EIM QRT 2 REVIEWER of service entrance conductor and the

conduit used, Type and size of wire for each

branch, Size of protective device for main
INTERPRET TECHINCAL DRAWINGS circuit breaker and each branch.
AND PLANS.

Title Block or the name plate indicates the

The Load Schedule following details:

The following details can be seen in 1. Name and location of the proposed
the schedule of load: Number of branch installation.
circuit of electrical wiring system, Number
2.Name and address of the owner.
of light outlets, power outlet and switches
per branch, Total wattage rating and of the 3. Name and signature and dry seal of
load per circuit branch, Total current load master electrician or electrical engineer.
per circuit and size of wire used.
4. Printed name of the owner.
Computation of the total wattage and current
of each circuit branch 5.Initial of the draft man and the data when
drawing was done.

The Riser Diagram is a schematic

presentation of the entire electrical circuit
from the service entrance up to the smallest
circuit branch. It shows: Character and type
of service, single phase 2 wire/ 3 wire, Size

Specification includes the following:

1.Classification of service,
2.Type of wiring method to be used,
3.Number of branch circuit and their
corresponding sizes,

Description Unit Watts Volts Amperes Circuit Wire Conduit

Protection Size
Location map shows the following details: 2. For small appliance load
The Philippine Electrical Code
1.Bordering areas showing the well know
specify 180 watts the load limit per
streets,
convenience
2.Location of the utility company pole outlet (C.O.)
which supplies electric energy.
*Circuit number 3 C.O. = 8x2-gang
per C.O. = 16 C.O.
SCHEDULE OF LOADS
FLA = 16 C.O. X 180 watts/C.O.
230
1. For lighting layout = 2880 watts =12.5 AMPS

The Philippine Electrical Code (P.E.C.) 230

specify 100 watts, the maximum load per

Size of wire
FLA = No. Of L.O. X 100 watts/L.O a. use: 3.5 mm2 THW copper wire
VOLTS b. Size of branch circuit breaker
use: 20 A, 2 pole c.b.
= 9 L.O. X 100 watts c. Size of conduit pipe
use: 15 mmØ PVC pipe
=900 watts = 3.91 amperes
230 *Circuit number 4 C.O. = 7x2-gang per C.O.
= 14 C.O.

a. Determine the size of the wire (refer FLA = 14 C.O. X 180 watts/C.O.
to P.E.C. Table) 230 Volts
use: 2.0 mm2 thw copper wire. =2520 Watts = 10.9 Amperes
b. Circuit protection 230 V
use: 15 amperes, 2 pole c.b.
c. Conduit pipe
use: 15 mmØ PVC pipe
3. Formula for 1Ø motor/single phase Wire sizing and ampacity
motor
FLA= HPx 746w/HP
V x P.F. X EFF
=1 HPx746w
230V x 80% x 90%
= 746
165.6
= 4.5 AMPS

IT= ( PT + 25% (HML) x 80% D.F

VOLTS

=(22,480w + .25 (1,492) x 80%

230 VOLTS
INTEPRETING DIAGRAMS

= 22,480w + 373 x .8
SCHEMATIC DIAGRAM clearly shows
230 V the path of current or actual connection of
the circuit. Emphasis on the location of
=99.3 x .8
electrical component is not necessary in this
=79.2 Amps diagram

USE: EXAMPLE:

2-30 30mm2 THW and

1-14 mm2 THW in
1-32 mmO dia. RMC/RSC pipe
1 – 100 Amperes 2 pole c.b.
Ground wire: 70%x30mm2=21mm2
WIRING DIAGRAM shown in the figure Ground (Earth) - is the reference point in an
is just like a combination of installation electrical circuit from which voltages are
layout and schematic diagrams. The measured, a common return path for electric
connection of the circuit is the same as in current, or a direct physical connection to
schematic diagram, but the conductors are the earth.
assumed to be traveling inside the raceway
and the electrical components are situated
where they should be as sketched in the
installation layout. Ground (Frame) - should connect to the
frame/chassis of the equipment, and to any
exposed metal parts. It will also connect to
ELECTRICAL SYMBOLS the green safety ground wire in the power
cord. Whether any part of your circuitry
connects to the frame ground is up to you.

Prepare and Interpret Technical Drawings

and Plans
Service Entrance (Power) - conductors are
those that run between the service point and
DESCRIPTION SYMBOL the service

Lightning Arrester - is a device used on 2-w or 3-w

electric power systems and
telecommunication systems to protect the
insulation and conductors of the system Service Entrance (Telephone) - a
from the damaging effects of lightning. The communications system, the point at which
typical lightning arrester has a high-voltage the network communications lines (e.g., the
terminal and a ground terminal. telephone company lines) enter a building.

Surge Arrester - is a device to protect Kilowatt-hour meters calculate electrical

electrical equipment from over-voltage energy consumption in billing cycles, which
transients caused by external or internal are measured in kilowatt-hours, or units of
events. Also called a surge protection device energy equivalent to 1,000 watt-
or transient voltage surge suppressor, this
class of device is used to protect equipment
in power transmission and distribution or
systems.
Safety Switch - disconnect switch, Fuse - breaks the circuit if a fault in an
represents a switch in low or high voltage appliance causes too much current to flow.
applications This protects the wiring and the appliance if
something goes wrong.

or

Fuse cut out - In electrical distribution, a

Disconnect Switch - A safety switch (also fuse cutout or cut-out fuse is a combination
known as a “disconnect switch,” or “load of a fuse and a switch, used in primary
break switch”) serves multiple purposes, but overhead feeder lines and taps to protect
its primary functions are to function as a distribution transformers from current surges
disconnect and overloads.

