BILL OF ESTIMATE FOR COMPLETE ASSEMBLY

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       S.NO  DESCRIPTION OF ITEM     UNIT             UNIT PRICE                  AMOUNT(#)
     

          1         Pump casing                              I                     150,000.00                150,000.00

          2         Impeller                                     1                       50,000.00                 50,000.00
          3         seal housing                               1                       15,000.00                 15,000.00
          4          Gasket -larger                           2                          9,000.00                18,000.00
          5          Spigot ring                                1                        25,000.00                25,000.00
          6          Drain plug                                 1                          5,000.00                  5,000.00
          7            Stud (M18)                              16                       1,000.00                 16,000.00
          8           Nut (M18)                                 16                         800.00                  12,000.00  
          9           Cap screws (M12)                     4                           800.00                  12,000.00    
         10          Adapter                                      1                         25,000.00               25,000.00
         11          Inserts                                        1                          16,000.00              16000.00
         12         Guard lock screws(M16)            8                              800.00                 6,400.00                        13          Bearing ( NDE)                          1                           6000.00                  6000.00
         14          Lip seal                                       2                           10,000.00             20,000.00
         15          Roller bearing                             2                          10,000.00              20,000.00
         16          Breather and Filter                      2                          10,000.00              20,000.00
         17          Bearing Housing                         2                           10,000.00             20,000.00
         18          Ball bearing                                 1                           10,000.00             10.000.00
         19          Bearing retainer(DE)                   1                             8.000.00               8,000.00

          20         Capscrew (M12)                          4                             2,000.00               8,000.00                       20         Lock Washers                               2                               500.00              10,000.00

          22         Lock Nut                                     7                                  250.00              1,750.00
          23         Coupling key                               1                              2,000.00               4,000.00

          24         Gasket (smaller)                          1                               5,000.00              5,000.00 

MANUFACTURING COST AND ENGINEERING BILL OF ESTIMATE

        S.NO        DESCRIPTION OF MANUFACTURE   UNIT    UNIT COST   AMOUNT
          1             Purchase high speed stainless steel
                         material to specification in the
                          BS.Code 18/8 302S25 (Non-magnetic
                           material)                                                     4            16000          60,000.00
          2               Take to workshop,measure dim.as spec
                           ified in the drawing and cut in power
                           saw machine.                                              3             3,300.00       9,900.00
          3               Inspection of materials to standard spec.
                         Bs.Code.18/8 302S25 (note non magnetic matr.l)
                                 ref.Mech.Eng.Data handbookCarvill.                            4                  10.000.00         30,000.00
          4                Carryout keyway operation in milling
                          Machine.                                                       5              3,500.00       70,000.00
          5                Polish surface to dimension as in surface
                        texture specification                                        5              3,500.00       18,000.00
          6               Mark 25% for Labour cost total.                     1              51,000.00      51,000.00

DEFINITION OF PROJECT ACTIVITY .UNIT

                      THE NUMBER OF EVENT IN ANY PARTICULAR ACTIVITY IS TAKEN
                       AS UNITS OF THE PROJECT. THUS:
  S.NO                       ACTIVITY                     PROGRAMME OR EVENTS         UNITS

DESIGN DETAILS

   NAME :Dr.Engr.ONYIRI,Chimezie Zachariah
   
        

PUMP SHAFT- CONCENTRIC TURNING , DESIGN AND CONSTRUCTION SEQUENCE OF OPERATION -2

     
         

         

 S/NO.        DESCRIPTION                                                           TOOLS                                      8              Change tool to threading tool               thread tool,thread chaser,roughing tool and
              and cut M180 x 150 and rough turn            vernier caliper and steel rule.
                       dia.58.1x123      
 
 9.             Rough turn dia.42.1x109.5                             Rough turning tool,vernier caliper
                 to nominal size                                                                     steel rule

 10            Finish turn surface to exact dimension               finishing tool ,steel rule,micrometer
                 to its tolerance range of 0.0i(mm) and 0.02        and vernier caliper.

