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ACKNOWLEDGEMENT
To carry out this project Developing a Maintenance Plan was big challenge for us since, it required technical and management knowledge in detail to build up a Maintenance plan in a hospital. Actually, we were not able to face this challenge and prepare this report successfully if we did not receive such a guidance and encouragement from the persons stated below.
At first, our sincere gratitude goes to Mr. IndradevaMendis and Ms. Gayani Konara who are our lecturers of Maintenance Management. It with particular pleasure that we grateful to them for the constant support, guidance and for the encouragement, which was provided for us.
Then my heartiest appreciation goes to Mr. L.P.J De Silva Group Maintenance Engineer, Mr. DeepthiWijerathne Maintenance engineer and all other managers, department heads and all other staff members of central hospitals for providing facilities and guidance to complete this project successfully.
We are particularly grateful to the staff of the Campus Library and computer lab for their help. We also fondly remind all the kind hearts & helping hands were together with us in making this project a success.
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TABLE OF CONTENTS
ACKNOWLEDGEMENT ................................................................................................... 1 TABLE OF CONTENTS .................................................................................................... 2 LIST OF FIGURES ............................................................................................................. 4 LIST OF TABLES ............................................................................................................... 5 1.0 INTRODUCTION ......................................................................................................... 6 2.0 INTRODUCTION TO THE VISITED SITE ................................................................ 7 2.1 Current Maintenance Practices at GSK ..................................................................... 7 3.0 MAINTENANCE MANAGEMENT ............................................................................ 8 3.1 Elements of effective maintenance management ....................................................... 8 3.2 Maintenance strategies or options .............................................................................. 9 3.3 Preventive maintenance ........................................................................................... 10 3.3.1 Preventive maintenance helps to: ...................................................................... 11 3.3.2 Long-term benefits of preventive maintenance; ................................................ 11 4.0 STEPS TO START A MAINTENANCE PROGRAM TO GSK ............................... 12 4.0 ASSETS REGISTRY .................................................................................................. 13 4.1 Assets registry for manufacturing equipments........................................................ 13 4.2 Assets Registry for Manufacturing Equipment ........................................................ 15 5.0 PRIORITIZATION OF EQUIPMENTS ..................................................................... 18 5.1 Preventive maintenance evaluation criteria ............................................................. 19 5.2 Preventive maintenance prioritization assessment sheet ......................................... 20 6.0 MAINTENANCE SCHEDULE .................................................................................. 21 6.1 Preventive maintenance schedule for chiller ........................................................... 21 6.2 Preventive maintenance schedule for condenser water pump ................................. 22 6.3 Preventive maintenance schedule for chilled water pump ....................................... 23 6.4 Preventive maintenance schedule for Cooling Tower ............................................. 24 6.5 Preventive maintenance schedule for AHU ............................................................. 29 6.6 Preventive maintenance schedule for Package Unit ................................................ 30 6.7 Preventive maintenance schedule for Split Unit ...................................................... 31 6.8 Preventive Maintenance schedule for Cool Room ................................................... 31 6.9 Preventive maintenance schedule for Exhaust Fan .................................................. 32 6.10 Preventive maintenance schedule for Air compressor ........................................... 33 6.11 Preventive maintenance schedule for Transformers .............................................. 34
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6.12 Preventive maintenance schedule for Capacitor Bank ........................................... 35 6.13 Preventive maintenance schedule for High Tension Panel .................................... 35 6.14 Preventive maintenance schedule for Illumination System ................................... 36 6.15 Preventive maintenance schedule for Generators .................................................. 37 6.16 preventive maintenance schedule for Boilers ........................................................ 39 6.17 Preventive maintenance schedule for Water Tanks ............................................... 41 6.18 Preventive maintenance schedule for Pumps ......................................................... 41 6.19 Preventive maintenance schedule for Sprinkler System ........................................ 42 6.20 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells ..... 43 6.21 Preventive maintenance schedule for Fire Extinguishers ...................................... 43 6.22 Preventive maintenance schedule for Fire Control Panel ...................................... 43 6.23 Preventive maintenance schedule for Elevators..................................................... 44 6.24 Preventive maintenance schedule for RO Plant ..................................................... 46 6.25 Preventive maintenance schedule for Doors and Windows ................................... 47 6.26 Preventive maintenance schedule for Painting ...................................................... 47 7.0 WORK INSTRUCTIONS FOR MAINTENANCE ACTIVITIES ............................. 48 7.1 General instructions ................................................................................................. 48 7.2 Civil Maintenance working Instruction ................................................................... 49 7.2.1 Cleaning............................................................................................................. 49 8.0 PREDICTIVE MAINTENANCE ................................................................................ 52 8.1 The characteristics of predictive maintenance are the following:............................ 53 8.2 Advantages of predictive maintenance .................................................................... 53 8.3 Thermography .......................................................................................................... 