1. INDUSTRIAL TROUBLESHOOTING Chapter 10
PLANNED MAINTENANCE
INMT
Vern Wilson

2. 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

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

5. 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

6. Count the lines?

7. 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

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

9. 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

10. 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

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

12. Belt Guard?

13. 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

14. Imagine the Belts and Chains

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

16. 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

17. 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

18. 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

19. PM – PZ-8 - GD

20. PZ - 8

21. PZ-8

22. Mud System

23. 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

24. Quadraplex

25. 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

26. 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