Main Distribution panel board are cabinets

Transfer Switch - A transfer switch is an that house and separate subsidiary/branch
electrical switch that switches a load circuits in addition to providing each circuit
between two sources. Some transfer with protective fuses or circuit breakers.
switches are manual, in that an operator
affects the transfer by throwing a switch,
while others are automatic and trigger when
they sense one of the sources has lost or
Power Panel board - is a component of an
gained power.
electrical distribution system which divides
an electrical power feed into branch circuits,
while providing a protective circuit breaker
or fuse for each circuit, in a common
enclosure.
Circuit Breaker - is an automatically
operated electrical switch designed to
protect an electrical circuit from damage
Lighting Panel board - An electric panel
caused by excess current from an overload
containing fuses or circuit breakers used to
or short circuit. Its basic function is to
protect branch circuits serving lighting
interrupt current flow after a fault is
fixtures.
detected.

Incandescent Lamp - is an electric light with

a wire filament heated until it glows.
Vapor Discharge Lamp - device consisting Weatherproof Convenience outlet - is a
of a transparent container within which a gas particular type of electrical outlet that is
is energized by an applied voltage and designed for installation outside the home.
thereby made to glow.
w
Cooking Range - have special wiring needs
Drop Cord Lamp - used to suspend a lamp because they require a 120/240-volt circuit
usually from an overhead outlet. and receptacle. ... Hence, it requires a
120/240 volt receptacle and circuit with an
independent neutral wire that provides a
return path for the 120-volt portion of the
Exit lamp - is a device in a public facility circuit.
(such as a building, aircraft, or boat)
denoting the location of the closest R
emergency exit in case of fire or other
emergency. Convenience with Switch – A receptacle
outlet consist of a single outlet and a single
switch.

Fluorescent Lamp - is a low-pressure SW

mercury-vapor gas-discharge lamp that uses
fluorescence to produce visible light. An Special Purpose – A special type of standard
electric current in the gas excites mercury outlet found in kitchens, bathrooms, and
vapor, which produces short-wave other rooms of your house that may be
ultraviolet light that then causes a phosphor exposed to damp conditions, GCFI
coating on the inside of the lamp to glow. receptacles are designed to prevent serious
injury or damage that could result from an
electric shock in places where there is the
potential for electricity and water to meet.
(ACU, WH, D, R etc.)
Single Convenience - It consists of only one
receptacle on a cover plate.

Antenna - In radio engineering, an antenna

is the interface between radio waves
Duplex Convenience - feature two outlets on
propagating through space and electric
a cover plate held on by one screw, two-
currents moving in metal conductors, used
duplex outlets feature four outlets on the
with a transmitter or receiver.
same cover plate, held on by two screws.

2
Microphone – It converts sound into an a lamp when a door is opened then turns it
electrical signal. OFF when the door is opened again. SAD
Key-Operated - is a switch that can be
activated only by the use of a key. They are
usually used in situations where access
Telephone - is a telecommunications device
needs to be restricted to the switch's
that permits two or more users to conduct a
functions. SK
conversation when they are too far apart to
be heard directly Master Selector switch - a switch that
controls the action of relays or that makes
and breaks the main supply line to a building
or other installation. SM
Intercom - is a stand-alone voice
communications system for use within a Junction Box - are metal or plastic
building or small collection of buildings, enclosures used as housings for wiring
functioning independently of the public connections. The connections within are
telephone network. called branch circuits and usually represent
the end of a conduit run.

Single Pole Switch - This type of light

switch controls one light fixture (or Pull Box - are used along with conduit to
electrical outlet) from a single location. simplify wiring installation, hence their
S1 name. They are made of sheet metal, cast
metal, or a non-metallic material, and
Duplex (2 single pole switch on one switch provide a way to pull conductors long
plate) - A duplex switch contains two distances without placing excessive strain on
switches on one body. S2 the wire or insulation.
Triplex (3 single pole switch on one switch
plate) - It is effectively three single gang
intermediate switches on one face plate. Circuit Homerun (Number Indicates Circuit
S3 No.) - is a wire that graphically represents
Three-way switch - is one that allows you to the wiring of a circuit to a central location
control a ceiling light (or other electrical that acts as the distribution point for the
fixture) from two separate locations. S3w power, typically, a panel. You do not need to
connect the home run to the panel. You can
Four-way switch - are used to control draw the home run in the direction of the
lighting from three or more locations. Four- panel, as is common practice.
way switches are used in combination with
three-way switches. S4w
Automatic Door light switch - This
automatic door light switch circuit turns ON
Pushbutton - is a small switching device, Annunciator - This is the panel (usually in
which used to close or disconnect control the front of your building) that has a
circuits to issue instructions or program blueprint of your building along with a
control. variety of lights and displays that indicate
where a fire alarm was set off.