53 8.4 lubricating oil analysis ............................................................................................. 54 8.5 Utrasonic Monitoring ............................................................................................... 54 8.6 Vibration monitoring ............................................................................................... 55 8.7 Motor Analysis ......................................................................................................... 55 8.7.1 Megger Testing.................................................................................................. 55 8.7.2 Resistance Testing ............................................................................................. 56 8.7.3 Impedance Testing ............................................................................................ 56 9.0 PREDICTIVE MAINTENANCE APPLICATIONS .................................................. 57 9.1 PREDICTIVE MAINTENACE STRATEGY ......................................................... 54 10.0 HUMAN RESOURCE ALLOCATION PLAN ........................................................ 55 11.0 CONCLUSIONS ....................................................................................................... 56
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LIST OF FIGURES
Figure 1 Signs .................................................................................................................... 48 Figure 2 Infrared camera ................................................................................................... 54 Figure 3 Thermal Imaging Camera.................................................................................... 54 Figure 4 Vibration Analyzer .............................................................................................. 55
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LIST OF TABLES
Table 1 Assets registry for manufacturing equipments ..................................................... 14 Table 2 Assets Registry for Manufacturing Equipment .................................................... 17 Table 3 Preventive maintenance evaluation criteria .......................................................... 20 Table 4 Preventive maintenance prioritization assessment sheet ...................................... 20 Table 5 Preventive maintenance schedule for chiller ........................................................ 22 Table 6 Preventive maintenance schedule for condenser water pump .............................. 23 Table 7 Preventive maintenance schedule for chilled water pump ................................... 24 Table 8 Preventive maintenance schedule for Cooling Tower .......................................... 28 Table 9 Preventive maintenance schedule for AHU.......................................................... 30 Table 10 Preventive maintenance schedule for Package Unit ........................................... 31 Table 11 Preventive maintenance schedule for Split Unit................................................. 31 Table 12 Preventive Maintenance schedule for Cool Room ............................................. 32 Table 13 Preventive maintenance schedule for Exhaust Fan ............................................ 33 Table 14 Preventive maintenance schedule for Air compressor ....................................... 33 Table 15 Preventive maintenance schedule for transformers ............................................ 35 Table 16 Preventive maintenance schedule for Capacitor Bank ....................................... 35 Table 17 Preventive maintenance schedule for High Tension Panel ................................ 36 Table 18 Preventive maintenance schedule for illumination system................................. 37 Table 19 Preventive maintenance schedule for Generators ............................................... 39 Table 20 Preventive maintenance schedule for Boilers ..................................................... 41 Table 21 Preventive maintenance schedule for Water Tanks ............................................ 41 Table 22 Preventive maintenance schedule for Pumps ..................................................... 42 Table 23 Preventive maintenance schedule for Sprinkler System..................................... 42 Table 24 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells.. 43 Table 25 Preventive maintenance schedule for Fire Extinguishers ................................... 43 Table 26 Preventive maintenance schedule for Fire Control Panel ................................... 44 Table 27 Preventive maintenance schedule for Elevators ................................................. 44 Table 28 Preventive maintenance schedule for RO Plant ................................................. 46 Table 29 Preventive maintenance schedule for Doors and Windows ............................... 47 Table 30 Preventive maintenance schedule for Painting ................................................... 47 Table 31 Predictive Maintenance Applications ................................................................. 59 Table 32 Predictive Maintenace Strategy .......................................................................... 54
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1.0 INTRODUCTION
Today, because of the competitive business environment, organizations tend to minimize the cost on every angel of expenditures occurred. Considering the expenditure of an organization, operations and maintenance consumes a large proportion out of total. As Facilities Managers, it is possible to contribute to reduce cost by introducing novel concepts regarding maintenance of organization. In that account, predictive maintenance strategies can be use as an excellent option with preventive strategies to improve the reliability of machines and to develop a reliability cantered maintenance plan. Developing maintenance plan is a huge task when considering the scale of the organization. Even though it is a huge task, preparing it is very pleasure task. Detail investigation must be carried out to do that well. There are various steps to follow to develop a better maintenance plan each step has to be followed very carefully. The main purpose on this report is to improve the reliability of equipment by introducing some predictive maintenance strategies in a particular building. In order to achieve that purpose we selected the most sophisticated factory in Sri Lanka named Glaxo Smith Kline (GSK). This report consists of four chapters and first chapter provides an introduction to predictive maintenance and highlighting its importance and includes includes the existing maintenance strategies of the GSK. The second chapter provides details about the Asset registry and the details of how it has been categorised based on its criticality. the third chapter, proposed preventive maintenance programme is mentioned along with maintenance schedule, check lists work instructions and human resource allocation plan. Appropriate predictive maintenance technologies are illustrated in fourth chapter. The last chapter is the conclusion to the report that depicts the findings and issues of our survey effort.
