Maintenance for Competent Technician in Rotating Equipment

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PART 1

MECHANICAL MAINTENANCE

MAINTENANCE FOR
ROTATING EQUIPMENT

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Maintenance for Competent Technician in Rotating Equipment
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PERFORMANCE STANDARD

Carry out maintenance of rotating equipment

using specified
Specified tools and
equipment documents
is isolated from so that; and
process
energy source, where applicable
Equipment and work area are confirmed properly
and safely
prepared for maintenance
Maintenance is carried out according to schedule
and other priorities without disruption to production
objectives
Plant and equipment are kept in a safe condition
HSE requirements are met
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LETS DO MAINTENANCE !

PREPA EXEC REINST

RE UTE ATE
Maintenance for Competent Technician in Rotating Equipment
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Enabling Requirements:

Participant must have the following knowledge:

Construction and operating principles of Equipment

(API 610 & Recip Comp)
Tools for Maintenance
HSE Procedures
Maintenance Procedures
Isolation of Equipment
Importance of Preventive Maintenance
Maintenance Schedule
Importance of maintaining good housekeeping and
cleanliness of component and parts after
maintenance
Consequences for not replacing lubricant of the
same grade, specs and quantity. 7/10
Importance of Maintenance program:

Equipment downtime is decreased and

the number of major repairs are reduced
Better conservation of assets and
increased life expectancy of assets,
thereby eliminating premature
replacement of machinery and
equipment
Reduced overtime costs and more
economical use of maintenance workers
due to working on a scheduled basis
instead of a crash basis to repair
breakdowns
Timely, routine repairs prevent fewer
large-scale repairs
Avoiding Lubricant Failures

Rotating parts fail for many reasons:

Improper lubrication: 40-50%
Improper mounting: 25-30%
Other causes: approx. 20%
Reaching the natural fatigue limit: <10%
so it is obvious that improper lubrication is at the top of the list.
Lubrication is to prevent metal-to-metal contact between the
shafts, rings, housings, rolling elements, raceways and retainers.
In addition, lubrication protects against corrosion and wear, helps
dissipate heat, helps seal out solid and liquid contamination, and
reduces noise. A properly lubrication has the best chance of
reaching parts maximum service life.
There are numerous causes for lubricant failure, including:
Insufficient lubricant quantity or viscosity
Deterioration due to prolonged service without replenishment
Excessive temperatures
Contamination with foreign matter
Use of grease when conditions dictate the use of static or
Cylinder lubrication is truly the lifeblood of the wearing
components inside the reciprocating compressor cylinder. Here
are some tips for improving the overall reliability of reciprocating
compressors:

Use the proper type of lubricant. Improved cylinder lubricating

oils are now available.
Establish the correct lubrication rates to the cylinder and
packing (too much oil can be as harmful as too little).
Try to select a lubricated cylinder compressor whenever possible
from the technical standpoint.
Look at new state-of-the-art lubrication systems. The trend is to
move from the self-priming vacuum-style pump-to point type
system (one pump for each point of lubrication on the
compressor) to a divider block system where lubrication is
properly proportioned and distributed by positive displacement
series flow valves.
Add a spare lubrication system (if one system fails, the other
comes on line and the compressor cylinders continue receiving
lubrication).
Consider continuous monitoring and alarm capability for the
Maintenance for Competent Technician in Rotating Equipment
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Ability to:

Use appropriate PPE

Use correct tools
Comply with HSE and Maintenance Procedures
Complete record correctly and legibly
Identify correct type of lubricant to use and
quantity required
Isolate equipment for maintenance

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Maintenance for Competent Technician in Rotating Equipment
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question

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Maintenance for Competent Technician in Rotating Equipment
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PART 2- MAINTENANCE

MAINTENANCE - Day-to-day work that is

required to maintain and preserve plant and
capital equipment/asset in a condition
suitable for its designated purpose and
includes preventive, predictive, and
corrective (repair) maintenance.
TYPE OF MAINTENANCE
There are three basic types of
maintenance:

Corrective
Preventive
Predictive
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Maintenance for Competent Technician in Rotating Equipment
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TYPE OF MAINTENANCE

Some establishment today adopted FOUR basic

types of maintenance:

Corrective
Preventive
Predictive
Detective

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Detective Maintenance

The way to find out if protective devices or systems

will work is to call/test on them to operate. If there
is a real demand and the item works, then of
course we know it is in good order. But we cannot
wait for a real demand to find out its state, so the
alternative is to functionally test them.

