Equipment Reliability

Equipment Reliability

Learning

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DOCUMENT NO. REVISION EFFECTIVE DATE PRINT DATE PAGE

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Learner Name


Intended Audience

Maintenance personnel in the Factory / Plant

Unit Coordinator: (Superintendent)

Unit Members: (Supervisor),

(HSE),

Thanks to the following people for their help with the development of this Learning Unit:


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UNIT OVERVIEW

Aim:

To provide artisans with the skills and knowledge to maintain, troubleshoot and set-up of the Equipment, using the required

materials, process and equipment in accordance with safety, quality and performance requirements.

Objectives:

On completion of this unit you will

follow Health, Safety & Environmental regulations related to maintenance requirements

identify different parts of the Plant / Equipment and understand their functions

explain basic hydraulic symbols

maintain the equipment to world class standards

understand, discuss and apply advanced world class maintenance principals

identify the appropriate maintenance documentation

perform fault finding

practically apply management concepts in your maintenance environment

Structure:

1 Overview ..................................................................................................................................................... 4

1.2 Environment ...................................................................................................................................... 4 1.3 Health ................................................................................................................................................ 5 1.4 Safety ................................................................................................................................................ 6

2 Hydraulics ................................................................................................................................................... 8

2.1 Basics ................................................................................................................................................ 8 2.2 Pumps & Motors ............................................................................................................................. 10 2.3 Valves.............................................................................................................................................. 11 2.4 Cylinders ......................................................................................................................................... 13 2.5 Accumulators .................................................................................................................................. 14 2.6 Powerpacks ..................................................................................................................................... 15

3 Electrical Motors ...................................................................................................................................... 16

3.2 Cooling Fans ................................................................................................................................... 16 3.3 Bearings .......................................................................................................................................... 17

4 Electrical Switches .................................................................................................................................... 18

4.2 Proximity Switches ......................................................................................................................... 18 4.3 Limit Switches ................................................................................................................................ 19

5 Screws & Conveyors ................................................................................................................................ 19

5.2 Gearboxes ........................................................................................................................................ 21 5.3 Scrapers ........................................................................................................................................... 23

6 Waste Gas System .................................................................................................................................... 24

6.2 AC Invertors .................................................................................................................................... 28 6.3 Fans & Valves ................................................................................................................................. 28 6.4 Dosing System ................................................................................................................................ 30 6.5 Pumps and Pipes ............................................................................................................................. 32 6.6 ESP Electrodes & Insulator ............................................................................................................. 33

7 Controls & Instrumentation .................................................................................................................... 34

OTHER THINGS I HAVE LEARNED ........................................................................................................... 35

RESOURCE GUIDE ......................................................................................................................................... 36

ASSESSMENT PLAN ....................................................................................................................................... 38


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Prerequisites: Departmental Fundamentals LM, Departmental Operations LM,

Associated Units: Hydraulics LM, Instrumentation Optimization LM, Modicon PLC LM, Team Excellence LM, Asset

Management LM, Legislative LM.


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C = Critical = No Verification required


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LEARNING OUTCOME AND VERIFICATION FORM

Each Learning Outcome must be Verified by a competent person to record that the individual has successfully demonstrated

the skills and knowledge identified. For resources available to assist in achieving these Learning Outcomes, see the Unit

Resource Guide. Critical Learning Outcomes that involve practical demonstrations must not be attempted except in the

presence of a competent person until the learner has been successfully Verified.

Ref

Learning Outcomes

C Ver’d & Date

Notes

1 Overview

1.1 Environment Check

Carbon Fund.

1.101 As part of your 4-step safety card, you need to think about what else can go wrong

when you do something.

Talk to at least one colleague about the consequences if you place rubbish or

hazardous or chemical waste in storm water drains.

C

1.102 At Our Company we separate our waste. Discuss with your colleague the waste

handling techniques and fill in, the blank spaces provided, the waste to be disposed in

which bins.

Black bins: ________________________________

Brown bins: _______________________________

Yellow bins: _______________________________

Blue Municipal bins: ________________________

Orange bins: ______________________________

Blue bins: ________________________________

C ISO

14001:2000

1.103 “The distinction between contamination and pollution may be worth noting, though

they are often used interchangeably.

Contamination is the presence of elevated concentrations of a substance in the air,

water, soil etc. not necessarily resulting in a deleterious effect.

Pollution is the, direct or indirect, human introduction of substances into the

environment such as to harm living resources, affect human health and impair

environmantal quality. (from GESAMP, 1982). “

Apply these concepts in your work environment and list at least one material that

could potentially pollute and one material that can contaminate our natural resources.

C


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Notes

1.104 Protecting the water table in this area is important, as it is only approximately 1 meter

deep at some places.

Discuss why maintaining equipment handling oil, chemicals or pitch is important to

protect the water table.

