Maintenance Engineering Assignment by Waqas Ali Tunio (Nov. 6th, 2010)
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Maintenance Engineering Assignment By Waqas Ali Tunio
Department of Mechanical Engineering, QUEST, Nawabshah Pakistan (www.aliwaqas.tk)
1
MAINTENANCEENGINEERING
ASSIGNMENT
BY WAQAS ALI TUNIO
(07ME34)
SUBMITTED TO
SIR ZAHEERUDDIN
MEMON SAHAB
DEPARTMENT OF
MECHANICAL ENGINEERING
QUAID-E-AWAM
UNIVERSITY OF
ENGINEERING, SCIENCE
& TECHNOLOGY,
NAWABSHAH - PAKISTAN
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COUPLING
MAINTENANCE
When it comes to coupling maintenance
attention to detail is the key. Depending on the
style of coupling, putting in the extra time is
crucial to getting maximum life and
performance. Insert and elastomeric style
couplings can be viewed with a strobe and
require little maintenance, if any. However, grid
and gear in addition to spool types may need a
little extra attention.
If a coupling is only lubricated and not parted,
things may get worse. When conducting
coupling maintenance it is necessary to partially
disassembled in order to remove as much of the
old lubricant as possible. Inspect the
components for signs of wear, looking for
indications of improperly aligned equipment.
Pre-lube the sliding surfaces of the coupling,
ensure that components have the required
freedom of movement prior to reassembly.
Proceed with manufactures recommendations
on lubrication of a new coupling. By following
this routine you may extend the life of your
couplings and increase reliability.
Coupling maintenance is generally a simple
matter, requiring a regularly scheduled
inspection of each coupling. It consists of:
Performing visual inspections,checking for signs of wear or fatigue,
and cleaning couplings regularly.
Checking and changing lubricantregularly if the coupling is lubricated.
This maintenance is required
annually for most couplings and more
frequently for couplings in adverse
environments or in demanding
operating conditions.
Documenting the maintenanceperformed on each coupling, along
with the date.
Even with proper maintenance, however,
couplings can fail. Underlying reasons for
failure, other than maintenance, include:
Improper installation Poor coupling selection Operation beyond design capabilities.
The only way to improve coupling life is to
understand what caused the failure and to
correct it prior to installing a new coupling.
Some external signs that indicate potential
coupling failure include:
Abnormal noise, such as screeching,squealing or chattering
Excessive vibration or wobble Failed seals indicated by lubricant
leakage or contamination.
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3
CLUTCH
MAINTENANCE
Clutches are prone to routine beatings and
need to be checked and maintained on a
regular basis. Clutch parts wear at different
rates depending on the riders style and riding
conditions. Here are a few basic tips that
anyone with a torque wrench can easily handle.
1. Lets look under the hood: Start by either
draining the engine oil, or laying the bike on its
side (if you prefer to change the oil after
working on the clutch). Drop the rear brakepedal by removing the screw holding it in place.
Remove the clutch cover bolts and pop the
clutch cover off. Careful not to damage the
gasket.
2. Remove the center clutch screws and springs.
You can now remove the pressure plate and
access all the clutch fibers and drive plates.
3. Inspect the clutch fibers and drive plates. The
service manual will give you minimum thicknessspecifications. If the plates are black and visibly
shot, play it safe and replace them. The steel
drive plates can warp when overheated. Inspect
them for warp age by laying them on a flat
surface such as a piece of glass.
4. Inspect the clutch basket for notches on the
sides of the tangs. A well maintained basket
should have smooth tangs. Notched tangs
inhibit smooth clutch operation and can keep
the clutch from functioning properly. The die
cast aluminum baskets wear easily. Investing ina good aftermarket clutch basket will improve
clutch feel, extend basket life, and improve oil
flow through the clutch. Forgings are tougher
and lighter than billet parts due to grain flow in
the material that is aligned to the features of
the part.
5. Inspect the inner clutch for notches on the
sides of the drive splines. Like the clutch basket,
the inner clutch can become notched after
time. If the drive splines are notched badly,
replace the inner clutch. The OEM innerclutches are relatively inexpensive, but
aftermarket inner clutches like the Hinson will
offer the same benefits as an aftermarket clutch
basket.