In their seminal work on Reliability Centered

Maintenance (RCM), Nowlan and Heap called these
tests Failure Finding Tasks. Moubray uses the term
detective tasks. Adopting the latter terminology,
the strategy which employs detective tasks is
identified as Detective Maintenance.
Detective tasks include,
for example:

Testing of smoke, gas and fire detectors

Periodically starting fire pumps
Testing the ejector seats of fighter aircraft
Building evacuation tests
Stroking of valves that stay in one position for
most of the time
Annual vehicle inspection
Testing of emergency disconnect/release
systems on cargo ships
Pre-overhaul testing of PRVs
Testing control loops of safety devices
Testing of relays protecting electrical equipment
Over-speed trip tests
Furnace/Boiler trip tests
Maintenance for Competent Technician in Rotating Equipment
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MAINTENANCE THE DEFINITION

To properly deal with repairable systems, we

need to first understand how components in
these systems are restored (i.e. the
maintenance actions that the components
undergo).

In general, maintenance is defined as any

action that restores failed units to an
operational condition or retains non-failed units
in a continuous operational state.

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Maintenance for Competent Technician in Rotating Equipment
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MAINTENANCE THE DEFINITION

For repairable systems, maintenance plays a

vital role in the life of a system. It affects the
system's overall reliability, availability,
downtime, cost of operation, etc. Generally,
maintenance actions can be divided into three
types: corrective maintenance, preventive
maintenance and predictive maintenance
(inspections and later there is detective
maintenance).

What does its relates here ?

RM $$$$$$ ( ECONOMIC ) 4/20

 Maintenance for Competent Technician in Rotating Equipment
What is corrective maintenance ?
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Corrective maintenance consists of the action

(s) taken to restore a failed system to
operational status.

Usually involves replacing or repairing the

component that is responsible for the failure
of the overall system.
Performed at unpredictable intervals because
a component's failure time is not known.
The objective of corrective maintenance is to
restore the system to satisfactory operation
within the shortest possible time.
Corrective maintenance is typically carried
out in three steps: 5/20
Maintenance for Competent Technician in Rotating Equipment
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Steps in corrective maintenance

Diagnosis of the problem. The maintenance

technician must take time to locate the failed
parts or otherwise satisfactorily assess the
cause of the system failure.

Repair and/or replacement of faulty

component(s). Once the cause of system
failure has been determined, action must be
taken to address the cause, usually by
replacing or repairing the components that
caused the system to fail.

Verification of the repair action. Once the

components in question have been repaired 6/20
Maintenance for Competent Technician in Rotating Equipment
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Preventive Maintenance

Preventive maintenance includes periodic and

planned maintenance actions taken to maintain
any equipment within their design operating
conditions, extend its life, and is performed to
prevent equipment failure.
This includes technical safety requirements
surveillances, in-service inspections, and other
regulatory forms of preventive maintenance.

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Maintenance for Competent Technician in Rotating Equipment
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Maintenance SCHEDULE

The schedule should be a management tool

(specifically including first line supervision) to
control and direct maintenance activities.
It should be used by management to determine
the critical path and explore alternatives when
needed.
The schedule also should be a concise method
for tracking completion of maintenance tasks,
particularly critical path activities

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Maintenance for Competent Technician in Rotating Equipment
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SCHEDULE

The schedule should be useful.

The individuals expected to follow the
schedule
To understand that it should make their
tasks and the tasks of others easier.
They also should understand the
importance of their tasks in relation to
the schedule as a whole.
Schedule should be strictly followed.

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Maintenance for Competent Technician in Rotating Equipment
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Predictive Maintenance

Predictive maintenance activities involve

continuous or periodic monitoring and
diagnosis in order to forecast component
degradation so that "as-needed" planned
maintenance may be performed prior to
equipment failure.
Not all equipment conditions and failure
modes may be monitored; therefore,
predictive maintenance should be selectively
applied. Tribology/vibration, thermogram and
oil analysis are good tools.
Reliable predictive maintenance is normally 9/20
Maintenance for Competent Technician in Rotating Equipment
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question

E/E
Mechanical Engineer Rotating Equipment
Working experience in maintenance and troubleshooting
of Rotating Equipment includes:

Major machinery overhauls, change-outs and retrofits of Gas Turbines

(GE Frame 6B), Centrifugal and Screw Air Compressor (Hitachi,
Mayekawa, CompAir, Ingersoll-Rand and Atlas Copco), Reciprocating
Compressor (Dresser-Rand and Caterpillar), Centrifugal and Vertical
Pumps (Sulzer, KSB & ABS), Diesel Engines (Caterpillar and Detroit 12 V-
71) Gearboxes, Blowers and Fans
Responsible in planning and coordinating of Preventive and Corrective
maintenance of various RE
Competent SAP Expert User, have experience with SAP (R/3) and SAP
ECC6.0 for Plant Maintenance module in PETRONAS Maintenance
Management System (PMMS) to support Asset and Work Management.
Familiarity and experience in Reliability Management including
equipment strategy, RCFA and Condition Based Monitoring for RE (lube
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