  11,           Drill end with dia14(mm) bit  to dimension         Attachment steady,vernier caliper
                 and tap to size with M16 X 150 and chamfer         tapping tool and drill bits.
                 45x2(mm) in all steps,debor edges and polish
                 surface to precise dimension..
  12          
               Unchuck job and mount and mount in vee-block             vee-block,surface plate,dial guage
                  block on a face plate to check diameter,with dial       with magnetic stand.
                  to exact surface roughness.
                                   
                                                          ALL DIMENSIONS ARE IN (mm)          

DESIGN OF A PUMP SHAFT, SEQUENCE OF OPERATION (CONCENTRIC TURNING.

S/NO                             DESCRIPTION                                                  TOOLS
  1                       Chuck HSS BAR IN THE LATHE MACHINE               CHUCK KEY, MEASU
                           ,DRILL AND POSITION TAILSTOCK,SURF              RING TOOLS,VERNIE
                            TURN TO IO6.1X351                                                 TAPE,ROUGHING TO
                                                                                                               OLS

  2                         SURFACE FINISH  dia 106.10x351 to dimension          vernier caliper,measuring
                             and rough turn surface to dimension dia..1x256 and         tape, finishing tool, rou
                              dia.85.1x251                                                               ghing tools.
  3                         Rough turn surface to dimension dia.58.1x221, dia           steel rule,roughing tool
                             55.1x200.5 and dia 40.1x76                                             vernier caliper.
  4                         Finish turn surface to exact dimension.drill internal          finishing tool roughing
                             dia.16 mm,tap hole to size of M18, chamfer ends            drill bits,tapping tools
                               to 2x45 for the entire steps,debor surfaces and edges.     thread gauge and  wire
                                                                                                                brush.
 5                          Re-chuck the job in the lathe machine by reversing the      End drill,vernier caliper
                             position,drill end and chuck the tailstock spindle              steel rule,chuck key,tur
                             rough turn surface to dia.96.1x201.5 and dia.85.1             ning tool.
                            x 196.5
 6.                         Check all dimensions specified in item 5. Surface              vernier caliper,micro
                             finishing should be within specified spec in design            meter screw gauge,dial                              drawing.                                                                         gauge .
7.                          Rough turn surface to dimension,finish turn with a             parting off tool,rough
                             Smooth tool.to dia 80 x 150. path-off 3x dia.75x3            ing tool, vernier caliper
                             rough turn surface to dimension,finish turn surface            steel rule and smooth
                             to dimension,finish turn with a smooth tool to             .     tool.
                              standard dimension dia 80x150.                                                                                                                                                                                                                                              

NETWORK NODES, NOTATION AND ANALYSIS.

              WORK PROGRAM AND NETWORK NODES
           
          S/NO       DURATION IN DAYS                        1   2    3    4     5     6     7       8    9        10
             1            PREPARATION AND
                           MACHINE JOB IN THE              
                           LATHE M/C                                      --------------- 

             2.           CUT KEY-WAY IN A
                            VERTICAL MILLING
                             MACHINE                                                          --------
             3.           LAP AND POLISH TO
                           SURFACE TEXTURE
                            SPECIFICATION                                                              ---------
             4.           INSPECTION MEASUREMENT &  
                            TESTING                                          -----------------------------------------------------





A-MOBILIZATION                                                                                                   2
B.PREPARATION AND MACHINING                                                                   3
C.CUTTING OF KEYWAYS IN A VERTICAL MILLING MACHINE                  4
D.LAP/POLISH TO SURFACE TEXTURE SPECIFICATION.                               3
E, INSPECTION AND TESTING                                                                              3
F. DEMOBILIZATION

DESIGN SPECIFICATION,SHAFT,AND PRIME MOVER.