6. If either the clutch basket or the inner clutch
need replaced, you will need to remove the
center nut from the transmission shaft that
holds the inner clutch in place. An impact
wrench works best for removing this nut.
However, if you dont have an impact wrench,you will need a special tool to hold the inner
clutch while you remove and install the center
nut. DO NOT jam something in-between the
inner clutch screw bosses to try and hold it.
They WILL break off.
7. Assemble the clutch by first putting the
basket on the shaft. MAKE SURE it drops down
onto the shaft all the way. There are 2-3 gears
that have to line up with the back of the clutch
basket, so make sure everything meshes and
the basket drops all the way onto the shaft. A
splined washer goes on next, and then the inner
clutch hub. The retainer washer goes on after
the inner clutch, and finally the retainer nut.
https://www.cyclepedia.com/amember/go.php?r=114&i=l64http://shop.thumpertalk.com/oem.asp?Click=38334http://shop.thumpertalk.com/SearchResults.asp?Cat=852&Click=19938Hinsonhttp://shop.thumpertalk.com/SearchResults.asp?Cat=852&Click=19938Hinsonhttp://shop.thumpertalk.com/oem.asp?Click=38334https://www.cyclepedia.com/amember/go.php?r=114&i=l64 -
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While holding the inner clutch with the special
holding tool, torque the center nut according to
the torque spec in the service manual. (I usually
snug the nut back on with the impact wrench,
but this is NOT recommended, as you run therisk of over torquing and stripping the
nut/shaft.)
8. Soak the new clutch plates in oil and then
install them into the clutch. Always start with a
fiber, and then alternate steel, fiber, steel, fiber,
until you end with the last fiber. The clutch
plates should stack up to about the same height
as the top of the clutch basket.
9. Return the lifting post to its proper location
in the end of the transmission shaft. Then install
the pressure plate, followed by the clutch
springs and bolts. Torque the spring bolts to the
proper specification.
10. Install the clutch cover and torque the bolts
to the proper spec. Lastly, install the brake
pedal.
11. Ensuring the clutch cable is adjusted
properly can have a large effect on the life span
and operation of the clutch. The general rule is
a nickels worth of play at the lever.
Maintaining a clutch is not very complicated,
but can have huge benefits to ensuring your
ride or race is fun and trouble free. Torquing all
the bolts according to the specs in the service
manual is the most important step. Buy a good
torque wrench and go for it!
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5
MAINTENANCE OF
ELECTRICALEQUIPMENTS
BATTERY MAINTENANCE
Battery Maintenance is an important issue. The
battery should be clean. Cable connection
needs to be clean and tightened. Many battery
problems are caused by dirty and loose
connections. Serviceable battery needs to have
the fluid level checked regularly and only at afull charge. The fluid level will always be higher
at a full charge. Distilled water is best; tap water
is loaded with chemicals and minerals that are
harmful to your battery, but not as bad as any
water. Don't overfill battery cells especially in
warmer weather. The natural fluid expansion in
hot weather will push excess electrolytes from
the battery. To prevent corrosion of cables on
top post batteries, use a small bead of silicon
sealer at the base of the post and place a felt
battery washer over it. Coat the washer with
high temperature grease or petroleum jelly
(Vaseline). Then place cable on post and
tighten, coat the exposed cable end with the
grease. Most folks don't know that just the
gases from the battery condensing on metal
parts cause most corrosion.
The quickest way to ruin lead-acid batteries is
to discharge them deeply and leave them stand
"dead" for an extended period of time. When
they discharge, there is a chemical change in
the positive plates of the battery. They change
from lead oxide when charged to lead sulfate
when discharged. If they remain in the lead
sulfate state for a few days, some part of theplate does not return to lead oxide when the
battery is recharged. If the battery remains
discharged longer, a greater amount of the
positive plate will remain lead sulfate. The parts
of the plates that become "sulfated" no longer
store energy. Batteries that are deeply
discharged, and then charged partially on a
regular basis can fail in less than one year.
