Sie sind auf Seite 1von 23

Presented by:

V.K. Gupta, Ex. Sr. Maintenance Engineer, NPCIL &


K.R.Mondal, Associate Professor, JIPT
By pitfalls in Maintenance we means the
factors contributing towards poor
maintenance quality and as a result of which
equipment availability and reliability is
reduced.

In this paper some areas have been


identified which are responsible for Poor
maintenance quality , equipment availability
and suggestions to improve.
WHAT WE MEAN BY MAINTENANCE OF
PLANT EQUIPMENT OR MACHINES:

By maintenance of any plant equipment, means the kind


of work performed on running, shutdown or on equipment
under break-down, for restoring its condition or
performance close to original within intended time and
intended quality. Maintenance personnel seldom have
good name as it is generally felt worldwide that once the
equipment is touched by maintenance technicians, it is
going to deteriorate further and may even have recurring
problems from then onwards.
To some extent it is true also. Those who have
long experience in maintenance of plant
equipment and training understand the truth
behind it. This is mainly due of poor
maintenance practices and bad working
skills/techniques.
Such poor maintenance practices and bad work
techniques can be as summarized below.
• Habit of using improper tools.
• Inadequate skill, knowledge and training.
• Inherited poor skills and bad work practices.
• Improper Housekeeping.
• Lack of proper procedures and check lists.
• Lack of supervision.
• No regard for safety.
• Lack of attitude for good work.
Figure showing correct
size of a screw driver
being used

Figure showing special


kind of tools
Figure showing tools abuse

A hook spanner used on slotted nut.


Hollow Punches
A gasket cutter tool Kit

A technician punching bolt


holes in a gasket

A Click or trip type torques wrench


Packing Extractors now easily available in market
Valve
Insitu
Seat
cutting
and
lapping
tool
EXPERIENCE WITH THE NEW EQUIPMENT OR A
MACHINE:
Keeping aside bath tub curve behavior every new equipment like
BFP or any other, when put into operation, will generally perform
satisfactory. This is thought to be due to the following reasons.
 All new components are inspected strictly as per drawing.
 Such components when assembled will have desired fit,
shouldering, squareness, properly balanced, running
clearance and alignment etc.
 A well written assembly procedure and check list is
followed during assembly.
 Due to the use of specific and correct size tools i.e.
wrenches, hook spanner, torque wrenches, bearing mounting
tools, solid punches, circlip pliers, plastic or nylon hammers
etc., no component will get damaged while assembling
In field maintenance though we strive for
everything as best but seldom achieve.
SUGGESTIONS FOR
IMPROVEMENTS IN
MAINTENANCE PRACTICES:
1. Implementation of condition monitoring in
place of preventive maintenance system (PM):
It has been well proved that condition
monitoring system of maintenance is far more
superior to usual system of Preventive
Maintenance, because preventive maintenance
may lead to over maintenance and
unnecessary stoppage of machine to fulfill PM
schedules.
2. A maintenance check list for every critical equipment
describing details of the equipment, step by step
disassembly and assembly procedure should be made
available (to be developed if not available), along
with list of tools to be used, gaskets, gland packing,
gland packing cutting procedure, bearings, bearings
installation and removal procedure (no hammer to be
used on bearings), torque wrench. Good housekeeping
and testing of the equipment after maintenance work
is completed. Such check lists can be reviewed time to
time for improvement as we gain experience.
A suggested list of procedures:
• Gasket cutting, installation, tightening and testing procedure.
• Gland packing cutting practice and adjusting procedure.
• Bearings removal and installation check list. Expert help from M/s
SKF, FAG and Timken must be taken initially to train technicians.
• Display torque tables in the maintenance workshop for every kind
and size of bolt.
• Display proper gasket and gland packing identification and
selection charts. Such information can be down loaded from the
websites of gaskets and gland packing manufacturer and supplier
like Champion and others.
• Buy and use only quality materials particularly Bearings,
Seals, “O” Rings and diaphragms. In India spurious bearing
are abundantly available and one of the major cause of
premature bearing failure is the use spurious bearing which
cannot be easily distinguished from the genuine bearing.
Best thing is to buy from manufacturers or their authorized
dealers.
• Develop special tools for specific use in free time as is felt
and make a mention of it in the maintenance check list.
• Train technicians to use hand held vibration measurement
machines like one from M/S SPM, IRD and others to collect
vibration data & educate them to analyze the data thus
collected.
• Develop in-house training facilities and mock up for in situ
training like installation and testing of Mechanical seals, use of
gate and globe valves seat machining and lapping by in situ
lapping tools.
• Lapping Room with lapping tools kits and testing facilities of
lapped components by Monochromatic check light and optical
flat
• Welder’s qualification and welding procedures for getting
welder’s qualified by agencies like IBR.
3. Implementation of International Standards like ISO 9000, 14000
and 18001: Implementation of ISO 9000 about quality, 14000
environment and 18001 regarding safety, are now well
established procedure bringing overall improvement. They must
be adopted.
4. Upkeep of maintenance Documentation Cell:
Maintenance documentation play key role in
establishing effective maintenance programs,
maintenance of spare parts and reducing
maintenance cost by reducing the occurrence of
shut downs and setting high maintenance
standards.
Having a comprehensive experience of working in Maintenance
of Nuclear and thermal power plants particularly in mechanical
maintenance department it is believed, if above measures are
implemented religiously, maintenance quality will definitely
improve, reduce machines down time, reduce maintenance cost,
increase in plant availability and as a result improve profitability.
Thank you

Das könnte Ihnen auch gefallen