Buzzer (Indicate Voltage) - is an audio

signaling device, which may be mechanical, Loudspeaker - an apparatus that converts
electromechanical, or piezoelectric (piezo electrical impulses into sound, typically as
for short). Typical uses of buzzers and part of a public address system or stereo
beepers include alarm devices, timers, and equipment.
confirmation of user input such as a mouse
click or keystroke.
Telephone Exchange - or telephone switch is
a telecommunications system used in the
public switched telephone network or in
Bell (Indicate Voltage) - is a mechanical or
large enterprises. It interconnects telephone
electronic bell that functions by means of an
subscriber lines or virtual circuits of digital
electromagnet. When an electric current is
systems to establish telephone calls between
applied, it produces a repetitive buzzing,
subscribers.
clanging or ringing sound.

Telephone Terminal Cabinet - to mount and

Horn - is a sound-making device that can be
protect telephone terminations,
equipped to motor vehicles, buses, bicycles,
telecommunications circuit accessories,
trains ... horns (sometimes even car horns on cross- connect terminal block ...
12-volt circuits are incorporated) and small
air horns powered by a small can have
compressed gas.
Manual Fire Alarm System - A building fire
emergency notification system consisting
minimally of audible and visual alarm
Amplifier - is an electronic device or circuit notification appliances (i.e., horns and
which is used to increase the magnitude of strobes) installed within all common-use
the signal applied to its input. Amplifier is areas of a building and manual alarm
the generic term used to describe a circuit stations (i.e., pull stations) installed at every
which produces and increased version of its exit from every level.
input signal.
Fire Alarm Control Panel - is the controlling ceramic, or plastic mounted on crossarms
component of a fire alarm system. The panel that are attached to poles or towers.
may also supply electrical energy to operate
–––––––
any associated initiating device, notification
appliance, control, transmitter, or relay. Intercom - An intercom
(intercommunication device), talkback or
door phone is a stand-alone voice
Heat Detector - is a fire alarm device communications system for use within a
designed to respond when the convected building or small collection of buildings,
thermal energy of a fire increases the functioning independently of the public
temperature of a heat sensitive element. telephone network —IC ——IC —
Bell System - is a mechanical or electronic
bell that functions by means of an
Flame Detector - is a sensor designed to electromagnet. ... When an electric current
detect and respond to the presence of a flows through the coils, the electromagnet
flame or fire, allowing flame detection. creates a magnetic field which pulls the
Responses to a detected flame depend on the armature towards it, causing the hammer to
installation, but can include sounding an strike the bell. —B ——B ——
alarm, deactivating a fuel line, and TV Antenna - is an antenna specifically
activating a fire suppression system. designed for use with a television ... —TV
—TV —
Closed Circuit Television - Closed-circuit
Smoke Detector - is an electronic fire- television, also known as video surveillance,
protection device that automatically senses is the use of video cameras to transmit a
the presence of smoke, as a key indication of signal to a specific place, on a limited set of
fire, and sounds a warning to building monitors. – CCTV – CCTV –
occupants.

Battery - is a device that stores chemical

energy and makes it available in an electrical
Wiring Symbols (crosslines indicate number form. It consists of one or more voltaic cells.
of wires)

Conduit - is a tube used to protect and route Resistor - are used to reduce current flow,
electrical wiring in a building or structure. adjust signal levels, to divide voltages, bias
active elements, and terminate transmission
lines, among other uses.
Open Wiring - Referring to a metallic wire
pair circuit comprising uninsulated electrical
conductors. The conductors are physically
separated, attached to insulators of glass,
Inductor - typically consists of an insulated important to lubricate them regularly.
wire wound into a coil around a core. Lubricating tools helps them to perform
better and reduces wear and tear of
components.
Capacitor - is a basic storage device to store • Lubrication is even more important
electrical charges and release it as it is when working with air or pneumatic tools.
required by the circuit. Capacitors are Pneumatic tools need to be lubricated once a
widely used in electronic circuits to perform day before use. When moisture or
variety of tasks, such as smoothing, filtering, condensation enters the interiors of
bypassing etc. pneumatic tools, it can cause corrosion.
Corrosion can decrease the life of an
instrument. Corroded parts are difficult to
repair and replace. Hence, the internal
components of pneumatic tools should be
MAINTAIN TOOLS AND EQUIPMENT coated with special air-tool oil. This oil
prevents corrosion by displacing any
moisture that enters the interior of the
1. Clean your tools. Cleaning the tools equipment.
regularly is essential to their proper 4. Inspect tools regularly. Regularly inspect
functioning. After a day of work, your tools your tools for signs of damage and faulty
will be covered with some amount of dirt. functioning. Inspections should take place at
It’s important to clean them after you’re the end of each construction job. Ensure that
finished using them. Although a thorough you repair them immediately if there is any
cleaning is not required on a daily basis, damage. This will avoid any last-minute
make sure you clean your tools regularly. hassle.
When cleaning your tools, don’t use
chemicals that are extremely harsh. Follow 5. Store tools with care. Storing tools
the manufacturer’s guidelines for proper properly is of prime importance. Although
cleaning and maintenance. tools are designed for rough use, it is
important to store them properly. Cover up
2. Protect electrical cords. Airlines and your tools to keep dirt and rain away from
electrical cords are prone to heavy damage the machine. If the tools aren’t used for a
since they are generally in the way of long time, inspect them regularly for signs
construction vehicles, and foot traffic. Other of damage, wear and tear, corrosion, etc.
machinery like forklifts, drills, etc. can
easily cut through wires. To keep the wires
and airlines from getting damaged, it is
Electrical safety practices save lives
important to protect them. You can cover the
electrical cords with industrial strength Electricity improves life. During power
casings or purpose-built ramps failures, much work and many routine
activities halt. However, electricity can
3. Lubricate tools. Whether you work
cause serious injury and even death if you
with pneumatic or regular tools, it is
fail to follow electrical safety practices, atmospheres; and wet and damp locations
particularly in the workplace. are some unsafe environments affecting
electrical safety. Finally, unsafe acts include
However, electricity is recognized widely as
the failure to de-energized electric
well as a serious workplace hazard that may
equipment when it is being repaired or
cause electric shock, burns, fires, and
inspected, using obviously defective and
explosions. In fact, according to the Bureau
unsafe tools, and using tools or equipment
of Labor Statistics (BLS), 289 employees
too close to energized parts.
were killed by contact with electric current
in 2002. Others were killed or injured in
fires and explosions caused by electricity.
SAFETY TIPS