C ISO 14001

1.105 Discuss the measures you will take to protect your health, safety and

environment when you need to work with hazardous waste or working

in areas where hazardous waste is stored:

spent pot linings

re-claim areas

oil or petroleum contaminated waste

fluorinated waste

C ISO 14001

1.106 Talk to a colleague about the most likely things that can go wrong when you perform

maintenance tasks. You may want to use some of the following guide lines:

introduction of contaminants to the environment or your anodes

over lubrication

cleaning solvents and chemicals

C

1.2 Health

1.201 Name at least three symptoms of dehydration, also known as heat fatigue:

C

1.202 One method to detect and monitor heat fatigue is to diagnose your urine.

Discuss the following stages of heat fatigue and what you will do to combat it.

urine colour: amber

urine colour: dark lemon

urine colour: light lemon

C


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Notes

1.3 Safety

1.301 Explain the function of your PPE:

safety hat

gloves

steel toe safety boots

Vinex 2 piece overalls; long sleeves

2 types of respirators; When & Where to use, What & How to maintain the canister

& filter

ear protection

safety glasses

C OHSA Part 4

1.302 Suppose one of your close family members work at Our Company. Explain to your

verifier the risk of injury or death of your family member having loose hanging hair,

jewellery or clothing and working with or close to moving or rotating machinery.

C

1.303 Demonstrate to your verifier what you will do when you hear the Evacuation Siren.

Mimic the siren or alarm. C

1.304 According to the OHSA Section 14 it is your duty as employee to report any unsafe,

hazardous, un-reasonable or safety incident. If you do not report incidents, your

company will not know about it and can therefore not take any action. According to

this act section 38, you will be held liable if you do not report incidents to your

employer or health and safety officer, possibly facing one or all of the following:

termination of your contract

a fine of R 50 000

imprisonment for period of 12 months

You might want to talk about the value of “Lessons Learned” from past experiences.

C OHSA Part 1

Sec. 14 & 38

1.4 Fire Fighting Equipment

1.401 Point out at least two things that are not

quite right in the photo, i.e. things that

will make the fire hose not functional for

fire fighting,.

C OHSA Part 1

Section 15


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Notes

1.402 It is against the law to use fire hydrants or

hoses for anything but fire fighting. You

could face a fine and/or imprisonment for

abusing fire fighting equipment. Give one

good reason for not abusing fire hydrant

like:

washing your car

cleaning plant or equipment

watering the garden

“horse play”, fooling around

Suppose a fire breaks out and the fire

brigade needs to use the hydrants and can

not because of the above. Talk about the

consequences.

C OHSA Part 1

Section 15

1.403 Safety and good housekeeping is everybody’s responsibility. Our Company uses the

term ”a place for everything – everything has a place” Explain how this is applicable

to:

unused fire extinguishers

used fire extinguishers

C

1.404 Point out to your supervisor at least three fire extinguishers in your work

environment.

On identifying their location, discuss the:

type,

usage and

condition

C

1.405 Point out the following and talk about aspects related to inspection of gas pipes and

connections:

the PMs & report/feedback process

inspection points

inspection materials

leakage test techniques

Demonstrate what you would do when you detect a leaking gas pipe or fitting.

Discuss the hazards and consequences in case of an explosion due to gas leakage.

C

1.5 Hoisting Equipment

1.501 Find out why you need to stay clear of the Plant / Equipment Intake Crane Area, only

entering when you have been officially authorised. C

1.502 Slings and chains need to be adjusted while moving the fire so that the equipment is

level when transported. Talk to an operator and confirm the importance of the

equipment being level when moved.


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Notes

1.503 With an operator, talk about the risks

involved by leaving hoisting equipment

unattended.

Suppose an incident occurred due to the

above. List at least 2 consequences:

Dicuss the additional maintenance cost

occurred while leaving the equipment

unnecessarily under load.

2 Hydraulics

2.1 Basics

2.101 According to ANSI B93.2.1971, contaminants are considered to be “…any material,

or substance which is unwanted or adversely affects the fluid power system or

components, or both.” Contaminants can be grouped as:

build in: from paint chips and overspray, rust, dust, Teflon tape & other sealing

compounds, metal chips from pipe & fitting threads, sand, lint & welding slag.

environmental: from dusty & moist air conditions & condensation

operational: high oil velocities causing erosion & sliding friction on surfaces

causes wear

oxidation: formation of solid carbon build-up

Talk about at least one preventive measures per group you can take to keep the

hydraulic system clean.

ANSI

B93.2.1971

2.102 Contaminants cause failure modes and can be grouped according to:

Catastrophic failure: immediate failure of a system component mainly caused by

large particles in the hydraulic fluid.

Degradation failure: a slow degrading process occurs daily but is not easily noticed

with time. Minute particles cause accelerated wear of close tolerance and sealing

surfaces, e.g. loss of flow & pressure, sluggish operation, sticky and irregular

movement.

Consider the two failure modes and find two applications in your work environment.


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Notes

2.103 World class aluminium producers perform fault finding effectively, with the aid of the

following:

hydraulic circuit diagram

electrical circuit diagram

operation sequence diagram

plant layout with valve-, cylinder- & sensor-locations

numbering and labelling of inputs, outputs, valves, cylinders & sensors

Discuss how the above documents could be used to your advantage in your own work

environment.

ISO 9001:2000, section 4.2 a quality management (QM) system is about document

control. Discuss with your group how the above documents are controlled and what

advantages good control can offer referring to:

document release

document evaluation

document revision

document availability

document identification

document handling

ISO

9000:2000

section 4.2

2.104 According to EN 13306:2001; Inspection can be carried out before, during and after

maintenance. Inspection is to “Check for conformity by measuring, observing, testing

or gauging the relevant characteristics of an item.”

