MEMG 09101 HEAVY EQUIPMENT

MAINTENANCE

LECTURE 3A: MAINTENANCE

Maintenance
 Maintenance can be defined as the process of
retains mechanical equipment in a safe
operationally efficient condition or, where items
have broken down, restores them to safe
operational status.
 By its nature, maintenance involves
 Delays
 Standing time and
 lost production
Maintenance
 The aim of maintenance department therefore is to
provide an effective service which achieves high
availability of equipment at the lowest achievable
cost.
 That is, adequate, well designed, formal systems,
procedures and resources are required to proper
carry out and support maintenance practice.
 In practical include training, quality control, record
keeping and application of information technology
The need to maintain
heavy duty equipment

 To attain high levels of productivity

 Health and safety
 Avoid delay project completion
The need to maintain
heavy duty equipment

Inadequate maintenance can lead to

[Link] contract completion
[Link] client goodwill
[Link] liquidated damages
[Link] levels of equipment utilization
[Link] hazardous site condition and
[Link] high operating costs
Damages as a result of
late completion

 Mechanical breakdown can have severe

negative ramification for contractor in
terms of contract overrun.
 If the contractor fail to complete the
works by the agreed completion date, the
client may be entitled to liquidated
damages
Loss of client goodwill
 It is unfortunate that the construction industry
has a fairly poor reputation in the eyes of the
general public.
 Consequently, projects which go wrong are
more widely discussed than those which excel.
 As such any loss of client goodwill has seriously
tarnish the contractor’s reputation, hence
negative impact on future business
Maintenance Objectives

 Maintenance objectives should be consistent

with and subordinate to production goals.
 The relation between maintenance objectives
and production goals is reflected in the action
of keeping production machines and facilities
in the best possible condition.
Maintenance Objectives
 Maximising production or increasing
facilities availability at the lowest cost and at
the highest quality and safety standards.
 Reducing breakdowns and emergency
shutdowns.
 Optimising resources utilisation.
 Reducing downtime.
 Improving spares stock control.
Maintenance Objectives

 Improving equipment efficiency and reducing

scrap rate.
 Minimising energy usage.
 Optimising the useful life of equipment.
 Providing reliable cost and budgetary control.
 Identifying and implementing cost reductions.
Maintenance Objectives
PLANT

Maximising Production Reduce Breakdowns

M
A
I
Minimising Energy Usage N Reduce Downtime
T
E
N
Optimising Useful Life of Improving Equipment
Equipment A Efficiency
N
C
Providing Budgetary Control E Improving Inventory Control

Optimising Resources Implementing Cost Reduction

Utilisation
Types of Maintenance

 Breakdown maintenance
 Preventive maintenance
 Proactive Maintenance
Corrective or Breakdown
Maintenance

 Corrective or Breakdown maintenance - Repair

of equipment/machinery in order to bring it back
to original operating condition, after the
equipment is failed.
 Quite justified in small factories where:
 Down times are non-critical and repair costs are less
than other type of maintenance
 Financial justification for scheduling are not felt
Breakdown maintenance (BDM)

 It means that people waits until

equipment fails and repair it.
 Such a thing could be used when the
equipment failure does not significantly
affect the operation or production or
generate any significant loss other than
repair cost.
Disadvantages of Corrective
Maintenance
 Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
 Excessive delay in production & reduces output
 Faster plant deterioration
 Increases chances of accidents and less safety for
both workers and machines
 More spoilt materials
 Direct loss of profit
 Can not be employed for equipments regulated by
statutory provisions e.g. cranes, lift and hoists etc
Preventive maintenance (PM)
 “Schedule of planned maintenance actions
aimed at the prevention of breakdowns and
failures”
 Primary goal-Preserve and enhance equipment
reliability.
 Anything that increases life of equipment, and
helps it runs more efficiently
 Examples of PM: Oil changes, Greasing,
Changing filters, Belt tightening.
 Candidates for Preventive
Maintenance

Frequency of Failure
Good candidates
have more normal
distribution with
low variability

Mean Time Between Failure (MTBF)

Advantages of PM
 Increases life of equipment
 Reduces failures and breakdowns
 Reduces costly down time
 Greater safety of workers
 Lower maintenance and repair costs
 Better product quality and fewer reworks and
scraps
 Increases chances to get production incentive
bonus
Preventive maintenance (PM)

 Preventive maintenance should be

performed on most equipment as
recommended by the Manufacturer.
 Note: Determine if time spent to perform
PM is greater than the replacement cost
 Preventive maintenance includes both
 planned maintenance and
 condition-based maintenance
Planned maintenance
 refers to the activity of replacing and inspecting
parts and materials on a regular basis following a
predefined schedule.
 Planned maintenance is in literature also referred
to as scheduled maintenance; time based
maintenance or planned preventive
maintenance.
 Planned maintenance is used to improve
equipment life and to avoid unplanned
maintenance activities.
Predictive (Condition-based)
Maintenance

 “Techniques that help determine the

condition of in-service equipment in order
to predict when maintenance should be
performed”
 This is often determined by monitoring the
equipment performance and condition.
 For example, vibrations, sounds or surface
roughness of the product can be monitored.
Predictive (Condition-based)
Maintenance

 Unusual sounds coming out of a rotating

equipment predicts a trouble
 An excessively hot electric cable predicts a
trouble
 Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble
 Therefore, PdM should only be performed by
trained personnel using proper equipment!
Predictive Maintenance
(Contd.)