A.ELECTRIC MOTOR:
                CASE         I           POWER I  HEAD  I SPEED   I   TEMP  I   FLOW   I        STANDARD   ------------------------~-----------------------------------------------------------------------------------------------     TRANSMISSION I 50KW   I  140M  I  3000 Rpm  I 60 OC   I    150 Cm3    I  Ansi (5-5), REF(5-8)
------------------------------------------------------------------------------------------------------------------------


B.SHAFT DEFLECTION:
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                                          DIAMETER AND MAXIMUM DEFLECTION
-------------------------------------------------------------------------------------------------------------------------                                106             I   96       I   85      I   58     I   55      I     40     I     42     I      80  
------------------------------------------------------------------------------------------------------------------------
                           0.00280         I 0.0004   I  0.001  I  0.003  I  0.003  I  0.012   I  0.01    I      0.001

SELECTION OF MATERIALS

It is important to emphasize that most construction or fabrication of rotating shaft involved some special test for the actual or the proper materials that will be used in such essential work. The test involved class of stainless steel materials that will be of a non magnetic structure.The stainless steel comprise a wide range of iron alloy containing more than 10% chromium.They classified Stainless steel as Austenitic,Ferric,and Martensite,But Austenitic Stainless Steel was selected for rotating shaft machining work, because of its characteristics, The standard composition of austenitic stainless steel are,18% Cr,18% Ni, 18/18 steel. the steel has high resistance to corrosion,good weldability,high toughness,a specially a low temperature and excellent ductility.It is good for production of shaft and non magnetic devices etc.

--------------------------------SPECIFICATION OF MATERIALS---------------------------------------------
                                   
BS Code               Remark               Yield Stress (N/mm2)        Tensile Stress (N/mm2)   Elongation    
---------------I------------------------I--------------------------------I-----------------------------I------------------
  (18/18)                   Austenitic                  630                                   700                               25
--------------------------------------------------------------------------------------------------------------------------
                                         
   
                                        COMPOSITION (%)                                                                                         
     C                              Ni                                     Cr.
------------------I--------------------------I-------------------------
       2                               8.11                                  17/19   

A DESIGN OF PUMP SHAFT INTRICATE AND PROCESS MACHINING.

The design of a heavy duty pump shaft may involved some intricate standard and professional cases, that may be reviewed to meet the necessary requirements for the production.And the presentation of the blue print (drawing) including the interpretation of the sectional details and the process adaptation and production.Such factors that militates the design must be taken into obvious consideration to with stand the impact of the load and the substance to which the design is investigated.The temperature and limitation shall also be determined..and all the load factors must be evaluated for effective performance. hence it shall be able to overcome the whirl velocity of the fluids..

THE JSA RISK POTENTIALS.

 Every project has some series of risks that are classified in their categories,implying that in the process of mobilization of personnel for a project, there are categories of risks that are involved such as the following i) Medium risk potential, and  high risk potential,
Arrangement of equipment and materials of a project also may involved :ii) low risk potential iii) medium risk potential and iv) high risk potential.
ALIGNMENT AND FABRICATION OF PUMP SUCTION AND DISCHARGE PIPEWORK may also involved the following series of risks, v) medium risk potential, vi) high risk severity, vii) medium risk criticality,and viii) low risk potential.
Finally the risk identification is one of the most essential issues to have in mind when classification of project phases are required.And when the nature of the traffic definition of the road and transportation becomes essential.

The symbols may appear in the following order,
P  Represents the risk potential
S  Represents the risk severity.
C  is Risk criticality
H Means high risk potentials
M Means medium risk potentials
L  is low risk potentials
 A risk is  a situation where there is likelihood of danger or being subjected to harm ,danger ,or probability of threat,of injury or liability that may be avoided by a preemptive action.