Discuss your inspection technique and interval when:

checking hydraulic hoses and fittings.

checking for loose bolts or nuts on the structure.

Explain how you might use each of your senses during inspection:

sight – (remember to wear your safety glasses)

hearing – (remember to wear your ear protection)

touch – (do not touch hot or hazardous materials)

smell – (do not smell hazardous materials)

taste – (do not taste hot or hazardous materials)

C EN 13 306

2.105 Hydraulic fluid seepage can easily contaminate a natural resource to such an extent

that it becomes polluted. One method to prevent pollution during an oil spill or leak

is to have drip trays fitted beneath hydraulic machinery and powerpacks. Drip trays

also known as “a double container” should be able to contain 1,5 times the oil volume

in the machine or reservoir.

Discuss the value of this preventive containment system and how you can help

protecting your environment by implementing this system.

C

2.106 Discuss your Isolation Procedure for the hydraulic system.

Be prepared to demonstrate your isolation, lock out, tag, de-energise and checking

procedures. Remember the Accumulators.

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Notes

2.107 One case study, see above, show the frequency of occurrence of 8 various failure/fault

types (left hand graph) and a Plan of Action with 5 main measures to improve a

hydraulic system reliability (right hand graph). The most frequent fault is due to

“Faulty Pressure”. The most frequent preventive measure is “Part Rebuild &

Exchange”.

As a team, consider your hydraulic system. Set-up, from your experience and by

group discussion, your own Pareto chart with your selected failure or fault types like:

leaking cylinder neck seal

leaking connection

valve not switching

limit made, but not responding

….also, us you SAP system to find other frequent hydraulic system fault types

Set-up another Pareto chart showing your plan of action to control the failure or fault

types.

You might want to apply the 20/80 rule and consider the following:

frequency of the fault/failure occurrence,

severity of the fault/failure and

the probability of detecting the fault/failure

2.2 Pumps & Motors

1)_d_ 2)___ 3)___ 4)___ 5)___ 6)___


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Notes

2.201 The above ISO 1219 symbols represent pumps and motors. Match the above symbols

with their descriptions below:

a) pump – variably capacity, two directional flow

b) pump/motor – variable capacity, two directional flow

c) motor – fixed capacity, one directional flow

d) pump – fixed capacity, one directional flow

e) motor – variable capacity, two directional flow

f) pump/motor – fixed capacity, one directional flow

ISO 1219

2.202 For a pump to function the direction of rotation must be correct.

Talk about why the pump rotation can be incorrect and the damage it could cause if

not quickly detected.

2.203 Hydraulic motors can be:

gear type; low torque & high revolution

vane type; low torque & high revolution

axial piston type; medium torque & medium revolution

radial piston type; high torque & low revolution

Discuss at least two reasons why motors or pumps might cavitate and present

solutions or preventive actions. Talk about the type of damage cavitation may cause.

2.204 Your powerpack is fitted with three electrical motors connected to hydraulic pumps.

One motor is planned for redundancy or backup, but is actually operational due to the

large ram cylinder not travelling fast enough.

Discuss how you can use accumulators to solve the same problem.

Team work

2.3 Valves ISO 1219


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2.301 Valve symbols can be:

single block – pressure control types

double block – flow control type

triple block – flow control type

Discuss the following:

number or ports; 4, 2, 3

port naming; P, A, B & T

actuation types; lever, pilot, manual push button, servo, solenoid, roller, plunger

spring return vs. indentation

valve positions in normal and energized states

flow direction

Explain the valve naming convention:

3/2-way, normally open, hand actuated, spring return

4/3-way, directional control valve, hand operated, notched/indented

2.302 The following valves are also used in your Plant / Equipment:

a) Directional Control Valve (DCV), 4/3 way, spring central return, solenoid

activated.

b) DCV, 4/2 way, spring return, solenoid activated

c) shut-off valves, normally open (n/o)

d) flow control valves, variable with nrv (throttle one way)

e) non return valves (nrv), spring loaded,

f) non return valves (nrv), piloted to open

Match the above description with the ISO 1219 hydraulic symbols. Discuss their

functions:

number or ports; 4, 2, 3

port naming; P, A, B & T

actuation types; lever, pilot, manual push button, servo, solenoid, roller, plunger

spring return vs. indentation

valve positions in normal and energized states

flow direction


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Notes

2.4 Cylinders ISO 1219

2.401 Double acting type cylinders are mainly in use at the Plant / Equipment.

From the ISO 1219 symbols above select the double acting cylinder type and discuss

at least another two cylinder types.

2.402 One of the 5 TPM pillars are; Housekeeping and Cleanliness. Point out and discuss

the practical application of the BAOS 5s system, focus on “Shine”.

Discuss at least 2 methods to keep the cylinders clean, preventing dirt entering your

hydraulic system.

2.403 Cylinder neck seals must be well maintained, else leakage will occur. Discuss the

following and the effects it have on the seal life:

clean and smooth (no grooves or scratches) cylinder rod

radial forces and misalignment of cylinder rods ends, especially when extended

outward.

Talk about preventive methods to maximize the neck seal lifespan.

2.404 Suppose your piston seal is not sealing

properly due to wear.

