EQUIPMENT MAINTENANCE

Maintenance

Maintenance, repair, and operations (MRO) involves fixing any sort of mechanical or electrical device should it become out of order or broken (known as repair, unscheduled or casualty maintenance). It also includes performing routine actions which keep the device in working order (known as scheduled maintenance) or prevents trouble from arising (preventive maintenance). MRO may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions." [1]

CONCEPT OF PREVENTIVE MAINTENANCE

MAINTENANCE CAN BE MAJORLY CATOGARISED INTO

Breakdown maintenance Preventive maintenance Predictive Maintenance

Preventive maintenance (PM)

The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects. Maintenance, including tests, measurements, adjustments, and parts replacement, performed specifically to prevent faults from occurring. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.

BREAKDOWN MAINTENANCE
This is done when machine breaks down because of failure of the machine components. In this condition you cannot further run the machine till the problem is rectified. This time lost is called breakdown time.

DISADVANTAGES OF BREAKDOWN MAINTENANCE

Downtime loss May further lead to more damages to the equipment Money lost in spare parts Equipment may suddenly stop when it is required.

PREVENTIVE MAINTENANCE

This maintenance is carried out in regular intervals as per the recommendations of the equipment manufacturer.

ADVANTAGES OF P.M. Reduce the downtime Improve the performance Improve the efficiency Increase the life of equipments Reduce the spares consumed etc.,

P.M. LEADS TO

Reduction in downtime cost and Reduction in machine maintenance cost

Preventive maintenance calendar year: No. Name of the eqt. I II

Quarter
III IV

1
2 3 4 6 7 8

Universal testing Machine . Izod Charpy Impact Tester . Dart Impact Tester for Pipes . Dart Impact Tester for Films with vacuum pump . Heating Oven . HDT/VSP Test Apparatus . Melt Flow Indexer . Precision Weighing Balance . ESCR with notch cutter 3 .

9
1

LIST OF Processing Equipments

Injection moulding machine Compression moulding machine Blown Film Extruder Microprofile Extruder Blow Molding Machine Rotational Molding

LIST OF TESTING EQUIPMENTS

MFI VSP/HDT tester Carbon black content Carbon black dispersion ESCR Deep freezer DSC/TGA app. Etc.

BASIC REQUIREMENTS FOR FUNCTIONING OF MACHINES

Electrical supply / Power Compressed air / Gas supply Oil or other working media Water supply for cooling / others Any other requirements as specified by equipment manufacturer

P.M.CHECK POINTS-Injection Molding Machineries

Power supply Clean the machine externally Lubricate tie rods at the start of every shift and regularly at hour intervals by means of a hand pump Check oil level of the tank, thrust unit and top up if necessary Check oil temperature. Temperature should not exceed 55 degree

Clean guide rods of injection units and lubricate well Check for any loose connections on machine elements and tighten if required Check water cooling system for leaks Check main valve and injection releif valve settings Check heater circuit Check functions of limit switch Check main electrical cabinets for any loose connections Check all tie bar nuts for tightness Use safety rods supplied with the machine when mould is not mounted

Extruder-Check points
Flush and change oil in drive gears Proper lubrication of all the parts that require oiling or greasing Visually check contact of band heaters Check conditions of belts in belt drives Inspect thrust bearing for wear Test die and extruder heates for burn- out Change frayed electric wires Check all the electrical points

Check nip rollers for uniform surface Check water circulating unit Check tightness of bolts of all the motors, gear boxes, bearing housing etc.

P.M.CHECK POINTS-for IMPACT TESTER

Power supply Oiling in ball bearing Visual inspection of pendulum Oiling of notch cutter

P.M.CHECK POINTS-for FALLING WEIGHT IMPACT TESTER

Air filter or lubricator Oiling the slidings Overall Visual inspection Levelling

P.M.CHECK POINTS-for DART IMPACT TESTER

Check the vaccum Vaccum pump oil level Power supply Electro magnetic holder

P.M.CHECK POINTS-for OVEN

Electrical Power supply Air circulator Oiling the motor Thermostat & Thermometer

P.M.CHECK POINTS-for HDT/VSP

Oil level Oil viscosity Power supply Potentiometer

P.M.CHECK POINTS-for MFI

Power supply Temp. controller Heaters connections

P.M.CHECK POINTS-for Weighing balance

Power supply Visual inspection Leveling

P.M.CHECK POINTS-for CARBON BLACK CONTENT

Power supply Temp. controller Thermocouple Visual inspection

P.M.CHECK POINTS-for ESCR

Power supply Temp. controller Thermocouple Visual inspection Stirrer Check the punch, Clean water tank