Check your batteries on a regular basis to be
sure they are getting charged. Use ahydrometer to check the specific gravity of your
lead acid batteries. If batteries are cycled very
deeply and then recharged quickly, the specific
gravity reading will be lower than it should
because the electrolyte at the top of the battery
may not have mixed with the "charged"
electrolyte. Check the electrolyte level in wet-
cell batteries at least four times a year and top
each cell off with distilled water. Do not add
water to discharged batteries. Electrolyte is
absorbed when batteries are much discharged.
If you add water at this time, and then recharge
the battery, electrolyte will overflow and make
a mess.
Keep the tops of your batteries clean and check
that cables are tight. Do not tighten or remove
cables while charging or discharging. Any spark
around batteries can cause a hydrogen
explosion inside, and ruin one of the cells, and
you.
It is a good idea to do an equalizing chargewhen some cells show a variation of 0.05
specific gravity from each other. This is a long
steady overcharge, bringing the battery to a
gassing or bubbling state. Do not equalize
sealed or gel type batteries.
With proper care, lead-acid batteries will have a
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long service life and work very well in almost
any power system. Unfortunately, with poor
treatment lead-acid battery life will be very
short.
FACTORS AFFECTING BATTERY LIFE
OVERCHARGING
It severely corrodes positive plate grids which
weaken and finally disintegrate. Overcharging
decomposes electrolyte into hydrogen and
oxygen which causes excessive concentration of
the electrolyte because of loss of water from
the mixture of the battery fluid. This damagesthe plates and separators. High temperatures
also show adverse effects on plates, separators
and container. Excessive gassing creates the
possibility of the active metal blowing away
from the plate surface and fine acid spray
escaping from the battery.
UNDERCHARGING
Perpetual undercharging results in sulphation of
plates and running down of cells. Sulphate
deposits are also seen on cell separators, which
leak through and create short circuits between
positive and negative plates. Undercharging
also leads to buckling of plates.
IDLE BATTERY
If left idle and self-discharge takes place,
sulphation is observed on battery terminals.
Sulphation of the battery kills battery life
sooner than normal.
HIGH SPECIFIC GRAVITY
High SG destroys positive and negative platesand also reduces battery life.
IMPURE WATER TOP-UP
Impure water introduces impurities in the
battery every time it is added. Iron and chlorine
attack the plates causing to shorten their
overall life. Chlorine bleaches separators which
is harmful.
NEGLIGENCE IN WATER TOP-UP
The concentration of the acid increases due to
less amount of water and so damages are borne
by the plates and separators. The plate areas
above the electrolyte level get hard and lose
capacity.
An effective motor maintenance program
boosts productivity, reduces unnecessary
downtime, maximizes motor efficiency, and
saves dollars.
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MAINTENANCE
FOR MOTORUnscheduled downtime in modern plant
operations results in high costs and possible
loss of business. That's why a well-planned
preventive maintenance program is key to
dependable, long-life motor operation.
However, a preventative maintenance program
for motors won't work if you don't have the
proper test equipment, tools, and training for
the process. When developing a plan, consider
the equipment you'll need, and allow adequate
time for performing inspections andmaintaining accurate records.
A variety of maintenance methods may apply
for each type of motor, controller, or related
equipment in your facility. You should choose
the best methods for your facility and then
determine how best to apply those methods.
For example, consider whether you should
check for possible bearing trouble on a motor
by feeling components for high temperature
and listening for unusual sounds, or installing
temperature-monitoring devices and making
inspections using a stethoscope or an infrared
scanner. The following presents basic guidelines
to follow when implementing an effective
motor maintenance program.
MOTOR MAINTENANCE
Lubricate regularly according to manufacturer's
instructions. On sleeve bearings and other oil-
lubricated machines, check oil reservoirs on a
regular basis. For example, in poor
environments, change oil at least once a month.
Never over-lubricate; excess grease or oil gets
into windings and deteriorates insulation. Be
sure to use only the lubricant specified for the
machine in question. However, check into the
possibility of using modern lubricants, which
have excellent life and lubricating qualities.