Causes of Electrical Accident

LIGHTEN YOUR LOAD. Plan what you
are going to do. Carry only the tools or
equipment you will need. Wear a tool belt
The U.S. Occupational Safety and Health
that fits and distribute the tools and materials
Administration (OSHA) cites three possible
evenly.
factors causing electrical accidents: work
involving unsafe equipment and PROTECT YOURSELF. Wear safety gear
installations; workplaces made unsafe by the that fits. Protect your knees from hard, sharp
environment; and unsafe work performance surfaces by wearing knee pads. Wear
(unsafe acts). The first two factors appropriate eye protection to protect your
sometimes are combined and referred to eyes from debris and flying particles. Protect
simply as unsafe conditions. Thus, electrical your hands from friction and sharp edges by
accidents can be generally considered as wearing gloves.
being caused by unsafe conditions, unsafe
SELECT THE RIGHT TOOL. Choose
acts, or in most cases, combinations of the
tools that fit your hand comfortably and
two. It should also be noted that inadequate
have soft grips. A good handle grip prevents
maintenance can cause serious damages and
your hand from slipping while using the
can create unsafe conditions.
tool. Consider using tools that reduce the
amount of force or movements you use.
Keep tools well maintained.
Occupational Health Safety Act (OHSA)
also states that some unsafe electric PRACTICE GOOD HOUSEKEEPING.
equipment and installations can be identified Pick up debris and scrap material to prevent
by faulty insulation, improper grounding, from trips, slips, and falls. Good
loose connections, defective parts, ground housekeeping allows you and your
faults, unguarded live parts, and underrated equipment to get closer for an efficient
equipment. The environment can also work.
contribute to electrical accidents.
Environments containing flammable vapors,
liquids, or gases; areas having corrosive
CHANGE BODY POSITIONS. Working Flash Point is the temperature at which oil
overhead, at floor level, or in cramped gives off ignitable vapors. The flash point is
spaces forces the body into awkward not necessarily a safe upper limit for oil
postures. To relieve muscle tension and because some decomposition takes place
improve circulation, change body positions, below the flash point.
alternate tasks, and stretch throughout the
Hirano refers to the terms Organization,
day.
Orderliness, Cleanliness, Standardized
Cleanup, and Discipline
Safe work practices Lubrication Additives is defined as many of
the physical properties of various oils and
greases.
• Use a good-quality multi-meter with
Pour Point is the lowest temperature at
external fused leads when measuring voltage
which oil will pour or flow and is most
on energized electrical equipment. Fuses and
critical in low temperature applications.
thermal resistors inside older multi-meter
cannot react quickly enough to protect Sorting means to sort everything in a work
against sudden spikes in voltage. area
• Expect line voltages to be 20 percent Viscosity Index indicates how viscosity
higher than rated when build-out capacitors varies with temperature, which can be an
are connected to the electric circuit. important consideration in applications
Investigation has found that build-out where operating temperatures very widely.
capacitors may cause higher than rated
Viscosity is a measure of “flow ability.” It is
voltages at the motor input terminals.
the resistance to flow caused by an internal
• Use a multi-meter rated at least 25 friction between the lubricant molecules.
percent higher than the expected voltage
when testing energized electrical equipment.
This allows spikes in voltage. Identification of Non-Functional Tools and
Equipment
• Use electrical testing equipment that
meets specific safety requirements.

I. Method of identifying non-functional

tools and equipment
TECHNICAL TERMS
5S means Sort, Systematize, Sweep,
Sanitize, and Self-Discipline. 1. Visual inspection. It refers to the
visual observation of an expert on the
CANDO means Cleanup, Arranging,
appearance of the tools and equipment.
Neatness, Discipline, and Ongoing
improvement. 2. Functionality. Vibration or extra
noise from the operation means problems on
Fire Point is the temperature at which oil
parts and accessories started to develop.
will be burn if ignited.
3. Performance. When there is 1. Efficiency of the work
something wrong with the performance of
either hand tools or equipment, they need an
2. High quality of the work
immediate repair or maintenance.
3. Speed of accomplishment
4. Power supply (for electrically
operated only). Failure to meet the required 4. Accuracy
power supply, malfunction will occur in the
part of hand tools or equipment. However, these advantages depend on the
three factors, namely:
5. Person’s involved. It refers to the
technical person who has the knowledge and 1. Availability and sufficiency of the
skills about the technology. materials
2. Experience and skill of the workers
in their respective fields
II. Classifications of tools and
equipment according to their uses: 3. Tools and equipment of good quality