Refer to the image to discuss how you can

check or confirm if the seal is not

functioning, using a manometer.

Bear in mind that:

the inward flow must be fully throttled

to avoid shock and sudden piston

movement

the initial test pressure should be very

low, full pressure should not be used.

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2.405 Hydraulic cylinders must be secured properly. The photo shows:

2 loose bolts & nuts

2 out to 4 bolts & nuts were missing (one shown in ellipse)

Make a list of the consequences for not replacing ALL screws, bolts and nuts when

maintaining equipment in general.

2.5 Accumulators ISO 1219

2.501 Discuss the risks involved working with

accumulators.

Explain your safety measures to prevent

any injury when working with

accumulators.

ISO 1219 Symbol: Diaphragm Type

Accumulator – Gas Charged

C

2.502 Accumulators can be grouped:

Group II: p > 1 bar & p1 ≤ 200 bar (loaded)

Group III: p > 1 bar & 200 bar < p1 ≤ 1000 bar

Group IV: p > 1 bar & p1 > 1000 bar

Group IV accumulators need to be internally inspected every 5 years and pressure

tested every 10 years.

Determine in which group your accumulators will fall and discuss their maintenance

procedures.

10 missing screws

Loose bolt & nut

Missing bolt & nut


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Notes

2.503 Discuss your accumulators, operation &

the following:

shut-off valve, normally closed (n/c)

manometer

piston type

operating pressure

gas charged pressure & gas type

charging procedure

2.6 Powerpacks

The ISO 1219 symbol for a powerpack

shows the following items:

a pressure reducing valve (PRV)

a reservoir

a hydraulic pump

an electrical motor

Point out the items on the sketch and

discuss their functions in detail.

2.601 Your Powerpack consists of the following items:

electrical motors x3

hydraulic pumps x3

reservoir

manometer

level control

thermometer

filtration system

piping, valves and fittings

Point them out and discuss the function of every item.

2.602 Studies have shown that over 60% of all

hydraulic system’s down time can be

attributed to untidy maintenance and lack

of the proper filtration. A good filtration

system work at 98% efficiency, i.e.

allowing 2 particles per 100 to pass

through the filter.

Discuss the function of the “Kidney Pack”.

Talk about the purpose of the pressure

differential gauge. Be prepared to

demonstrate a filter change, if clogged.

ISO 1219 Filter Symbol

by The Hycon

Corp.


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2.603 The above table is used in a SAE standard to classify the levels of hydraulic system

cleanliness. From your oil analysis, determine your cleanliness class by matching the

results with the table above.

Talk about methods to improve (if needed) or maintain your hydraulic system

cleanliness.

SAE, see

ISO 4406,

NAF? as

alternative

methods

2.604 Find and discuss a resent oil analysis, mentioning the following:

type of wear metals

particle count/ml & size

viscosity

Talk about the advantage and use of having good historical data to aid your predictive

maintenance strategy.

3 Electrical Motors

3.101 It is good practice to protect electrical motor from overload. Discuss the electrical

protection methods to prevent electrical motors from burn-out:

drive control settings

current overload limitation

3.102 Discuss operational and maintenance methods to prevent damage to bearings and

other electrical connections due to heat exposure. Explain the effects of electrical

motors being exposed to high temperatures for periods.

3.2 Cooling Fans

3.201 Discuss at least two purposes of fan motor housings (cowling).


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3.202 Electrical motors are normally cooled down when running by the fan and cooling fins.

Studies showed a drop in operating temperature when the electrical motor, cooling

fins, cowling and cooling fan were kept clean. The small drop in operating

temperature extended the motor life span dramatically.

With your verifier and a Plant / Equipment Operator/Cleaner, talk about autonomous

maintenance by using “inspection & cleaning of electrical motors” as an example.

3.3 Bearings

3.301 The graph shows the typical trend for a

lubricant viscosity-temperature ratio.

Another function of a lubricant is to

maintain a thin separating film between

two wearing surfaces.

Talk about the importance of selecting and

using the correct lubricant, suitable for the

relevant operating conditions:

normal lubricant = 0 to 70C

synthetic lubricants = -20 to +350C

Remember that some synthetic lubricants

can cost 30-50 times more than mineral

lubricants, but it might prevent a

breakdown costing 10 000 times more.

Point out your high temperature working

areas and talk about methods to effectively

lubricate machinery.

You may want to use the Exhaust

Manifold or Cooler Bridge electrical

motor ball bearings as examples.

3.302 The following scenarios could cause a dry or cold start:

If a bearing has been exposed to high temperature while standing, the lubrication is

most likely to settle at the lowest point.

Bearing exposed to high temperature and caused the lubricant to fail.

Bearing exposed to high temperature causing seals to leak, loss of lubricant.

Discuss in a group preventive measures to avoid the above scenarios.

3.303 Grease basically consists of the following:

oil basis – mainly mineral oil

thickener – mainly soup or mineral based

additives – viscosity, corrosion, temperature enhancing materials

The oil is absorbed by the thickener and is dispersed again to lubricate when the

grease is pressurised or placed under load. One disadvantage of grease is that dust

and dirt particles will collect and stick to the grease, causing more problems.

Talk about the importance of firstly cleaning greased areas removing old grease with

impurities prior to re-greasing.