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accomplishments.
Work Order Job planning Priority and backlog control Data recording system Performance measurement measures or indices
Maintenance performance for an organization or plant can be assessed through analysis of Reliability, Availability and Maintainability. Relevant parameters, measures or indices for specific plants/equipments can be identified .The performance over a period of time will show if it is improving, going down or being sustained. This will also help in knowing how well the objectives are being met. In addition, it will guide the areas which are strong and which need to be strengthened.
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vibration, temperature, oil analysis, etc. have been developed, which guide the users in planned maintenance Opportunity Maintenance In opportunity maintenance, timing of maintenance is determined by the procedure adopted for some other item in the same unit or plant. Design out Maintenance In design out maintenance, the aim is to minimize the effect of failures and in fact eliminates the cause of maintenance. Although it is an engineering design problem, yet it is often a responsibility of maintenance department. This is opted for items of high maintenance cost that are due to poor maintenance, poor design or poor design outside design specifications. It may be mentioned that a best maintenance strategy for each item should be selected by considering its maintenance characteristics, cost and safety.
3.3.1 Preventive maintenance helps to: Improve production by reducing machines down time Is cost effective in many capital intensive processes and equipment Provides flexibility for the adjustment of maintenance periodicity Increases component life cycle and efficiency Generates energy savings Avoid unexpected equipment or process failures that cause to product loss. Results in an estimated 12% to 18% cost savings over that found in a reactive maintenance program It also helps to avoid the replacing of the parts of the equipment before the scheduled time. It also ensures the safety of the person who is working with the machine since if the machine is not in a proper condition it might also lead to a major accident which is not desirable at all.
Improve system reliability. Decrease cost of replacement. Decrease system downtime. Better spares inventory management
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Finally to carry out the maintenance programme prepared the human power was allocated for each equipment separately. Because the organization must provide enough qualified personal resources to perform maintenance tasks.
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Description
No 8 2 2 1 1 1 1 1 2 2 5 1 2 1 2 1 1 1 1 1 1 1 1 2
Serial No
Location Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Glucolin Production Area Glucolin Production Area
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Belt Conveyer Spiral Flow Conveyer Band Heat Sealer Dust Collector(Glucolin) TEW Heat Sealer Y Con Blender Printing Equipments Rejafix Printer Leaflet Folder Coding Machine Leaflet Folder (New) OTC Equipments Rejafix Printer Atles Copco Airdryer Storcklin Stacker Dust Collector(Panadol) Drum Lifter Drum Lifter De-Blisterin MC
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1
Glucolin Production Area Glucolin Production Area Gluolin Production Area Glucolin Production Area Glucolin Production Area Glucolin Production Area Ground Floor Ground Floor Ground Floor Ground Floor OTC Section OTC Section OTC Section OTC Section OTC Section OTC Section OTC Section
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Electrical
50
Water Treatment
Activated Carbon Filter Ultra Violent Lamp Membranes Sand Filter Treated Water Tank Boiler Solar Water Heater Heat Detectors Smoke Detectors Fire Panel Fire Alarm System Fire Hydrants Fire Hose Reel Fire Extinguishes Diesel Engine Pump Fire Pump Fire Doors Water Supply Storage Emergency Lighting
1 1 4 2 1 1 2
2 5 2 177 1 2 2 1 50 1 2 2 1 5 5 5 1 1 1 1 1 1 1 4
Building Transportation
Lift Cars(Goods) Lift Motors Lift Cables Lift Control Panel (Goods) Instruments/Tools Volt Meter Ohm Meter Tachometer Flame Guard Tester Air Sampling Pump Light Meter Sound Level Meter Air Sampling Meter Enviro Meter Personal Dose Meter Structural Door Closers Automatic Doors Claddings Dock Leveler Roofing Roof Penetrations Roof Drains Roof Flashing