1. Measuring tools Types of tools and equipment

2. Holding tools There are three main types of

tools/equipment in the shop. One type is
3. Cutting tools known as hand tools because your hand
supplies the energy to operate them. The
4. Driving tools
other type is called machine or power
5. Boring tools tools/equipment which uses either
electricity, compressed air, or hydraulic
6. Electrical equipment
pressure to make them operate. The last type
7. Miscellaneous is referred to as measuring tools.
tools/instrument/equipment

Hand tools
Tools are defined as implements used to
They include screwdrivers, hammers, pliers,
modify raw materials for human use. Tools
wrenches and pullers.
can be considered as extension of the human
hand thereby increasing its speed, power, 1. Screwdrivers are used to drive, or
and accuracy. turn screws. The common type has a single
flat blade for driving screws with slotted
heads. The other type has the cross slotted
Importance of Tools head
2. Hammers are mostly used tools in
the shop. They should be gripped at the end
Advantages of using the proper tools of the handle.
3. Pliers are specified types of 2. Air impact wrenches use a pounding
adjustable wrenches. The two legs move on or impact force to loosen or tighten nuts or
a pivot so that items of various sizes can be bolts.
gripped.
3. Air drill is lighter than a comparable
4. Wrenches are used to turn screws, electric drill. Repeatedly stalling or
nuts and bolts with hexagonal heads. overloading does not damage or overheat the
“Hexagonal” means six-sided. A variety of air drill.
wrenches are used in the shop.
4. Air racket uses the sockets and
5. Pullers are used to remove gears and attachments from a standard socket set.
hubs from shafts, bushings from blind holes,
5. Pneumatic floor jack uses
and cylinders’ liners from the engine blocks.
compressed air to flow into the jack cylinder
and causes the ram to extend and raise the
vehicle.
Power tools/Equipment

C. Hydraulic tools
A. Electric tools
1. Electric drill has an electric motor
that drives a chuck. The chuck has jaws that 1. Car lifts-single or double post are
can be opened and then closed to grip a drill both have pads that must be placed under the
kit. designated lift points of the car frame.
2. Grinding wheels can be either bench- 2. Hydraulic floor jack is used to raise
mounted or installed on a pedestal. They the lifting saddle. A lever on the handle
may either have a grindings wheel, view releases the pressure so that the saddle and
wheel, or two grinding wheels. load will settle back down.
3. Vacuum cleaner is used for cleaning 3. Portable crane is used for lifting the
the floor and car interiors after service. engine out of the car. It is operated
hydraulically by a hand pump.
4. Hydraulic press is used to apply
B. Pneumatic tools
force on bent parts to straighten them. It can
also do such jobs as press brushing in and
out and can press out rivets.
1. Air chisel uses reciprocating motion
to drive a cutting hammering tool. An air
hammer drives a chisel to cut off a nut that
Measuring tools
has frozen to a stud. It can be used with a
variety of tools-cutters and punches-to do The different kinds of measuring tools that
many jobs. are used in electrical workshop otherwise
known as “Rules” are:
1. Two-foot four folding rule
 2. Extension rule
3. Zigzag rule
PERFORM BASIC MAINTENANCE
4. Push pull tape rule
5. Slide caliper rule Preventive Maintenance of Electrical
6. Marking gauge Tools and Equipment
1. Zig-Zag rule is available in 4 feet
long commonly used by carpenters for rough
lay-out. There have been a large number of
workplace incidents where workers have
2. Push pull Tape is used to measure been electrocuted or suffered electrical
longer distances available from one meter to shock or burns while using electrical tools
50 meters long. and equipment. Most often, the lack of
proper maintenance is the cause of these
3. Slide Caliper Rule is a special tool
incidents.
used to measure outside diameter of
cylindrical objects.
4. Marking Gauge is a tool most Preventive maintenance is a schedule
appropriate in making lines parallel with the planned maintenance actions aimed at the
edges of the wood. prevention of breakdowns and failures. The
primary goal of preventive maintenance is to
prevent the failure of equipment before it
III. Perform the segregation of non- actually occurs. It is designed to preserve
functional or defective hand tool and and enhance equipment reliability by
equipment, following the given method replacing worn components before they
previously. actually fail. Preventive maintenance
activities include equipment checks, partial
or complete overhauls at specified periods,
IV. Safety Practices: oil changes, lubrication and so on. In
addition, workers can record equipment
1. Always check the tools/instrument deterioration so they know to replace or
and equipment before using. repair worn parts before they cause system
2. Use the appropriate materials, tools, failure. Recent technological advances in
instrument and equipment as per job or task tools for inspection and diagnosis have
requirement. enabled even more accurate and effective
equipment maintenance the ideal preventive
3. Always wear personal protective maintenance program would prevent all
equipment like gloves, goggles, hard hat equipment failure before it occurs.
etc., at all times.
4. Wait for the final instruction before
doing the job or task. There are multiple misconceptions
about preventive maintenance. One such
5. Report to the person in authority misconception is that PM is unduly costly.
whenever untoward incident happens. This logic dictates that it would cost more
for regularly scheduled downtime and potential for flammable and explosive
maintenance than it would normally cost to atmospheres.
operate equipment until repair is absolutely
o Tools for competent people to repair
necessary. This may be true for some
damaged electrical leads, tools and
components; however, one should compare
equipment.
not only the costs but the long-term benefits
and savings associated with preventive
maintenance. Without preventive
maintenance, for example, costs for lost NEVER:
production time from unscheduled
equipment breakdown will be incurred.
Also, preventive maintenance will result in o Use damaged electrical leads, tools
savings due to an increase of effective and equipment.
system service life o Use electrical leads, tools and
equipment in damp or wet conditions unless
they are specially designed for use in those
Long term benefits of preventive conditions.
maintenance include:
o Place electrical leads in areas where
o Improved system reliability they may be damaged (on the ground,
o Decreased cost of replacement through doorways and over sharp edges).

