PREVENTIVE MAINTENANCE

JF 510 - INDUSTRIAL MAINTANENCEPREVENTIVE MAINTENANCE

Implement the maintaining of history log has implemented several hundred preventive maintenance systems in industry worldwide. Best results have been achieved where we have trained and coached clients employees to implement the preventive maintenance optimization and systems.

Implementation and coaching of preventive maintenance typically include:Formal assessment of current preventive maintenance systemsCoach the review of lubrication practicesTrain operators and craftspeople in inspection techniques

Plan an effective Preventive MaintenanceWhether you want to start a new one or upgrade an existing preventative maintenance program, these steps will help maximize machine profits and make machine maintenance more cost effective. Proper maintenance is a must if you want to get the most out of your equipment and avoid unnecessary downtime.

determine a starting point for your new maintenance program. Begin by listing every piece of equipment and assign asset or identification numbers to each unit. These identifiers will help later in tracking costs and giving an indication whether or not the system needs to be replaced.

Implement the execution of preventive maintenance safelyPreventive maintenance is the routine servicing of equipment, tools and vehicles, including periodic inspections to prevent the development of problems and provide for maximum economy of operation. Safe Work Practices (SWP), are a set of guidelines or "Dos and Donts on how to perform a specific task that may not always be done in the same way and should be developed to mitigate hazards that have been identified through the hazard identification process.

Demonstrate of retrieving proper permits and procedures for hazardous and confined spacesAn Entry Permit is an administrative tool used to document the completion of a hazard assessment for each confined space entry. Someone fully trained and experienced in confined space work should complete the Entry Permit.Before entering a confined space, an entry permit should be written. It should contain at least the following information:

The length of time the permit is valid for.The name(s) of the worker(s) that are authorized to enter the confined space.The name(s) of the attendant(s) (safety watch) and/or supervisor.The location and description of the confined space.The work that is to be done in the confined space.

Identify some visual symptoms that indicate imminent bearing failureGenerally caused by lack of maintenance or overloading.Overheating: the presence of solid or caked lubricant. -a result of high temperatures,which would caused by different conditions.Rusting: causes by moisture on surfaces -a form of oxidation that occurs when moisture is present and lubrication is lacking.Underlubrication: lack of lubrication causes friction and overheating within the bearing -overlubracation can place excessive internal pressure on the bearing because the rolling elements have to move the excess amount of lubrication within the bearing as well as the load

Identify some visual symptoms that indicate imminent gearbox failureGearboxes usually contain oil to keep the gears lubricated and cooled.Oil -the presence of small metal particles in the bottom of the oil reservoir. -In gearboxes that have brass gearing, the oil begins to have a metallic look to it as a sign of gearbox wear. -This is the reason why the oil should be checked and drained on a regular basis.

Tooth wear on the gear -if excessive wear is noticed,replace the gear before putting the gearbox back into service. -if a replacement gear cannot be found,replace the entire box -Check all of the seals as well.

Diagnosis gear wear and eliminate as many of theconditions as possible that cause premature gear wearModerate Wear -takes place over a relatively long period of time the contact pattern indicates that metal has been removed in the addendum and dedendum area; also the pitch line begins to show as an unbroken line. -caused by an inadequate lubrication film, with the film thickness being too thin for the load (dirt in the lubrication system also). -solution, specify a lubricant with a greater film strength or one with a higher viscosity(kelikatan).

Excessive Wear -progressed to the point where considerable amount of material has been removed from the surfaces. -caused by the material has been worn from the tooth surface,the involute profiles are destroyed and the gears begin to run roughly and get worse. -solution, could be avoided by increasing lubricant film strength or viscosity or increasing pitch-line velocity.

Abrasive Wear -contacting surfaces show signs of a lapped finish,radial scratch marks or grooves or some other unmistakeable indication that contact has taken place. -caused by foreign materials particles in the lubrication system. -solution, use a filter.alternatively,a higher-viscosity lubricant will develop a thicker oil film,which will pass fine particles without scratching.

Corrosive Wear -deterioration of the surface due to chemical action. -caused by active ingredients in the lubricating oil such as acid, moisture and extreme-pressure additives. -solution, by checking the lube oil for breakdown and by changing the lube oil at regular intervals.

5.2.4 common problem with belt drives and recommend how to prevent these problems from occurring again

Problems Belt Drives 1) improper tension 2) misalignment3) handling 4) hardware 5) environmental factors 6) design factors.

Chain

5.2.5 common problems with chains and sprockets and recommend how to prevent these problem from occurring again

Sprocket

5.2.6 the signs of coupling wear

Coupling 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, squealingExcessive vibration or wobbleFailed seals indicated by lubricant leakage or contamination.

5.3 Apply the preventive maintenance for electrical

5.3.1 Categorize five types of records that should be maintaineda. Equipment informationb. Inspection checklistc. Repair informationd. Preventive maintenance schedulee. Parts inventory

Equipment informationInformation about existing equipment or used.Information necessary equipment should be records:Name of equipmentTypes of equipmentRegistration dateSeries number

Inspection ChecklistA form for maintenance personnel to check the condition of a building or mechanical device.Information that should be included:Machines or devices nameFrequencyTypes of inspectionDateReference

Repair informationInformation about the faulty equipment and the action taken.The details should be record:Type of damageDate of damageSolution

Preventive Maintenance scheduleSchedule maintenance work done by a certain time period.Seeks to avoid greater damage.A maintenance refers to the frequency at which the service types are performed.

Parts InventoryAn inventory of replacement parts.Details about the partsNameTypeSizeQuantity

5.3.2 Discuss four rules of electrical maintenance a. Keep it clean b. Keep it dry c. Keep it tight d. Keep it friction-free

Keep it cleanDirt is a common cause of electrical failure.it can contaminate electrical equipment causing overheating and increased electrical resistance.This includes activities such as weekly cleaning of motor casings and keeping electrical cabinets free of dust by vacuuming.Every maintenance opportunity should include a thorough cleaning of apparatus.

Keep it dryElectrical equipment operates best in dry and corrosive-free atmospheres.High moisture levels can lead to direct short circuiting and immediate failure.Humidity should be controlled if possible and guarded against by using equipment designed for use in damp or wet conditions.

Keep it tightMotion of operating equipment will eventually cause wear and imbalance.create vibrations in equipment and loosen vital connecting parts.Routine maintenance is necessary to detect wear and loosening of parts and connections.Tightening a screw or connection can only take but a moment.

Keep it friction-freeOver-lubrication is a dangerous practice because excessive oil can collect dust and abrasive materials.Machinery must be properly lubricated at recommended frequencies.Alignment of machinery components is critical to help reduce friction.

5.3.3 Identify the inspection checklistIn engineering activities inspection involves themeasurements,tests, andgauges.The results are usually compared to specifiedrequirements.Inspections are usually non-destructive.

5.3.4 Justify the person take responsible for electrical maintenanceLicensed maintenance electrician.Unlicensed person under the supervision of a licensed master electrician, licensed maintenance electrician.electrical engineer employed by same employer.Master electrician of record for an electrical contractor who has contracted with the employer to do electrical work for which an electrical contractors license is required.