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Ro Plant Ro Plant Ro Plant Ro Plant Ro Plant Boiler Room Roof Top All Areas All Areas Panel Room All Areas Ground Floor All Areas All Areas Pump Room Pump Room Office Pump Room All Areas Liquid Manufacturing Area Lift Motor Room Lift Motor Room Lift Motor Room Electrical Room Electrical Room Electrical Room Welding Room Electrical Room Manufacturing Area Manufacturing Area Manufacturing Area Manufacturing Area Manufacturing Area All Areas Office Entrance Building Exterior All Areas Roof Roof Roof Roof
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Administrative
Laboratory
Gutters/Downspouts Fax Security Alarms Telephone Computers Conveyors Photo Copy And Scanning Steam Sterilizers De-Ionized Water Bottle Washer ETO Sterilizers Fume Cupboard Oven Heater Kheldal Apparatus Burner Gas Chromatogram
30 50 1 2 1 2 2 2 4 4 1 3 1
Building Exterior Office Security Room Office Office Office Office Chemical Laboratory Chemical Laboratory Chemical Laboratory Chemical Laboratory Chemical Laboratory Biological Lab Chemical Laboratory Chemical Laboratory Biological Laboratory Biological Lab
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The GSK is consist lot of equipment use for the medicine manufacturing. According to our assets registry we mentioned that the equipments categorized into two types such as manufacturing equipments and non manufacturing equipments therefore the proper management of this equipment is a complex and costly task that can be accomplished through careful and systematic risk assessment regarding various types of equipment. to this assessment we mainly concern about the non manufacturing equipments. The identified risks can then be used as a basis for structuring and operating an equipment management program. Once the initial assessment is made, an organization can develop programs of preventive maintenance based on the risk involved.
Investigations have been carried out to identify the maintenance requirements of the building and identified some risk levels for the equipment. This risk levels are base for the identification of the maintenance requirement of equipment. Following describe about the risk levels. Those risk levels have some sub categories
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Risk level I Equipment Functional Areas - Various environmental areas in which equipment is used Risk level II Impact of Failure or Malfunction - Defines potential impact scenarios that may result due to failure or malfunction of the equipment. Risk level III Preventive Maintenance Frequency - Defines the level and frequency of preventive maintenance required. Assets are described under above risk level clarifications and it receives some points. Then according to the total value of points we can decide the Maintenance Priority for the equipments.
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Monthly Risk Category III Preventive Maintenance Frequency Semi-annually Annually Not Required Table 3 Preventive maintenance evaluation criteria Quarterly
5 4 3 2 1
Category Category I II
Air Conditioning/Ventilation building Transportation Potable Water/Plumbing Fire Protection Electrical Structural Administrative Laboratory Instruments/Tools Heating Emergency Backup power Water treatment (RO) 5 5 5 10 5 4 3 9 3 5 5 9 4 2 4 5 5 2 2 4 2 3 5 4 5 5 5 5 4 2 2 5 5 4 4 5 14 12 14 20 14 8 7 18 10 12 14 18 3rd 4th 3rd 1st 3rd 4rd 5th 2nd 5th 4th 3rd 2nd
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Overall visual inspection Check set points Checking refrigerant level Check oil heaters
Clean strainers Dust clean electrical panels Compare design parameters against present values Check measuring equipments Clean litter, dirt, or debris in the panels Check all wiring connections are tight. Check all contacts for pitting and corrosion Check crankcase heaters are working properly Check and clean electrical control panel
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Check Flow rates Check chilled water reset settings and function Compressor motor and assembly Verify motor amperage load limit Check refrigerant condition Clean evaporator and condenser tubes Compressor oil system Check chiller lockout set point Compressor motor and assembly Clean condenser tubes Clean evaporator tubes Table 5 Preventive maintenance schedule for chiller
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Check visual inspection/abnormal noise Check water pump bearing Check flexible coupling bush Check electrical system Check alignment/levelling Clean strainer Check gate valve Table 6 Preventive maintenance schedule for condenser water pump
