INDUSTRIAL TROUBLESHOOTING Chapter 10 PLANNED MAINTENANCE INMT 2345 - 01 Vern Wilson

Last week we studied: Breakdown Maintenance Breakdown Maintenance means time for teamwork Primary failures are followed by Secondary failures Only call in with solutions – not problems Temporary fix – plan permanent fix Get organized – fix it together as a team Study your situation -Do trial runs and assess Take call, assemble team, assess, review records, cause, plan repair, review Workorders, emergency training, use your downtime

Chapter 10 - Preview PM Benefits Unscheduled maintenance Bearings Drive Belts Chain Drives Piping Systems Records Inspection Reports Lube

PM PM = PREVENTIVE or PLANNED MAINTENANCE REASON - COST In downtime Program known work Forecast problems Manufacturers recommendations Utilize your downtime Standardization Yearly turnarounds REASON - COST In downtime In emergencies that could have been prevented In compound failures In labor In parts In weather In reporting - workorders

Count the lines?

BENEFITS Lowers cost Improves communications Improves transportation Operations Production Allows team to discover better ways Improves communications Improves transportation Improves parts supply Improves tool availability Reduces numbers of workers

UNSCHEDULED MAINTENANCE Preparing for turnaround – keep it going Temporary repairs are good things Do what is needed to get going again

PARTS Verify catalogue number Check standards for that specific part Plan your common stock Check for alignment Check for side play Observe normal operations Clean and replace Solvent can destroy seals Bearings and belts common parts

BEARINGS SLEEVE BEARINGS – Usually lined with babbitt or with bronze (high speed) Don’t lubricate bronze bearings (unless speced) ANTIFRICTION BEARINGS – Balls or rollers Effected by corrosion or poor lube Shut down and lock out power when greasing

DRIVE BELTS Require care – fail for neglect Replace them all Need ventilation Need guards Safety Weather Dirt Chemicals Replace them all

Belt Guard?

CHAIN DRIVES Long life with little maintenance Dirt is main culprit Wears out pins and bushings Stretches as wears Lubricate generously Sag is good ¼” for every 12” between sprocket centers Measure with straight edge

Imagine the Belts and Chains

PIPING SYSTEMS Very little maintenance Valves and fittings normal failure spots Valve stem packing leaks Threaded Flanged Clamped Types of pipe Types of fittings

RECORDS Maintenance records = good management Takes time and effort Pays off PM won’t work without records Every machine has – Model, Description, Name, Weight, Purpose, Capacity, Cost, Serial Number, Drive Specifications All have manufacturers recommendations for PM

INSPECTION RECORDS Document your own inspection routine Require swing operators to maintain records Plant Drawings – current P&ID’s kept in engineers office Equipment lists – parts requirements Logs of operations and problems Emergency training

LUBRICATION Program lube – must match equipment Worn parts cost money Safety Equipment wear Minimizes downtime Safer operation Lower maintenance cost Improves quality of product Improves life of machinery

PM – PZ-8 - GD

PZ - 8

PZ-8

Mud System

CONSTRUCT A PM PROGRAM Only consider the pump and driver List at least thirty points Estimate time to do each of the jobs Start the job September 1, 2010 Show how long to complete the job

Quadraplex

MUD PUMP LINER SIZE (GPM PRODUCTION) Max engine rpm:  2100 rpm.  This will need to be reduced to 1800 rpm in 3rd gear Transmission gear ratio’s:  1st gear (4:1), 2nd gear (2.584:1) – 3rd gear (2.013:1) Pump Performance 360 UNITIZED PACKAGE PERFORMANCE DATA ENGINE RPM   TRANS GEAR MUD PUMP LINER SIZE (GPM PRODUCTION) 3 3-1/2 4 4-1/2 5 5-1/2 6 1800 FIRST 62 84 109 138 171 207 247 2100 72 98 127 161 199 242 288 SECOND 92 125 163 206 254 309 367 107 146 190 240 297 360 429 THIRD 122 166 217 275 339 411 490

What good is studying? Mr. Wilson, today was my second day in the field interning with a chesapeake well tender in west verginia. i am learning more than i thought possible, and applying what i have already learned. i realize what a great opportunity this is, and i will continue to give it my all. the classes that you and the other teachers in the program have really made it possible for me to get my foot in the door, for which i am thankfull. before i left we talked briefley about continuing your wednesday class on line. what can i do to continue with your class? thank you, russell storch March 25, 2010