers include: plain break, magnetic blowout, and air chute.  Their main application is for use in maintaining indoor voltage and switch gears.

Plain Break

The simplest of all air circuit breakers is the plain brake.  Two horns shape the main point of contact.  This creates an arc that extends from the tip of one to the other. 

Magnetic Blowout

In higher voltage capacity’s, up to 11KV, magnetic blowout air circuit breakers are used.  The arc extension gets by the magnetic field that is made from the current in blowout coils.

Air Chute

Air chute air break circuit breakers have main contacts of copper and conduit which are in the closed position.  They are most often silver plated and have a low contact resistance.  The arching contacts are created from copper alloy and are resistant to heat and are solid. 

Air circuit breakers are most often used for controlling the power station auxiliaries and industrial plants.  They provide protection to electrical machinery such as transformers, capacitors, and generators.  Where ever there is a possibility of fire or explosion, air circuit breakers are most often installed.   They offer a higher resistance to power that allows an increase in the resistance of the arc by splitting, cooling, and lengthening.  The main drawback in air circuit breakers is that the arc chute principle is less efficient under low currents where electromagnetic fields are weak. 

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers.  More information can be found at https://www.jpelectricalcompany.com

No matter what business you are in, be it manufacturing, banking, health care, or education a sudden change in the power situation can be a debacle.  A loss of power means a loss of time, resources, and more so it is imperative to prepare for just such an occasion. 

 To plan ahead to avoid an electrical interruption companies could choose to install a permanent generator. An installed permanent generator can be a large maintenance expense.  To avoid this extra expense the installation of a tap generator is a viable, cost effective option.  When a natural disaster like storms,blackout, and what not a tap generator allows businesses to get your electricity back up and running quickly. 

A tap box is a simplistic generator that is installed outside of the business.  It plays the role of connecting the business’s portable generator to the electrical system.  This allows you to get a temporary supply of electricity running to avoid downtime.  This connection can be made either manually or using an automatic transfer switch.  The power is generated so efficiently that it can be up and running without any delay using programable logic circuits and auto start generators.  Your power system will be emergency ready and the cost savings of no down time and not having to hire a professional electrical contractor to temporarily connect power will be pay off the first time the power goes out.  Being prepared ahead of time pays off.

When having a generator tap box installed you will want to assess your electrical needs.  The needs and requirements that your specific business have will vary from even your competition.  Here are some things to consider when choosing a generator tab box. 

• How often do you lose power?
• What are your electrical needs?
• What systems are crucial to keep running?
• What is your budget?

No matter what the answers are to these questions, J & P Electrical will have a solution that fits your exact needs. 

J & P Electrical Company is a full-service electrical company that supplies contractors, end users, and supply houses with new surplus, quality reconditioned, and obsolete electrical equipment. We purchase a wide range of electrical equipment such as bus plugs, bud ducts, panel switches, substations, and transformers. More information can be found at https://www.jpelectricalcompany.com