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Check water leak Clean pump and motor Check visual inspection/abnormal noise Check water pump bearing Check flexible coupling bush Check electrical system Check alignment/levelling Clean strainer Check gate valve Table 7 Preventive maintenance schedule for chilled water pump
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Check motor supports and alignment Clean fan blades Check lubrication Check fan motor condition and belts and pulleys Operate makeup water float switch manually Clean suction screen Check drift eliminators, louvers, and fill Test water samples Strainer cleaning Check motor supports and alignment Clean fan blades
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Check lubrication Check water distribution and sprinkler operation Check fan motor condition and belts and pulleys Operate makeup water float switch manually Clean suction screen Check drift eliminators, louvers, and fill Test water samples Check tower structure Clean tower Strainer cleaning Check motor supports and alignment
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Clean fan blades Check lubrication Check fan motor condition and belts and pulleys Operate makeup water float switch manually Clean suction screen Check drift eliminators, louvers, and fill Test water samples Check tower structure Check bearings Clean tower Paint tower
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Cleaning the plant surface Filter cleaning Wash coil with pressure gun Clean exterior of the unit Check belts/bearings and pulleys
Blower inspection
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Paint rusted surfaces Check valve operation Paint AHU room Table 9 Preventive maintenance schedule for AHU
Duration W
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BA
Check the refrigerant leaks Check the belt tension of the blower fan Lubricate the blower fan motor Check safety devices Check wires for loose connection Check the compressor current Check the outdoor unit for corrosion Table 10 Preventive maintenance schedule for Package Unit
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Clean drain and drain pan. Clean door gasket. Check and clean condenser fan. Check door micro switch. Clean condenser Clean drain and drain pan Clean door gasket Check and clean condenser fan Check door micro switch Check evaporator blower Check thermostat operation Check electrical connections Check drain pan heaters Clean condenser. Clean drain and drain pan. Clean door gasket. Check and clean condenser fan. Check door micro switch. Check evaporator blower. Check thermostat operation. Check electrical connections. Check refrigerant charge. Check for corrosion and repaint with anticorrosion. Check door hinges for wear. Check drain pan and defrost heaters if fitted.
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D Dust cleans the unit. .Check bearings. .Check and clean cooling fan. Check electrical connection. Get clip on reading. Dust cleans the unit. Check bearings. Check and clean cooling fan. Check electrical connection.
BA A
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Check fans, controls, alarms & anounciator points Table 15 Preventive maintenance schedule for transformers
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Clean and vacuum all dust and dirt. Check for loose connections. Audibly check motor bearings. Check for excessive vibration tighten loose mounting bolts or report where necessary. Check generators R. P. M. and the frequency and battery charger and the D. C. voltage. Visually check wiring insulation. Check for tightness of all nuts and bolts screws wires etc. of the breaker and the panel. Clean and remove loose external and internal dirt and dust. Visual checking of MCCBs door handles, settings for thermal and magnetic tripping, time delay, discolouring, check the circuit breaker trip function using test button. Measure the current. Check all Panel meters and indicator lamps of the electrical distribution panels and distribution board. Visual check for any discolouring or burning marks. Check and correct the earth fault settings. Test the function of relay and shunt trip of circuit breaker. Clean inside and outside of the panel using a soft pad or cotton waste applying an evaporative liquid, bus bars and bus bar insulators. Clean power control cables. Wax polished exterior of capacitor banks. Check the earth connection, condition of the moving and fix contact points of the contactors.