On essential motors, or those you frequently
duty cycle, check bearings daily (or at least
weekly) using a stethoscope, infrared scanner,
or vibration analyzer. Check bearing surface
temperature with a thermometer, electronictemperature sensing device, or stick-on
temperature indicating labels. Compare the
temperature of hot bearings with the
temperature of normally operating bearings.
Check oil rings and keep an eye on excessive
endplay.
Check air gap between the rotor and stator with
feeler gages at least annually. Make the
measurements at the top, bottom, and both
sides of the stator. Differences in readings
obtained from year-to-year indicate bearing
wear.
CHECK BELT TENSION
Belts should have about 1 in. of play. Be sure to
firmly seat sheaves with little or no play.
Couplings should be tight within tolerances, and
should operate without excessive noise. You
should make an alignment check on all motor
gensets and motor-load couplings when you
suspect trouble.
Inspect brushes and commutators of DC motors
for excessive wear. Be sure all brushes are of
the proper type, hardness, and conductivity and
that they fit properly in brush holders. Check
spring pressure of brush holders with a small
scale. In most instances, pressure should be 2 to
2.5 lb/sq in. of brush cross-sectional area. Call
manufacturers or a service company to solve
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recurring problems of brush chatter, excessive
brush wear, sparking, streaking, or threading of
commutator.
Check mounting of motors regularly. Inspectmounting bolts and steel base plates for
possible warping and concrete base plates for
cracking or spalling. Annually, perform vibration
analysis tests. Excessive vibration may be hard
to detect by hand; but it could be enough to
shorten motor life significantly. You can
accomplish field vibration analysis with portable
instruments that identify vibrations and display
their amplitudes and frequencies. Then, you can
identify and correct the source of the problem.
Keep the motor clean and cool. In dirtyoperating environments, blow out dirt with dry
compressed air (no more than 50 lb) as often as
needed. In high-temperature locations where
high reliability is a priority, consider the use of
oversized motors. Excessive ambient
temperatures will shorten motor life. Pull and
disassemble important motors during
summer/holiday shutdowns for a thorough
inspection, testing, cleaning, check of bearings,
couplings or accessories, or complete
reconditioning.
KEEP ACCURATE RECORDS
Perform annual insulation-resistance tests and
other appropriate test. You should also visually
inspect important motors, as well as perform
voltage and current checks. Record and
compare all values each year. The trend of the
readings indicates the condition of the motor
and offers a guide to its reliability. Motor
control maintenance. Keep control equipment
clean. In dirty operating environments, blow
out dirt weekly, otherwise a quarterly or
semiannual cleaning should be adequate.
Check operation of contactors and relays by
hand, feeling for any binding or sticking. Moving
parts should operate without excessive friction.
Look for loose pins, bolts, or bearings. If the
control is dirty, wipe or blow it clean.
Check contacts for pitting, and signs of
overheating such as discoloration of metal or
charred insulation. Make sure contact pressure
is adequate (see the manufacturer's
specifications) and is the same on all poles.Watch for frayed flexible leads.
On essential controls, perform contact-
resistance tests with a low-resistance
ohmmeter on a regular basis. Proper contact
resistance should be about 50 micro-ohms.
Record the readings for future comparison to
identify trends.
Inspect, clean, and check overload relays for
proper setting. In general, maintenance
requirements for these relays include checkingthat: the rating or trip setting takes into account
ambient temperature as well as the higher
inrush currents of modern, energy-efficient
motors; contacts are clean and free from
oxidation; the relay will operate dependably
when needed.
To ensure reliable operation, test and calibrate
relays every one to three years. You can use
special equipment to perform these tests, such
as OL-relay testers.
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9
MAINTENANCE
FUNCTIONS
Aviation companies, educational facilities, local
governments and commercial property owners
often hire maintenance supervisors to oversee
their repair departments. Maintenance
supervisors direct staff in the maintenance of
buildings, equipment and vehicles, including the
installation and repair of cooling, electrical,
heating, plumbing and other related mechanical
systems. In addition to the technical and safety
requirements, maintenance supervisor training
should include accounting, budgeting,
marketing and human resource management.