Discuss the reasons for enclosing greased areas, i.e. the exhaust manifold screws, you

may want to recommend enclosing improvements.


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3.304 Bearing fitment plays a cardinal role in the bearing’s future life. A bearing

improperly fitted or damaged during fitting will most probably not have a normal life

expectancy.

Talk about at least four aspects to consider when replacing a bearing.

3.305 Conveyors wheels use (SKF 607?) ball bearings. With other team members, using

your RCA process, discuss methods to reduce frequent bearings replacements. not “forever

young”

3.306 Clevis bearings on hydraulic cylinders often wear. Explain how you will determine if

the bearings are still good for use.

4 Electrical Switches

4.101 Due to vibration electrical switches and brackets need to be checked & tightened if

needed.

Point out the following electrical switch inspection points on site:

intake system

exit system

exhaust manifold

Talk about the “PM”:

inspection interval

preventive or corrective action to be taken, if any

4.102 Talk about the different types of electrical switches and their application:

proximity switches

pressure switches

limit switches

photo optical sensors

Consider the electrical switches in your plant. Talk about the possibilities using

different switches to improve the operational reliability without increasing the plant

maintainability. You could also mention spare part standardisation or rationalisation

methods.

4.2 Proximity Switches

4.201 Proximity switches need to be kept clean, especially the photo optical type.

Discuss the inspection “PM”:

inspection interval

preventive or corrective action to be taken, if any


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4.3 Limit Switches

4.301 Limit switches are mainly fitted with antennas, but still can be bumped and damaged

during operation.

Suppose your verifier is a new maintenance electrician and that there is a breakdown

in the plant. Explain to him, as you would explain to a new artisan, how you would

trace a fault, e.g. a damaged limit switch.

Cost Accumulation

R 750 R 1,500

R 50,000

R 0

R 10,000

R 20,000

R 30,000

R 40,000

R 50,000

R 60,000

1 2 3

Cost

4.302 With your verifier & a Plant / Equipment Operator discuss the following. Suppose

they are new Plant / Equipment operators and they accidentally knocked over or

damaged an electrical switch during operation.

Explain by referring to the graph above, as you would explain to new Plant /

Equipment Operators, the consequences of the incident. Calculate the following three

variable costs:

1. cost for replacing the damaged part – assume a cost of R 750

2. cost of maintenance downtime – assume a rate of R 500/hour down for 3 hours

3. cost due to loss of production – assume a rate of R 10 000/hour down for 5 hours

Remember to talk about how these costs will affect the operator’s BAOS system &

performance. Consider the “ripple effect” of an incident, i.e. how a small incident can

have a dramatic effect on other people and departments.

C 4 Safety Steps

5 Screws & Conveyors

5.101 Discuss the function of the wear guides, e.g. how you can determine the state of wear.

Talk about other complications the wear guides may cause when not properly

fastened.

5.102 Talk about the consequences of getting foreign metal parts in the conveyor screw.

How can a maintenance artisan or production operator prevent foreign material

entering the screw? Talk to an operator about the reporting procedure and action to

take when a foreign object was accidentally dropped into the conveyor screw.

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5.103 Discuss the process, step by step, to

remove and replace the screw. Point out

the Standard Operation Procedure.

5.104 “My sister lost her right hand, more than 4 years ago, when her hand was caught in a

screw conveyor. The doctors could not sew her hand back on again as the ligaments,

fingers and muscles were ripped and crushed beyond recognition. We had to support

her during her rehabilitation period. Only then, I noticed how much she had to learn

again by doing everything with her left hand. It was very difficult for her and she

often broke down in tears because of pain and frustration, feeling very helpless. At

one point the doctors considered removing some of her toes and fit it to her hand so

that she can use her hand again. She could not even do simple things like slicing

bread, opening a bottle or peeling an orange, any more. This accident also caused a

lot of trauma to the rest of our family for several years after the accident.”

The screw conveyor is considered, rotating & moving machinery. Demonstrate the

Lock Out Tag Out process and talk about how you will prevent getting your hand

caught in any other moving or rotating machinery.

Tell your verifier; how you would feel if one of your family members gets badly hurt

while working unsafely and ignoring safety procedures?

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5.2 Gearboxes

5.201 The table shows potential problems that

one can experience with gearboxes.

This is a great method of using and

combining different matrix tables.

The warning signs and wear mechanisms

will give an indication to the cause and

effect leading to a failure.

Discuss the application of this table in

your work environment.

Use this method to develop your own

maintenance troubleshooting matrix in an

area of your preference.


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Various maintenance strategies exist for various reasons. Gearboxes can be

maintained at regular time intervals, based on history of environmental conditions.

This strategy is known as “Time Based Maintenance”(TBM). TBM is scheduled &

performed at predetermined time intervals and falls under Preventive Maintenance.

Another method is known as “Condition

Based Maintenance” (CBM). CBM is

where the condition of technical

equipment is monitored, and maintained

according to the data collected. CBM falls

under Predictive Maintenance. Parameters

monitored can be:

temperature

performance

efficiency

lubrication

wear

vibration

pressure

5.202 Discuss at least one advantage of both

CBM & TBM:

CBM-

TBM-

Select one of the maintenance strategies

and talk about how you apply it to

maintain a gearbox or an electrical motor

in your work area.