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Duration Activity Check the electronic ballast function in regulate Ensure the power sources of that fittings Ensure the Efficacy and efficiency Check the light colour Ensure the starting time of the lamps and fittings Check the colour temperature Check the fluorescent tube Ensure the all fittings function in accurately Table 18 Preventive maintenance schedule for illumination system D W M Q BA A
Activity W
BA
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Before starting the engine, check oil level Check fuel level in the tank Before starting the engine, check coolant level in radiator Check all instruments are functioning Check for leakages of coolant, fuel and lube oil Check the engine protection system daily for fault lamps Whenever the generator is operating ensure the space heaters are disconnected Check for loose electrical connections in the battery chargers and tighten as required Check the batteries. Clean the top of the batteries with a clean cloth. Clean all cable clamps and battery terminals using a bristle brush. Check the battery charger Check the operation of the supply air fan/fans Clean and remove loose external and internal dirt and dust. Check the bearing bracket temperature. Check the wires and connection on the voltage regulator assembly Repeat all A checks Change oil in sump, drain off while still hot Clean magnetic drain plug Lubricate the FIP linkage by using oil can Clean the area around the fuel filter head and filter. Change the lubricating oil and filters at the specified oil change interval. Clean radiator core with compressed air Check connections of starter motor & alternator and tighten
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Check coolant concentration Clean and check the oil drain plug threads and the seal surface. The tube is to be removed and check and internally for obstructions or sludge build-up. Inspect the bypass oil filter and cooling system hoses and connections for leaks Remove and clean air ducting hoses Adjust both the intake and exhaust crossheads. Lean each battery cell with distilled water. Remove & clean the engine breather cap in kerosene oil Blow air in reverse direction & refit, replace rubber gasket in the breather Check valve clearance Lubricate water pump with bearing grease Check the thermostat for proper functioning and operating temperature Check the engine oil heaters and coolant heaters for proper operation. Check the torque on the nuts and bolts Check tightening of oil pan mounting cap screw Check tightening of oil pan mounting cap screw Apply grease to fan hub & belt tension Clean the fuel tank for the dirt and the sediment Table 19 Preventive maintenance schedule for Generators
Activity
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Ensure that feed water meets the boiler requirement Check burner operation Clean Blow Down Valve Check blow down and water treatment procedures Check the low water cutoff Remove and clean the gauge glass Examine water level of the boiler. Check Pressure of Diesel Clean the Eye Glass Check damper seals for leaks Check air inlet Measure the co2 level Check Air Pressure Check oil Pressure Check oil pump suction condition. Check Leakages in Oil Pumps Check Flame Condition Clean burner nozzle Replace the burner Inspect burner components Check clean the Photo cell Clean flame sensor Open and clean, out doors of Boiler and lubricate Check the Condition of Door Seal Ensure Proper Lubrication of all moving Parts Check feed water pump Clean Water Filter in Feed Water Pump Check water sample Check and clean/replace oil filters and strainers. Remove Water Level Controller and floaters, clean the scale and sediment materials Check water level control Clean Electrical Contacts and relays Check all valves and joints for leaks Clean Water Pump Seal and Non-Return Valve Lubricate the modulation motor linkages Inspect the combustion air louvers and or ventilation screens Inspect and clean the cover of the boiler Inspect boiler insulation Test safety relief valve Check steam control valves Clean Blower Fan blades
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Clean Fuel Filter Fix the new manhole and hand hole gaskets Check for leaks. Clean return tank and strainer. Prevent any sediments Control temperature & Safety check Table 20 Preventive maintenance schedule for Boilers
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Check electrical terminal connections at motor Check tension of all mounting and securing and blots Check indicator lights Remove dust and dirt from the motor terminals at the terminal box using a compressed air (blower). Vacuum clean the terminal box Check that motor air vents are free of dust build up Check and record the phase current and line voltage when the motor is running. Table 22 Preventive maintenance schedule for Pumps
Duration M Q A d d
6.20 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells
Duration Activity D tight the communication terminals Clean and remove dust and dirt from the top part of the detector Clean and remove dust and dirt from the alarm bells. Clean and tight communication terminals. Paint the bell housing if necessary kkkk Table 24 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells W M Q A
Duration W M Q A
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Check security of electrical connections Table 26 Preventive maintenance schedule for Fire Control Panel
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Figure 1 Signs
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When maintenance acidities take place the above shown signs should be taken in to consideration by the work force. Make sure to cut the electrical supply for an equipment before starting to clean or to do any maintenance activity. Proper PPE should be worn by the work force. Make sure theres no litter, dirt, or debris in the panels. If there is anything unusual should be removed quickly. Updating daily log for all equipments is a major requirement, since it is the most important tool contributing for the overall efficiency. The supervisors should ensure that all componants of equipments are in safe condition. Confirmation of no smell of gas or evidence of fuel leaks exists in the working area need to be informed to the department.
