PREVENTIVE MAINTENANCE
JF 510 - INDUSTRIAL
MAINTANENCE
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 systems
Coach the review of lubrication practices
Train operators and craftspeople in
inspection techniques
Plan an effective Preventive Maintenance
Whether 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 safely
Preventive 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 spaces
An 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 failure
Generally 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 failure
Gearboxes 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
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.
conditions as possible that cause
premature gear
wear
Moderate 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
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 higherviscosity lubricant
will develop a thicker oil film,which will
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) misalignment
3) 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, squealing
Excessive vibration or wobble
Failed 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 maintained
a. Equipment information
b. Inspection checklist
c. Repair information
d. Preventive maintenance schedule
e. Parts inventory
Equipment information
Information about existing equipment or
used.
Information necessary equipment should
be records:
Name of equipment
Types of equipment
Registration date
Series number
Inspection Checklist
A form for maintenance personnel to check
the condition of a building or mechanical
device.
Information that should be included:
Machines or devices name
Frequency
Types of inspection
Date
Reference
Repair information
Information about the faulty equipment and
the action taken.
The details should be record:
Type of damage
Date of damage
Solution
Preventive Maintenance
schedule
Schedule 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 Inventory
An inventory of replacement parts.
Details about the parts
Name
Type
Size
Quantity
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 clean
Dirt 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 dry
Electrical 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 tight
Motion 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-free
Over-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
checklist
In 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 maintenance
Licensed 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.