Talk about one disadvantage

of both CBM & TBM:

CBM-

TBM-

5.203 We lost a gearbox. Discuss how CBM,

i.e. Vibration Analysis or Bearing

Temperature Monitoring might have

helped to early detect the failing gearbox.

Suppose a bearing failed. Talk about the

“ripple effect” i.e. due to a bearing failure

caused damage to the shafts, pinion (drive

gear), driven gear, gearbox housing, shaft

coupling and possibly the electrical motor.

Present at least two ideas on how this can

be prevented in future.

Damage


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5.204 According to DIN 50 320, the following

wear mechanisms can be present in

gearboxes:

Adhesive type wear

c,

Abrasive type wear

d,

Surface damage wear

f,

Tribological-chemical wear

l,

Match the following indicators

with the wear mechanisms:

a) holes

b) wave patterns

c) material deposit

d) pitting

e) scratches

f) grooves

g) cracks

h) dimples

i) corrosion

j) material seizure

k) ridge formation

l) material washed out

DIN 50 320

5.3 Scrapers

5.301 Discuss with a Plant / Equipment Operator and your verifier the allowable/acceptable

wear or wear limit of scrapers. Explain how you will determine if the function of the

scrapers is still acceptable.

Double Lock Nut

Wear


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5.302 Vibration in the exit system could cause bolts and nuts to rattle loose.

Ways to combat this are:

eliminate vibration

make use of “Nylock” nuts

make use of double locking nuts

make use of “Loctite”

Talk about the purpose of following regular continuous inspection PM.

Brainstorm with your colleagues to determine other vibration elimination methods.

Go onsite while the plant is running and determine which equipment induces shock

and vibration into the system.

Set-up a Pareto chart to help you prioritize the severity and frequency of the vibration,

e.g:

anode tilting table – 2x 260 times per day

ram cylinder – 260 times per day

6 Waste Gas System


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6.101 Refer to the image above and explain how air pollution takes place.

Discuss the importance of maintaining your Waste Gas System.

Make a list of the consequences if your Waste Gas System do not function properly,

refer to our natural resources:

soil/ground

water

air

animal wild life

Talk about what will happen to you and your family over a period of time when

exposed to polluted air.

6.102 The Cooling Tunnel and the ESP is placed outside, main equipment. Discuss the

Waste Gas Cleaning process. Refer to:

the inward and outward flow of materials

function of the tunnel

function of the ESP

6.103 Talk about the risk related to environmental, health and safety aspects if:

the tunnel is not functioning properly due to incorrect maintenance

the ESP is not functioning properly due to incorrect maintenance

C


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6.104 Inside the Plant is the Exhaust Manifold. Suppose that the seals require more frequent

replacement than before. Talk about possible causes and preventing solutions.

Discuss the effect of the different seal compression.

Seal Compression

New Seal Fitted

Uncompressed


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6.105 One way to think about troubleshooting is to use what is known as an Ishikawa

(fishbone) diagram. In this the “problem/failure/error” is shown on the right hand

side and the factors that could lead to the problem are identified on the left hand side

of the diagram. The possible causes can then be grouped per factor. Factors can be

known as the 4M´s:

Man: what could a person (operator or maintainer) have done or not done that

could lead to the problem?

Machine: what aspect of machine function could have caused the problem

Material: sometimes faulty material causes problems in the production process

Method (System): often the method of manufacturing or control could be

inconsistent, causing problems.

The following cause “Pitch flue causes clogging” and the possible effects/failures are:

valves to function improperly, i.e. opening & closing difficulty

instrumentation equipment being inaccurate

screw threads getting stuck

valve gates getting stuck & not sealing

Select a team, choose one of the above failures and discuss the possible causes.

Suggest a potential solution. As a “Team Effort” draw an Ishikawa, Failure, Cause &

Effects, diagram – Considering the 4 M´s; Man, Machine, Material and Method

(System).

6.106 With the information gathered above, use

your Risk Assessment process to prioritize

the consequences and risks.

This method could help you decide where

to focus your maintenance activities to

make a big difference.


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6.2 AC Invertors

6.201 AC invertors are used with electrical motors obtaining soft start & speed control.

Refer to the Safe Work Procedure for the set-up of new drives, used through-out your

plant! With the aid of the process picture maps discuss the set-up process.

6.202 Discuss how you can use an AC Drive to

prevent gearbox damage. Identify what

the correct current setting would be.

Talk about the cost to install an AC drive

compared with the cost to repair or replace

the gearbox & motor, as well as the cost

due to possible loss of production.

6.3 Fans & Valves

Broken Gear Teeth


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6.301 Products and equipment are often designed with Redundancy. This is normally done

to reduce the risk in case of a catastrophic failure or an unplanned breakdown. The

designed Redundancy helps to quickly change over to an alternative method. A

simple example is the spare-wheel of your car. It is redundant, stored in the car’s

boot, until you have a flat tyre, which can happen at any time. Here Redundancy is

designed and allows you change over to an alternative, the spare wheel. Think about

Redundancy as; “Plan B”.

What will happen if your redundant alternative is not functional or reliable, i.e. the

spare wheel is also flat/deflated or has a slow puncher?

With new technology Redundancy can be eliminated without increasing the risk by

using advanced Condition Based Monitoring (CBM) techniques.