Toilets/ wash rooms All toilets i.e. male toilets, female toilets, executive toilets must be cleaned thrice a day. Mild detergents should be used for cleaning purposes. Using of abrasive cleaner should be avoided. Hard disinfectants and the cleaning products in aerosol cans should also be not used. Always close cleaning agent securely to prevent fumes from escaping or spills. Always toilets should be dry to prevent slippery.
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Always put cleaning supplies away when finished the cleaning tasks. Cleaning should not be a disturbance to the users.
Window Cleaning Use a solution of mild detergent and water, or a mild commercial cleaner whose label says it is safe for painted surfaces. Always rinse off the cleaning solution. Wipe off excess water with a dry cloth. Do not use strong cleaners or scouring powder as these can damage the paint. Clean window frames before cleaning window glass to avoid solution spot on glass panes. Use hand vipers to remove the water droplets. Use soft detergent such as t-pole to clean the glass of the window. Clean the glasses occasionally (normally, once in 18 / 24months)to remove rust by applying cleaning agent such as renotec and cutting it using buffer pad.
Gardening Watering plants should be done before 8.30 a.m. in the morning and after 5.30 p.m. Tools and equipment should be replaced to their allocated location After finishing the task all the leftovers should be discarded properly.
Painting
Good surface preparation is the key to a long-lasting and great-looking paint job. Repair cracks or chips, sand and smooth rough edges, and clean chalky surfaces. Give the walls 24 hours to dry after wiping them down.
Assemble all painting tools and cleanup supplies before starting. Protect floors and furniture with a drop cloth or sheet. Remove loose fibers from roller covers with painter's tape or a lint roller before using.
Spray or roll from top to bottom, left to right to cover neatly and evenly. Lighter, multiple coats will cover better than one heavy layer of paint.
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Sprayers offer the best and most efficient coverage when painting large areas or exteriors. After spraying, back roll to ensure even coverage.
Use a quality brush or roller. Place a garbage bag over your paint tray, brush or roller to prevent the paint from drying. This will keep the paint for 24 hours - and let you take a break without worrying that your paint will dry out.
For water-based paints, rinse brushes, rollers and tools with water. For oil-based paints, use paint thinner.
Use bristle protectors that fit over brushes and protect them when not in use. They are available at most hardware stores.
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Condition Monitoring Some parameters can be monitored; using sophisticated measuring equipment, to detect signs of imminent failure. Examples of these are Vibration, Shock Pulse, Oil condition, Acoustic emissions, Equipment Performance, Thermography, and Non-destructive Testing. These techniques are discussed in detail in the following section.
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8.3 Thermography
Thermographic testing is a technique that uses the latest infrared imaging technology to detect problems that cant always be seen by the human eye. Using a thermal image camera, abnormal heat generation caused by loose connections or other sources in electrical panels, compressors, pumps, switchgears, motors and motor control centres can be easily identified. The images taken during these tests can be used to quickly identify problem areas so preventive maintenance measures can be taken to correct the problems before equipment is damaged. This predictive maintenance technique reduces costly downtime by identifying faulty equipment before it becomes a problem and helps to
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reduce hazardous fires or other life threatening malfunctions. Types of Thermographic tools are mentioned below. Spot radiometer (Infrared thermometer) Cooled infrared detectors Fully automated sensors Infrared cameras Un cooled infrared detectors Thermal imaging camera & screen
Figure 2 Infrared camera
Figure 4 Analyzer
Vibration
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8.7.2 Resistance Testing Resistance is measured by using an ohmmeter. In reality, an ohmmeter does not directly measure resistance; it measures current instead. The scale of the meter is calibrated in ohms, but the meter movement responds to current. The amount of current supplied by the meter is very low, typically in the rage of 20 to 50 microamperes. The meter functions by applying its terminal voltage to the test subject and measuring the current in the circuit. 8.7.3 Impedance Testing Impedance has two components: a real (or resistive) component and a reactive (inductive or capacitive) component. This method of testing is useful because it can detect significant shorting in coils, either between turns or to ground. Other non-intrusive methods are not existed to detect a coil that is shorted between turns. Types of impedance testing tools are mentioned below. Eddy current tester Ohmmeter Mega-ohmmeter
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Frequency
Oil Analysis
Annually
Annually
Annually
exchangers within chiller. It can detect inside diameter and outside diameter defects. This test also determines the severity of the defect and whether immediate action should be taken.