 Primary goal – Minimize disruption of

normal system operations, while allowing
for budgeted, scheduled repairs.
 Examples of Predictive Maintenance
 Vibration Analysis
 Infrared Thermography
 Oil Analysis
 Visual Inspections
Oil Analysis
 Long term program that may take years before
its benefits are seen
 1) Oil analysis determines:
 Condition of oil
 Quality of the lubricant
 Suitability for continued use
 2) Wear particle analysis determines:
 Mechanical condition of machine components
 Identifies particle size, type, etc.
Oil Analysis Report

Oil Analysis results may:

Detail the types of metal fragments in the
sample
Show a continued increase in particle size
Recommend increasing sampling intervals
Recommend shutting down machine
Thermography

Used for Electrical Infrared Inspections

Detects hot spots, load imbalances and
corrosion at a safe distance
Detect failures due to excessive heat
1) Indoor equipment such as MCC’s,
disconnect switches and transformers
2) Outdoor equipment such as substations,
transformers and outdoor circuit breakers
Vibration Analysis

 Usually done on large equipment, such as

blowers, pumps, etc.
 Determines if bearings or components are
loose, moving or wearing
 Allows for scheduled repair of equipment
 Can provide trending that enables shutdown
of equipment BEFORE failure and major
damage
Equipment Inspections

 Visual inspection of equipment such as:

 Clarifiers and associated equipment
 Mechanical bar screens
 Allows for equipment to be coated, such
as bar screens
Benefits of PdM

 Provides increased operational life

 Results in decrease of downtime
 Allows for scheduled downtime
 Allows for money to be budgeted for
repairs
 Lowers need for extensive parts inventory
Proactive Maintenance
 Proactive maintenance refers to not only
preventing failures but to eliminate the possibility
of the failure,
 i.e. to work proactively means to foresee possible
failures and eliminate the possibility of them by for
example redesign.
 This is most complex maintenance approach
requiring large amount of resources since all
possible failure modes needs to be defined before a
failure can be eliminated
Proactive Maintenance

 It indicates the design of new equipment.

 Weakness of current machines are
sufficiently studied (on site information
leading to failure prevention, easier
maintenance and prevents of defects,
safety and ease of manufacturing) and
are incorporated before commissioning a
new equipment.
Autonomous maintenance

 Maintenance tasks carried out by the machine

operator rather than special maintenance
staff is referred to as autonomous
maintenance.
 The task can be both reactive and preventive
in its nature.
 The aim of autonomous maintenance is to
avoid small production stops and to ensure
equipment availability.
Heavy Equipment
Maintenance and Repair

Maintain and Repair Engine

• Change oil and filters
• Maintain fuel system
• Apply knowledge of 4-stroke engines
• Maintain cooling system
• Maintain intake and exhaust systems
Heavy Equipment
Maintenance and Repair

 Maintain and Repair Power Train

• Service and repair final drives
• Service power shift transmissions
• Service and inspect drive lines
• Service and maintain mechanical
transmissions
Heavy Equipment
Maintenance and Repair

 Maintain and Repair Electrical System

• Maintain/repair electronic controls
• Service and test starting system
• Service and test charging system
• Service and test battery
• Maintain basic electrical system (lighting
accessories)
Heavy Equipment
Maintenance and Repair

 Maintain and Repair Brake System

• Inspect air brake systems
• Apply knowledge of wet brake systems
• Apply knowledge of hydraulic brake systems
• Identify brake components
Heavy Equipment
Maintenance and Repair

 Welding
• Identify various types and components of
metals
• Apply knowledge of shielded metal arc
welding
• Demonstrate safe use of welding and
fabrication tools
Heavy Equipment
Maintenance and Repair

 Preventive Maintenance
• Inspect and maintain tire performance
• Monitor gauges and warning lights
• Inspect hydraulic system
• Adhere to maintenance schedules and
manage record keeping
• Measure and maintain oil and fluid levels
• Perform oil sampling
Heavy Equipment
Maintenance and Repair

 Maintain and Repair Hydraulic System

• Identify basic hydraulic system components
• Describe operation of various hydraulic pumps
• Service and troubleshoot hydraulic system,
valves, and pressure controls
• Apply knowledge of hydraulic schematic symbols
• Apply knowledge of hydraulic circuits
• Service and rebuild hydraulic cylinders
Heavy Equipment
Maintenance and Repair

 General Shop Practices

• Identify personal protective equipment (PPEs)
Select proper fasteners
• Select and use sealants properly
• Perform drilling and tapping operations
• Describe proper use of hand tools
• Demonstrate safe use of jacks and lifting
equipment
Heavy Equipment
Maintenance and Repair

 Air Conditioning
• Identify air conditioning components
• Maintain air conditioning system
• Recover and recharge air conditioning systems
• Troubleshoot air conditioning malfunctions
Heavy Equipment Undercarriage
• Inspect undercarriage and components
Heavy Equipment
Maintenance and Repair

 Air Conditioning
• Demonstrate appropriate use of ground
engaging equipment
• Perform track tension adjustments
• Demonstrate appropriate blocking/cribbing
techniques
Summary

Types of Maintenance
Corrective - Repairs
Preventive (PM) – greasing, oil, filters
Predictive (PdM) – Inspections
Proper maintenance programs have huge returns
Keeps equipment running longer
Allows for scheduled, budgeted repairs
Reduces unscheduled down time
Makes life less stressful