Identify possible redundant equipment and discuss how CBM can be implemented.

If feasible, drive the initiative to implementation stage using your BAOS system.

6.302 To open or close some valves you might need to climb on top of plant equipment.

Discuss with your HSE co-ordinator and an operator the safety procedures to work at

heights.

C OHSA Part 4

6.303 Discuss in a group to find the best practise on how to open or close a stuck valve.

Brainstorm to find implement-able methods on how can you prevent the valves from

getting stuck, i.e. to improve the valve reliability?


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6.304 According to SAE JA 1011, the essence of reliability in maintenance is described in the

following:

A Breakdown is defined as the inability of a technical device to execute, or

perform a function, as expected by the owner or operator of that technical

device, at a required quality and performance level.

Example: A shut-off valve’s function is to open and close. The seal is suppose to be

airtight. When it can not perform it’s function at the expected performance level,

then it is not reliable and considered to be in a functional breakdown state.

When the valve closes but partially leaks it is not performing at the expected quality

or performance level and can be considered not reliable and is in a potential

breakdown state.

Talk to at least two of your colleagues about ideas on how you can improve

equipment reliability, referring to a valve’s:

breakdown

expected function

quality level

performance level

SAE JA 1011

6.305 Rotating equipment, like fans, should at least be “statically balanced”. Discuss the

consequences effects for running unbalanced equipment.

Refer to the effects it will have on:

bearings

machine casing

other equipment in close vicinity

List at least two causes for equipment being unbalanced:

6.4 Dosing System

6.401 Discuss the function and purpose of the dosing system. You might want to use the

following guidelines:

pH level – actual/current value vs. permissible dumping value (5,5-9,5)

flue soot level

fire prevention

Explain the environmental and safety consequences if the correct levels are not

maintained.

How will the system detect if the operational standards are not met?

C SABS

241:1984

6.402 Point out the three most critical dosing equipment and discuss the maintenance

requirements.


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6.403 At the dosing area identify and explain to your verifier the hazardous “Material Safety

Data Sheet”. Talk about:

the chemical and environmental hazards if spilled

the consequences if swallowed & the appropriate first aid measures

the consequences if vapour is inhaled & the appropriate first aid measures

the consequences if eye contact occur & the appropriate first aid measures

the consequences if skin contact occur & the appropriate first aid measures

the manufacturer contact details

fire fighting and handling procedures, e.g. PPE requirements

waste disposal procedures

C

6.404 Talk about the purpose of hazardous material signage. With your verifier, identify

other hazardous materials and look for:

signage and demarcation

Material Safety Data Sheet

C

6.405 It is good Environmental protection to use

a double container system when using

hazardous materials.

Explain why for the black container

should be at least 1,5 times the volume of

the blue container.

Find at least another container holding or

storing hazardous material.

C

6.406 Discuss with an operator the function of

this filter.

Suppose the operator is new at the Plant /

Equipment. Point out the filter to the

operator and explain how he will know

when it is needed to clean the filter.

The operator needs to be prepared to

demonstrate.


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6.5 Pumps and Pipes

6.501 Point out at least two pumps, Furnace and explain how you will bleed the pumps.

Mention the purpose of bleeding pumps. Be prepared to demonstrate if your verifier

requests.

6.502 Suppose this effluent pump and motor

have been making strange vibrating noises

for a while.

Make a list of at least 4 possible root

causes.

For every cause list one corrective action

and one preventive action.

6.503 Discuss your maintenance actions when you notice a pump is leaking while in

operation. Talk about when some leakage could be useful to cool the pump bearings.

6.504 Describe the different noises an effluent

pump or motor can make due to:

cavitation

a faulty pump bearing

a worn motor bearing

a blocked or restricted suction pipe

a closed or restricted delivery pipe

the motor turning in the wrong direction

Explain what you will do in each case.

6.505 What actions will you take if you notice a

water leak, as shown in the photo?


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6.506 Rubber hoses, firstly harden, then perish

and crack when they are exposed to high

temperature for extended periods of time.

Cracking can also occur then the hoses

age, called “aging”.

Places where cracks normally occur are:

where hoses are bent

close to fittings

How will you determine when the hoses

need to be replaced?

Cracked hoses might eventually burst

when pressurised.

Discuss the consequences when a hose

burst. Your verifier might request you to

demonstrate your emergency actions, be

prepared to demonstrate.

Find alternative hoses that will not crack

and compare the costs.

C

6.6 ESP Electrodes & Insulator

6.601 Discuss the function of the insulator. Demonstrate how you will inspect the condition

of an insulator.

6.602 One way to check the ESP & Cooling tunnel efficiency is to look at the gas exhausted

at the stack.

Discuss at least two disadvantages this “regressive-”, “fire fighting-” or “corrective-“

maintenance method presents:

The ESP’s “milli-Amps” is monitored by the SCADA system. Talk about at least two

advantages of how this data can be collected over time and used to predict and

schedule the optimal maintenance tasks:

You might want to talk about the risks & consequences and the importance of having

a time buffer to plan, react and execute maintenance.

6.603 Point out on the SCADA system the ESP “milli-Amps”. Discuss the current value

compared to the planned value.

From the trend line, predict the ideal maintenance date.