SKILLS
1. General maintenance supervisors must havebroad technical repair knowledge. Abilities vary
by field, but can include carpentry, parts
fabrication, masonry, welding and wiring.
Maintenance supervisors must also know how
to read blueprints, diagrams or schematics.
They need to use time management techniques
to coordinate a maintenance schedule and
management skills to effectively lead the repair
staff, including communication and conflict
mediation. Some companies may require
maintenance managers to develop and
maintain a budget that considers supply and
labor costs.
ON-THE-JOB TRAINING
2. Many maintenance supervisors advance to theirposition by first working entry level
maintenance jobs. There they learn the
technical skills necessary to advance to a
management position. Entry-level maintenance
workers learn troubleshooting techniques,
maintenance routines and tool usage. This
training gives workers the underlying
mechanical and procedural knowledge
necessary for a maintenance supervisor
position.
SCHOOLS
3. Technical schools and community colleges offertraining in repair and maintenance techniques.
While a degree is not required for a
maintenance position, an associate's degree
or education certificate such as the Industrial
Maintenance Technician Certificate fromMarion Technical College will help a candidate's
credibility. Formal courses in business practices,
particularly accounting, leadership and human
resources, may be required for a maintenance
supervisor position. Colleges and universities
often offer these business classes afterhours
MAINTENANCE TRAINING
MAINTENANCE SUPERVISOR TRAINING
SHOULD INCLUDE LEADERSHIP AND
COMMUNICATION SKILLS FOR
EFFECTIVE STAFF MANAGEMENT.
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and at a discounted rate for nontraditional
students.
CERTIFICATES
4. According to the U.S. Bureau of Labor Statistics,certification through the International
Management Institute (IMI) may increase
advancement opportunities for maintenance
supervisors and workers. The IMI offers the
highest industry standard certification, the
Certified Maintenance Manager. Certification
coursework covers technical skills along with
mathematics and troubleshooting.
CONTINUING EDUCATION
5. Organizations such as the IMI, the Society forMaintenance and Reliability Professionals
(SMRP) and the Association for Maintenance
Professionals (AMP) offer workshops and
conferences for advanced maintenance
supervisor training. SMRP workshop topics
include business management, manufacturing
process reliability, equipment reliability, people
skills and work management.
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ENVIRONMENTAL
MEASURES
INCREASING ENERGY EFFICIENCY
One of the most straightforward ways to cut
carbon is to improve energy efficiency. The idea
may be blindingly obvious the lower your
consumption, the smaller your emissions but
as one Inner Mongolian coal mining operation
recently demonstrated, it
is also highly effective.
The upshot of this is lower
fuel usage and
significantly reduced
greenhouse gas emissions,
along with smaller
maintenance and repair
costs and less spillage on
the haul roads.
GREEN OPTIONS
Ever since the diesel engine rose to prominence
in the mining industry, emissions have been the
focus of some concern, though initially most of
these were more about particulates and their
effect on industrial health than the
environment.
More recently, contemporary concerns on
issues of pollution and fossil carbon release
have encouraged many mining companies to
examine diesel usage and explore the potential
of a range of alternative fuels. For coal mines atleast, however, it is the growing trend towards
gas-fired cogeneration that perhaps holds the
most immediate potential.
Not only can cogeneration provide on-site heat
and power but it also helps minimize the obvious
explosion danger and the more insidious
environmental threat posed by releasing
methane to the atmosphere a gas with more
than 20 times the greenhouse potential of CO2.
Such results highlight the importance of a fulllifecycle assessment to identify such specific hot
spots, if any emission reduction is going to
stand a chance of being meaningful. With much
of mining and mineral processing predicted to
face the specter of future increases in
greenhouse gas emissions as ore grades fall,
knowing where to channel your efforts and
where emerging technologies can help will
inevitably become
increasingly vital.
CARBON INNOVATION
The mining industry is no
stranger to technological
innovation. Developments
in catalysts and other
advanced diesel engine
technologies will, for
instance, undoubtedly
offer carbon-savings for
loading and hauling applications, while the newgeneration of high-pressure rolls and stirred
mills will do the same for grinding operations.