Every 3 to 5 years
Annually
Annually
Annually
the equipment Inspect the unit to ensure it is operating in a normal condition for vibration, noise, and odors. Verify gauges and thermometers are reading within range. Inspect for leakage due to Daily access doors not being properly closed. Verify that any internal lighting is off. Verify all safety guards are in place. Visual Inspection Inspect belt tension and alignment. Look for rubber shavings under the pulleys. Inspect visible grease for metal shavings, indicating a possible failing bearing. Wipe away all excess grease after greasing. Inspect grease tubing if installed for integrity to make sure grease is getting to the bearings. Check bearings for excessive heat, noise, or vibration. Check all set points such as pressure and temperature for proper setting and function. provide non-contact temperature mapping of abnormal heating or cooling in systems Semi Annually
Weekly
Daily
Infrared thermograph surveys Airbourne Electricity Distribution System Visual Inspection ultrasonic detection
Every 3 months
Every 6 months
System load, amperage, power factor and/or voltage recording reducing catastrophic cable failure and downtime Line disturbance detection, location and
Daily
Insulation testing
Line disturbance
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detection Carry oil analysis tests Generator Carry out visual inspection
analysis. Only if the results show it should be changed, the oil filters should be changed Record Water, oil and battery levels
months
Annually
Weekly
Inspect and record data regarding the governor Visual Inspection Lift and Escalators Motor Current Analysis Motor amperage should not exceed manufacturer's specification This test would show indicators of wear metals, contaminants, viscosities and inhibitor level this test indicates an imbalance, misalignment, Vibration Analysis bearing defects, open rotor bar conditions, gear wear, harmonics and excessive shaft run-out Table 31 Predictive Maintenance Applications rope, counter weight, control panel, data transmit cable, etc.
Once a month
Every 3 months
Annually
Annually
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Service Category
Equipment Name
Thermography
HT Breakers Transformer Generator System Electrical System Main Distribution Boards LT Panel Central Ups System Capacitor Bank System Chiller Cooling Tower Air-Conditioning System Condenser Water Pump AHU Supply Exhaust Fans Water Pump Water/Drainage And Fire Dosing Pump Pump System Main Receiver Tank Smoke Extraction Fan Fire Protection System Staircase Pressurization Fan Lift Motors Lift & Escalators Escalators Water Purificators Water Purifier
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11.0 CONCLUSIONS
The ultimate goal of any maintenance plan is to identify the imminent failures and make a prognosis of the remaining useful life of analysed component regardless of which technique is used. Predictive maintenance is not just acting according to a prescheduled operational programmed but predicting the likely defect of the equipment and its affection to overall reliability of the facility. The maintenance environment of tomorrow will exist mostly for those who are highly skilled in maintenance. Therefore, careful study to improve methods and reduce maintenance costs is imperative. Achieving these initiatives will help potentially save millions in maintenance-related expenditure over time. Analysis of the various elements of strategic maintenance management indicates that it is a comprehensive and composite system of integrated processes, but not necessarily a complex one. This process, as depicted within this project, will achieve an orderly flow of work when each element is appreciated and properly placed in relation to the other, thus allowing mission, vision and goals/ objectives of any pharmaceutical facility maintenance strategic plan to develop and experience success. Continues monitoring through some specified selected instruments to identify the different parameters of each equipment is the key operational difference in predictive maintenance. Strategic decision making is also another key characteristic feature of the procedure which make possible the predetermining the problem occurrence time frames and provisions to be made and relative time constrains too. Cost effectiveness and reliability are correlated features in predictive management where according to the monitoring frequency demanded cost parameters and reliable operations can be achieved with less and motivated work force. Since this is not highly practiced within Sri Lanka assuming and analyzing accuracy can be deviated from the actual provisions. But this synergic effect is a highly economic feature to present economic circumstances where moving towards reliability centred operations of the facilities. Even though this predictive maintenance strategy is an improved worker and environmental safety feature this will be a new bench mark for green concept for the buildings.
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12.0 REFERENCES
POLMER, D., 1999. Maintenance Planning & Scheduling Handbook,USA: McGraw Hill.
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