P.M.CHECK POINTS-for COMPRESSION MOULDING

Power supply Hyd.oil level Oil condition Safety system

P.M.CHECK POINTS-for CLIMATIC CHAMBER

Power supply Evaporator, condenser, solenoid relays Contact thermometer Humidifier, Wet bulb wick Submersible pump filter Glycol level, Distilled water level

P.M.CHECK POINTS-for CONTOUR CUTTER

Power supply Vaccum pump Limit switch Safety system

INJ.MOULDING MACHINE CHECK LIST-Daily

Check hydraulic tank level and oil temperature under operating conditions.Check position of indicator on oil filter.Change filter as required. Check and refill toggle mechanism lubricator.Check setting of the system.A small excess of oil should always be present in knuckle joints,tie bar,bushings etc.. Grease wheels on safety doors.

MOULDING MACHINE CHECK LIST-Weekly

Wipe down and clean the entire machine. Operate the machine to find oil leaks and correct as required. Check connections and wiring to heaters and thermocouples.Correct as required.

MOULDING MACHINE CHECK LIST-Annually

Control circuit of electrical system. Looseness in the terminal connections. Broken toggle pins. Level of oil in the reservoir. Entrapping of air in the hydraulic lines.

MAJOR FACTORS EFFECTING PERFORMANCE OF EQUIPMENT

Power supply Environmental conditions Handling of equipment Equipment Safety etc.

PUMP AND MOTOR

Wrong function source of faults
rotates in wrong direction oil level too low Filter clogged Pump does not bring oil Air in system Suction line leaking Pump shaft broken Wrong oil quality

Elimination
Change terminals on motor refill oil clean filter Ventilate system Tighten or replace packing Find out the source(pump assembled under stress)and replace shaft Observe oil recommendations

PUMP AND MOTOR

Wrong function
Pump or motor produce loud noise

source of faults
Suction line leaking Filter clogged Oil level too low Pipe bendings in suction line Too high axial or radial load Pressure too high Cooling system clogged

Elimination
Seal or replace packings Clean filter Refill oil system. Loss? Eliminate or reduce bendings Reduce to admissible load Reduce pressure setting Find out the reason and eliminate defect

Pump or motor overheated

PUMP AND MOTOR

Wrong function
Pump or does not develop pressure

source of faults
Wrong pressure setting Pressure valve is jammed Fault in electric control Leakage in the system (Cylinders, valves) Control plate dislocated

Elimination
Change pressure setting and/or increase pressure Eliminate defect Check electric dia. and eliminated fault accordingly Seal system, replace defective parts Remove motor and eliminate reason Replace defective parts

Losses on r.p.m. on motor Motor cartridge defective

PLANNED MAINTENANCERECORDS AND REPORTS

A description of the symptoms and date detected. Description of the preliminary investigation and its results. Explanation of corrective action taken,replacement parts required,date repairs were made,and length of down time.

PLANNED MAINTENANCERECORDS AND REPORTS

Keep a record of when major parts are changed or major repairs carried out
These reports and records,if analyzed frequently,will indicate areas which require special attention as well as recurring troubles which may be anticipated and corrected before breakdown occurs.

SAFETY-DONT`S
Do not start the machine if it is not properly earthed. Do not run the machine without safety gates. Do not keep rear safety gate open. Do not run the machine if oil filter is damaged and/or oil is found contaminated.

SAFETY-DONT`S
Switch off the machine if supply voltage is more than suggested. Do not allow any foreign material to get into hopper.This can seriously damage screw barrel unit. Do not run the machine with base covers open as this will allow contaminants to go into the oil.

BEFORE BEGINNING SERVICING OR REPAIRS:

CHECK
Are the tools or possibly necessary eqt.available? Are the required spares(seals etc.)available? Are the safety requirements fulfilled? The main switch must be switched off and locked! If the machine is equipped with a pressure regulator:The pressure accumulator must be in an unpressurised state!