A whole innovative wave of upgrades,
improvements and energy efficiencies await
their role in the future of carbon-compliant
mining but on the global stage it is perhaps with
carbon capture and storage that the industry
may be best placed to take a major lead.
Described by the Australian Coal Association as
"one of the most promising long-term solutions
for reducing global greenhouse gas emissions,"
the underlying idea behind carbon capture and
storage could hardly be simpler: capture the
CO2 from coal-fired power plants and other
large, fixed sources, transport it somewhere
safe and then store it deep underground -
permanently.
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SUGGESTIONS
Alhamdulillah, the course syllable is very
balanced covering all possible major topics, also
teaching methodology, but as nothing is perfect
and theres always room for improvement, so
following areas may be of improvement, which I
observed during the class.
CURRICULAR
Alhamdulillah the curricular taught was very
much balanced and general, giving in-depth
knowledge of the subject.
Possible suggestion could be that Chain-
Sprocket topics should not be taught generally,
rather make them specific. When the term
Chain-Sprocket was pronounced, most of
guys used to limit it to one bicycle only.Advanced and overall applications of that
power transmission system may be first taught
in detail.
TEACHING
Alhamdulillah, the teaching methodology has
been truly exceptional, to me at least. This was
the only subject where every student was more
than involved and class discussion has been a
real confidence booster. Honestly speaking, I
have benefitted from class discussion a lot forwhich I am very thankful to Sir Zaheeruddin
Memon Sahab for providing such a conducive
learning environment. I gained the confidence
to speak with my natural LOUD vocals in class,
and thats why I will always cherish all four
subjects which he taught, the reason was that
such class discussion compelled to brainstorm
and then speak, something which has helped in
lot of ways.
The teacher encouraged sharing personal
industrial experiences, which was also very
Apart from that I used to match the topics
demanded me to express the real-time
industrial experiences that I have had during my
three internships at TSML, FFBL and BOPL
respectively, even that proved very handy.
AREA OF IMPROVEMENT
STUDENT INTERRUPTION SHOULD BE
STOPPED
Only thing which I observed in all four subjects
ofSir Zaheeruddin Memon Sahab was that
when any student is speaking, the so-called
good students used to interrupt at small
intervals, disturbing the tempo and mind-set of
the student speaking and trying to degrade him.
Everyone had the chance to speak, if someone
finished then other student should have been
allowed, and those who interrupt should have
been strictly dealt, else those who spoke
everyday will try not to speak, as foul practiceof disturbing was always on.
My personal experience was that whenever I
spoke, few selected guys used to disturb, the
only reason what I can see was that they were
unable to digest the facts which I exposed in
class, beyond their level of thinking and little
knowledge, and mostly my points proved their
statements wrong in-front of the whole class,
so the only thing they could do was to disturb
me by various means, and they were not
compelled by the teacher to remain silent.
Result was that I was always made to deviate
from the real point. In future, at least this
practice should be STOPPED and everyone
should be given fair chance.
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WHY TO PROVE WRONG POINTS MADE BY
OTHERS?
Discussion should be on the topic, rather than if
a student makes an statement and then the
teacher turns to other student and ask him to
prove the statement of the first student, so that
was more than harsh, because what I saw that
mostly guys never knew of what is happening in
the industrial backyards, and then other was
made to prove a wrong point which an student
made earlier.
One example from my personal experience
Once, a student said that theres no need of
lubrication between Bearing and the Shaft. So,
when I stood up, I told that lubrication between
bearing and shaft in very critical, and its the key
to reliable operation of the shaft, the teacher
said that the other student has claimed that
theres no need of lubrication. I
straightforwardly said that why should I start
proving wrong points made by others?
Moreover I said that such students in-order to
show off in class are making wrong points, and
if they continue doing that, same theyll do in
field, ultimately defaming the image of theuniversity.
In fact, the teacher should himself indicate at
the very moment when any wrong point is
made, otherwise if the class discussion stops
without its clarification, therell be students
wholl consider wrong points to be right.