6.604 Electro Static Precipitator (ESP) electrodes often get damaged or broken during

routine high pressurised water jet cleaning process. Talk about preventing methods.

You may want to, as a group, investigate the root cause for the routine cleaning

process or discuss a best practise for cleaning the electrodes.


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6.605 Good maintenance practice is to conserve

our natural resources.

While cleaning the electrodes, water is

wasted at approximately 5 l/min., 8 hours

a day, 15 days every 4 months, 2 ESPs =

216 000 l/year; enough water to last a

South African family of 4 people, for 13,5

years.(15 l/d/p)

Consider the photo, talk about the best

practice to save water when cleaning the

ESP.

Find alternative cleaning means.

C

6.606 With your colleauges, select a topic and brainstorm to find ideas on how you can

improve the following from a maintenance perspective:

ESP efficiency

operational effects causing breakdown

operational effects causing poor anode quality

pitch type variation

pitch content in green anodes

7 Controls & Instrumentation awaiting a new

upgrade

7.101 In your control room, use your plc/scada system to look at the Plant & Equipment.

Discuss at lease three different screens, mentioning:

plc inputs

plc outputs

location of cylinders, electrical switches & valves, on site.

7.102 Suppose that G01 is not functioning or responding. Explain how you will identify the

fault using the plc/scada system.


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OTHER THINGS I HAVE LEARNED

Ref

Learning Outcomes

C

Ver’d

Date

Notes


Learning

Module

1. Recommended

2. Relevant

3. Supporting

Manuals

Multimedia/

Intranet

Procedures/

Regulations

Process Picture

Maps

Video/Film

Other

Specialist

Persons


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RESOURCE GUIDE

Competent people at the workplace are a key resource you may use to help you achieve the Learning Outcomes in this Unit.

This Resource Guide provides a list of additional flexible learning resources you may also use.

Reference Rating / Type Resource Location

1 Overview

Management 1 Leadership & Teamwork, Innovation,

Kaizen, 5s, Risk Assessment,

BTC

OHSA Part 1; section 14, 15, 38

OHSA Part 4;

2 Employee Duty, Misuse of Equipment,

Penalties.

Regulations relating to General Aspects

BTC

DIN 31 051 3 Definition of Wear Internet

VDI 2246 3 Reliability, Maintainability & Availability

Relationships

Internet

EN 13 306 3 Maintenance Concepts Internet

http://www.fdl.uea.ac.uk/airpol/modules/de

finition.asp

3

University of East Anglia Internet

SABS 0228 2 Identification and Classification of

dangerous substances and goods.

SABS

Department of Health 3 Malaria Roll back Plan.

Berufsgenossenschaft 3 Hazard Material Identification & Symbols §15 Abs 1 GefStoffV

Berufsgenossenschaft fuer Electrotechnik 3 Dr.Ing. J. Juhling; Cologne

InWent, Carl Duisberg Gesellschaft;

www.cgd.de

2

Change-, Innovation- Management,

Leadership Development, Team

Dynamics

Internet

Clear Air Association 2 Air Pollution & Monitoring

2 Hydraulics

ISO 1219 1 Fluid Power; Hydraulic Symbols BTC

ISO 4406 3 Hydraulic Fluid Analysis BTC

ISO 9001:2000 2 ISO Quality Management BTC

ANSI B93.2.1971 3 Hydraulic Fluid Contaminants

5 Screws & Conveyors

DIN 50 320 3 Wear Mechanisms

http://www.fdl.uea.ac.uk/airpol/modules/definition.asp

http://www.fdl.uea.ac.uk/airpol/modules/definition.asp


Learning

Module

1. Recommended

2. Relevant

3. Supporting

Manuals

Multimedia/

Intranet

Procedures/

Regulations

Process Picture

Maps

Video/Film

Other

Specialist

Persons


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Reference Rating / Type Resource Location

6 Waste Gas System

PM-PC-001 2

Replacing & Setting AC Drives/Invertors Attached to this LU

OHSA Part 4 Regulation 6 1 Work in Elevated Positions BTC

SAE JA 1011 3 Reliability Centred Maintenance

SABS 241:1984 2 Water Specifications BTC

Guide completing MSDS 2 Department of Labour, Chief Directorate

of OHS

HSEC


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ASSESSMENT PLAN

Successful completion of this Learning Module requires each step of the Assessment Plan to be successfully completed and

signed off by the Assessor(s). Assessment is carried out by competent Assessors.

Learner Name:

____________________________________

Learner ID:

___________________

Assessment Step Assessment Result Date Assessor Signature

1. Learning Outcomes (all 129) Verified? Yes

No

2. Critical Outcomes re-verified to 100%?

(attempt and pass all 46)

Yes

No

3. Random selection of 10% of remaining

(non-critical) Learning Outcomes to 80%

competency? (attempt 8, pass at least 7)

Yes

No

4. Integration/problem solving exercise? Yes

No

Please sign to confirm that assessment was performed in a fair and competent manner and that the results are accepted.

Assessor Learner Observer

Name _______________________ _______________________ _______________________

Signature ______________________ ______________________ ______________________

Date _______________________

Learner Feedback: Learning Outcomes and general feedback (additions, changes, resources used, etc.)

Check this box if Learner Feedback is provided on back of this sheet.

Equipment Reliability

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