o Decreased system downtime

o Better spares inventory management PREVENTIVE MAINTENANCE TASKS
The following tasks should be performed at
least every three months
The following safety precautions should be
adopted to prevent possible electrocution. 1. Clean the exterior and the interior of
the equipment cabinet, using a
vacuum cleaner and/ or a clean cloth.
ALWAYS: 2. On larger systems clean air filter using a
vacuum cleaner to remove accumulated dust
o Test and tag electrical leads, tools
or dirt.
and equipment regularly.
3.Visually inspect all wiring and cables for
o Visually inspect electrical leads,
cuts, fraying, deterioration, kinks, strains
tools and equipment for damage before each
and mechanical holders. Tape, solder or
use.
replace any defective wiring or hooded
o Use safety switches when using connectors.
electrical tools and equipment.
4. Inspect all mechanical security: key
o Use flameproof electrical tools and switches, indicating lamps, control knobs,
equipment in areas where there is the fans and data entry keyboards. Tighten or
replace as required.
5. Inspect all modules mounted in panels on
I/O slots to ensure that each module is
• Oils cover a broad class of fluid
securely seated in its connector. Remove and
lubricants which has particular physical
clean any module which may have collected
properties and characteristics. Petroleum oils
excess dust or dirt.
(mineral oils) are made from naphthenic or
6. Inspect the power supply for proper paraffinic oils. Naphthenic oils contain little
voltages and check components such as wax and their low pour point makes them
capacitors or resistors for leakage or good lubricants for most applications.
overheating. Replace any defective Paraffinic oils, on the other hand, are very
components waxy, which makes them useful for
hydraulic equipment and other machineries.
7. Check disk drive for proper speed. Adjust
speed according to the manufacturer’s • Ideal for lubricating bearings,
specifications gaskets, seals and other moving parts,
greases consist of an oil or synthetic fluid
8. Clean disk drive heads, magnetic tape
(~80%), a thickening agent (~10%) and
heads or optical paper tape reader
additives (~10%). The consistency of
9. Perform all preventive maintenance greases is usually ranked by their relative
procedures for each peripheral device hardness on a scale set by the National
included in the system. Lubricating Grease Institute (NLGI). The
softest greases are rated at 000 (which is a
flowing liquid) with higher numbers
CLEAN LUBRICATE TOOLS indicating harder grease. Most grease falls in
the range between 1 and 4.
• Solid lubricants are usually fine
BASIC LUBRICATION powders, such as Molybdenum Disulfide
(Moly), graphite and Teflon® (PTFE). They
can be used alone, or as additives in grease
The function of a lubricant is simple. It or dispersions, or as dry film bonded
reduces friction between moving metal lubricants. Lubricating solids can last longer
surfaces. A lubricant coats surfaces and than unfortified oils and greases because of
resists being displaced by the pressure, their ability to form burnished films on
keeping the metal parts separated. surfaces.
Lubricants also prevent corrosion, block
contaminants and can serve as a coolant. A • Rust remover is used mainly to
good lubricant flows easily under pressure dissolve rust. It is also use as an excellent
and remains in contact with moving cleaner. For example, to remove a rusted
surfaces. It does not leak out from bolt, spray remover directly on the bolt, wait
gravitational or centrifugal forces nor does it for approximately five minutes and unscrew.
stiffen in cold temperatures. For a bicycle chain, apply the rust remover
to clean the chain, and then apply a thick
lubricant (oil or PL-100). Another useful
There are several types of lubricants: trick, try it to remove stuck-on store labels!
It works perfectly and won't harm glass or longer life than petroleum materials. They
plastic. WD-40 and Release All are two of are even applicable to elastomers, seals and
the many brands of rust removers on the O-rings.
market.
• Dry lubricant is a product that,
• Synthetic oils are used to lubricate
although greasy when applied, dries in a few
instrument bearings, hydraulics, air
minutes and leaves a protective film. Since it
compressors, gas and steam turbines and
dries rapidly, it doesn't attract dust, so there
other applications. They have excellent
is no mess. This is why it is recommended to
viscosity-temperature characteristics, good
be used on rubber, car door gaskets,
resistance to oxidation and an extremely
handsaws, mitre saw, saw sliders, window
wide operating temperature range.
sashes, etc. It can also be used on balky
wooden drawers, but cabinetmakers usually
prefer floor wax because it is more durable.
JIG-A-LOO is the common brand of a dry • Synthetic greases can last a lifetime,
lubricant. making them very cost-effective. They are
chemically inert, and their high thermal
stability makes them useful for aerospace,
electrical, automotive and other high-tech or
Locksmiths also use a dry lubricant,
industrial applications. Some of these
graphite, to free stuck door locks. This
lubricants keep their viscosity in
product, commonly found in stores, should
temperatures ranging as high as 550° F and
be applied sparingly into the keyhole, as it is
are nonflammable up to 1,200° F.
very messy. Graphite lubricant is composed
of a fine black powder that no cleaner can
remove, so it is wise to protect the door
when graphite is applied. Silicones are very stable and very inert
lubricants, which provide a wider range of
operating temperatures than non-silicone
synthetic lubricants. Other advantages
• Penetrating lubricant. Its
include water repulsion and electrical
lubricating properties persist even after
insulation. Flour silicones have a higher
having removed residues, as it penetrates
resistance to harsh environments and the
into metal. It is ideal for door hinges, even
ability to carry bearing loads. Lubricant
the fridge, hard to open pliers, ski bindings,
manufacturers can provide technical data
etc., as it does not hold dirt and dust. The
sheets on their products to advise you on the
PL-100 which is thick and very efficient.
best applications of each type of lubricant.