JOB SAFETY ANALYSIS - JSA 2

PUMP FINAL ALIGNMENT: Final alignment of pump and pipe work is completed,secured and  in place,the observable harzards may includes the following trapped hands,slips and falls,manual handling personnel injury.The accompanied precaution shall includes the following,good house keeping ,watch out for tripping hazards,ensure correct tools are used for jacking the pump into position,proper handling and competent personnels should be used .

SMALL BORE PIPE WORK AND INSTRUMENTATION:Hazard associated with such activity are as follows,manual and personnels injury,and other precautionary measures that shall be adopted are as follows,proper handling procedures and correct tools for each task to be performed..

MOBILIZATION FROM SITE.The event shall envisage transportation, operating equipment and materials and personnels.Associated hazards shall include the following.traffic, accident and vehicle breakdown,armed robbery attack along the road,impact and damage to facilities.The necessary precautionary measures that shall be involved are as follows,to drive defensively,use only serviceable vehicles and there shall be no night driving,while driving observe speed limits,and transportation shall be supplied by the client.There shall be no stepping along the way,maintain speed limit.Before embarking on the travel, there should be adequate good house keeping on the project site and.restate site after the work.

JOB SAFETY ANALYSIS ----- JSA-1

WELDING AND CUTTING:The most likely danger to encounter in hot work application is fire and the most important precaution to observed are: hot work permit must be duly signed prior commencement of the task.the permit. and fire extinguisher should also be available in case of fire.Only the person involved to hot work that will be adjacent in and around working area.Welding to be carried by certified personnel only. In case of burns good house keeping must be adopted by wearing the necessary personal protective equipment (PPE) specified, and all necessary restricted access must be identified.
GRINDING WORK:The same fire hazards identification and dangerous work system therefore the hot-work permit should always be in place before the actual work commence.The client fire wardens and equipment must be in place before the work commence.All fire equipment certification to be checked before the task starts, only person involved in grinding shall be in place and adjacent to and around the working area.To avoid incidence cases like burns, a good house keeping culture should be adopted,and proper personal protective equipment (PPE) must be worn.
WELDING AND PRESSURE TEST. The actual task for welding inspection is radiography for cracks, and porosity detection which might results to personnel injury,damage to equipment in and around the work area, whence inspection must be conducted for certification of the personnel only to avoid unprecedented situation.And the work must be carried out by the contractor at the site.Slip and fall must be avoided by making sure that correct personal protective equipment are worn.And also to ensure that the necessary tools are available at the site.

JOB SAFETY ANALYSIS, ----- JSA

The process engineering construction is very important and consideration are made in various area to fulfill the requirement of the project.It is way of an organised steps to enhance the mateial and human needs or requirements are the worksite,so it connotes observing the necessary risks that may arise in the process of the tasks and other equipment,human and transporting phenomena.Agood survey of JSA may involved the following steps.Description of the work activities,which may involved the following steps including the accompanied hazards while on mobilization for the project..
    .PERSONNEL TRANSPORTATION: traffic accident and vehicle breakdown,may require the following remedy ,drive defensively,use only serviceable vehicle.no night driving and driver to observe speed limits and transport to be supplied by the client and shall be careful for armed robbery along the ways so no stops along the way and personnels must be alert and observant.

   . ARRANGEMENT OF EQUIPMENT AND MATERIALS TO THE SITE.:May be associated with the following hazards,awkward lifting and fall of materials,road accident while driving on the road,unexpected intersection by community or robbery attack along the way.and impact on facilities and other damages.loads must be carefully secured and covered ,the driver and vehicle must be certified and the speed limits observed and personnel must be responsible for the arrangement of materials.
  .ALIGNMENT OF PUMP TO DRIVER:there might be following series of hazards,slips,trips and falls,trap hands, manual handling and personnel injury. the remedial steps might be the following ,good house keeping,watch out for tripping and hazards.ensure correct tools are used for lifting pump into position,and proper handling procedure,competent personnel should be used.