Synthetic lubricants cover a broad category

of oils, greases, and pastes of varied
properties. Synthetic lubricants are more
inert, generate less waste, are capable of a
wider range of temperatures and have a
Observe Periodic Preventive and
Maintenance of Electrical Tools and
In addition, another key distinction between
Equipment
5S and "standardized cleanup" is Seiton.
Seiton is often misunderstood, perhaps due
to the efforts of translating into an English
5S (METHODOLOGY)
beginning with "S" (such as "sort" or
5S is a reference to a list of five Japanese "straighten"). The key concept here is to
words translated into English, the letter order items or activities in a manner to
5S are actually the first name methodology. promote work flow. For example, tools
This list is a mnemonic for a methodology should be kept accessible for use, workers
that is often incorrectly characterized with will not find difficulty to access materials,
"standardized cleanup. In fact, it is much flow paths can be altered to improve
more than a cleanup. 5S is a philosophy and efficiency, etc.
a way of organizing and managing the
workplace and work flow with the intent to
improve efficiency by eliminating wastes, The 5S's are:
improving flow of production, reducing
process delays.
SEIRI: SORT (CLEAN UP)
5S is a method of organizing a workplace,
especially shared workplaces (like a shop This is the step 1 in the 5S program:
floor or an office space, even in school). It
is sometimes referred to as a
housekeeping methodology, however this "Sorting" means to sort everything in each
characterization can be misleading work area. Keep only what is necessary.
because organizing a workplace goes Materials, tools, equipment and supplies that
beyond housekeeping. are not frequently used should be moved to a
separate, specified storage area. Items that
are not any more useful should be discarded.
The key targets of 5S are workplace morale Do not keep things around thinking they
and efficiency. The assertion of 5S is, that might be used someday.
time must not be wasted. Additionally, it is
quickly obvious when something is missing Sorting is the first step in making the work
from its designated location. 5S advocates area tidy. It makes easier to find the things
believe the benefits of this methodology you need and frees up additional space.
come from deciding what should be kept, In sorting process, you can eliminate (or
where it should be kept, and how it should repair) broken equipment and tools.
be kept. This decision-making process Obsolete fixtures, molds, jigs, scrap
usually comes from a concept of material, waste and other unused items and
standardization which builds a clear materials are disposed.
understanding, among employees how work
should be done.
SEITON: SET IN ORDER (ORGANIZE)
This is the step 2 in the Five S program: SEISŌ: SWEEP (REGULAR
Step two is to organize, to arrange to CLEANING)
identify everything in a work area for the
Step Three: Once you have everything from
most efficient and effective retrieval and
each individual work area up to your entire
return of the item to their proper places.
facility, sorted (cleaned up) and organized,
you need to keep it that way. This requires
regular cleaning or to go along with our
Commonly used tools should be readily
third S, "shining" things up.
available. Storage areas, cabinets and
shelves should be properly labeled. Clean Regular, usually daily, cleaning is needed or
and paint floors for you to make it easier to everything will be returned to their original
spot dirt, waste materials and spilled parts places. This can be done by regular
and tools. Outline areas on the floor to inspection. While cleaning its needed also to
identify work areas, movement lanes, inspect the machines, tools, equipment and
storage areas, finished product areas, etc. Put supplies you work with.
shadows on tool boards, making it easy to be
Regular cleaning and inspection make it
located.
easy to spot lubricant leaks, equipment
misalignment, breakage, missing tools and
low levels of supplies. Problems can be
In an office/school, provide bookshelves for
hardly identified and fixed when they are
frequently used manuals, books and
small. If these minor problems that are not
catalogs. Label the shelves and books so that
addressed, they can lead to a serious loss of
they can be easily found.
production. On the other hand, frequent
cleaning and inspecting waste time will
result to good production.
The objective of this step is to put
everything in the workplace and properly SEIKETSU: STANDARDIZE (SIMPLIFY)
identified and labeled.
Step Four: To ensure that the first three steps
in your Five S program are done effectively,
the fourth step is to simplify and to
This means that there are two important standardize actions
parts to systematic organization. The first
part is putting everything in its proper place
and setting up a system so that it is easy to
The good practices developed in steps 1
return each item to its proper place. The
through 3 should be standardized and made
second part is where good labeling and
easy to accomplish. Develop a work
identification practices are important. Both
structure that will support the new practices
the equipment/tools and materials you use,
and make them into habits. As you learn
as well as their proper storage locations,
more, update and modify the standards to
need to be clearly identified and labeled.
make the process simpler and easier.
One of the hardest steps is avoiding old "Standardize" is also used as an alternative
work habits. It is easy to slip back into what for "Systemize". Sometimes "Safety" is
you have been doing for years. It gives included as 6th S. Similarly, 5Cs aim at
comfort most of the time for this is part of same goal but without the strength of
your habit. Use standards to help people maintaining the 5S name.
work into new habits that are a part of your
• Clear out and Classify
Five S program.
o Clearing items no longer required
o Tagging items that may be required
Any easy way of making people to be aware
and storing away from workplace
of, and reminded of the standards is to use
labels, signs, posters and banners in the
workplace.
• Configure
o A specific place for specific items
SHITSUKE: SUSTAIN
o “ A place for everything and
Step Five: The final step is to continue everything in its place”
training and maintaining the standards.
Have a formal system for monitoring the
results of your Five S program. • Clean and check

Do not expect that you can clean up, get o Identify the cleaning zones and
things organized and labeled, and ask people establishing cleaning routines
to clean and inspect their areas every day --
and then have everything continue to happen
without any follow-up. • Conformity

Continue to educate people about

maintaining standards. When there are • Custom and practice
changes - such as new equipment, new
products, new work rules - that will affect o Monitoring process adherence
your Five S program, and adjustments to o Continually validating process
accommodate those changes. Make any
needed changes in the standards and provide o Customer satisfaction by doing
training that addresses those changes. scientific training to workers
o Continually focus on man, machine,
material & method
Translations and modifications

Alternative acronyms have also been

Often in the west, alternative terms are used introduced, such as CANDO (Cleanup,
for the five S. These are "Sort, Straighten, Arranging, Neatness, Discipline, and
Shine, Systemize and Sustain".
Ongoing improvement). Even though he Solvents are usually used for cleaning
refers to the ensemble practice as "5S" in his in automotive shops. They are water,
canonical work, Hirano prefers the terms gasoline, kerosene, thinner and detergent
Organization, Orderliness, Cleanliness, soap.
Standardized Cleanup, and Discipline
because they are better translations than the
alliterative approximations. In the book, Properties of Cleaning Solvents
there is a photo of a Japanese sign that
shows the Latin "5S" mixed with Kanji.
A useful generalization much quoted
is that “Like dissolves like”. More
Kinds, Uses and Properties of Cleaning specifically, high solubility occurs when the
Solvents molecules of the solute are similar in
structure and electrical properties to the
molecules of the solvent.
Kinds of Cleaning Solvents
Solutions are homogeneous mixture of
When there is a similarity of electrical
two or more components; can be gaseous,
properties (e.g. high dipole element between
liquid or solid. When we speak of a solution,
solute and solvent) the solute-solvent
we usually think of a solid dissolved in
attractions are particularly strong. When
water. While water is the most common
there is dissimilarity, solute-solvent
solvent, other liquids are frequently
attractions are weak. For this reason, a polar
employed as solvents for certain substances
substance such as H2O usually is a good
– for example wax maybe dissolved in
solvent for a polar substance such as
gasoline. The dissolved material in a
detergent soap but a poor solvent for a
solution is termed as solute (e.g. wax) while
nonpolar substance such as gasoline.
the dissolving medium is called solvent (e.g.
gasoline). However, the term can be
interchanged depending on which substance
is of greater amount. USES OF CLEANING SOLVENTS
1. Gasoline - It is used to
wash oil/greasy tools/ equipment.
Solvent is a component of a solution
that dissolves solute and is usually present in 2. Diesoline - It is used to
large proportion or amount. It can be wash oil engine, transmission and other parts
classified as polar or nonpolar. Polar of the vehicle.
solvents are solvents which dissolve/are 3. Kerosene - It is used to
soluble in water; while nonpolar solvents are remove dust, grease oil, paint, etc.
solvents which do not dissolve/are insoluble
in water. 4. Thinner - It is used to
remove spilled paint on the floor, walls and
tools.
5. Soap and water - It is
used to wash/clean upholstered furniture
such as seats, tables, cabinets, etc.

Occupational Health and Safety Practices

in Handling Cleaning Solvents

A great percentage of eye injury and

cuts results from a disregard for the simplest
of rules in handling cleaning solvents. You
should never use compressed air to clean
your clothes, hands or body. The pressure
can cause the cleaning solvents and dirt
particles to penetrate your skin, resulting in
infection and /or blood poisoning.

Do not use compressed air to clean an object

immediately after it has been removed from
a hot cleaning tank. Rinse the cleaning
solvents away with water. Do not use carbon
tetrachloride as a cleaning solution. The
fumes, when inhaled can cause serious
internal injury and possibly result in death.
When steam-cleaning, place the object to be
cleaned on a pallet and wear a face shield
and rubber gloves for protection against
loose debris.

If a job or cleaning task requires the

use of gloves, use the appropriate gloves. If
you have cut, nicked, or burned yourself, or
something has got into your eyes, report
immediately to the first-aid person.

Keep all inflammable cleaning solvents

in closed tin containers and whenever
possible, store them in a separate area.