  MODIFICATION OF SUCTION AND DISCHARGE PIPEWORK:removal of main pipe work and falling load, the following hazards may apply,injury to personnel or damaged to equipment in and around the working area, personal and damaged to equipment.certified slings and shackled to be supplied by the company and all other lifting equipment by client,all lifting and slinging to be carried out by the company and client representative in accordance with the company lifting plan..

 .COLLISION WITH OTHER EQUIPMENT:May involved lifting equipment,damage to equipment,personal injury,slip and fall,of material,damaged to existing facility. and the following steps shall formed the remedial steps involved :plan lift and route. check all certificates and test date of all equipment,secure materials properly,Ensure personnels are aware of task when lifting pipe work into position.use correct tools for tasked performed. and apply proper handling procedure..

CONSTRUCTION SITE AND FABRICATION PROFILING

In most construction site tents are prepared for fabrication of  bracket and inspection is conducted on the accessories before the application techniques and further modification of the process design. And such processes may includes the following i) welding, ii)grinding,iii)brushing and iv) painting,which should be coated and  performed to suite the specification . Moreso a grinding wheel will not be mistaken for a cutting wheel despite the specification that exist between them,because where adequate training is not provided in a construction site,anomaly on the activity is possible ..An effective gas leakage test is also conducted by using a calibrated explosive meter instrument, including an environmental sanitation to avoid unforeseen disaster .If a welding or grinding work is to be carried out, each section of any of the area to be grinded or welded should be fully accommodated in the the tent.And some fire extinguishers are located within the grinding zones. It is imperative to fit pump suction and discharge spools to the expected recommendation. And the alignment of the adjoining flange to flange of the gearbox and pump be obtained as data derived from the measurement will be in the order of the expected priority of concentricity or results.

THE SITE FABRICATION ,MEASUREMENT, EVALUATION AND MATERIALS AVAILABILITY.

1.   The activity areas are carefully supervised ,material losses are also minimised. So the construction and fabrication of materials are essential and very sensitive to the smooth operation of the contract and material storage facility. Fitting application including the welding techniques facilitates the activity phase of the project and completion interval of each to avoid unexpected material wastage. There is need for adequate security and  accurate measurement of engineering profiles and data .The consumable are also controlled with some standard parameters to conform with the phases of the projects.It is very important in every construction or project site to ascertained that material storage are controlled through the engineering secretary or store keeper.It is good idea for a project to be technically sound, and effectively fit to identify the materials needed for each phase of the activity .And it will also be nice to provide an avenue to control essential equipment inventory. A safety officer shall also be enabled to audit the site which shall serve as a way of communicating and regulating   proper wok procedures, for instance the tent for welding work may require inspection and test to avoid an unsafe work.

PROJECT DETAIL ,2

The methodology of project shall conform to the activity stage, and the visual outcome would be discussed at the management meeting each morning and evening after the day activity, and it will be in consistent stage.The contractor report of  the site performance and other related activity shall be presented in each meeting with the company management indicating the scopes and stage of completion.the process of construction and fabrication including validation of permit for daily toolbox meeting and site inspection takes place morning. And thereafter the site will be tidied or cleaned after the daily activity. it is also imperative to have effective site supervision making sure that all the fabricated parts meet the regulated standard and specification of the design.

AN ENGINEERING ACTIVITY REPORT PRESENTATION .

The contractor arrived at the site at a certain time but there seem to be problem to pass through the main gate of the operating company but it was finally resolved. They were taken to the department that had the project and were introduced to the safety department for actual identification and orientation by the safety officer. A tag-in and tag-out identity card were issued to the contractor company.The contractor operating equipment and devices were located to a suitable place, for easier accessibility to the project site and would be provided accommodation in a favorable area, if it were  part of the contract agreement. And while the activity will be ongoing the reports shall be stated thus:
a. Arrived at the site and there was entrance issues,contacted the department concerned and the issue were finally resolved.
b. The truck conveying equipment and tools for the job arrived at a certain interval and it was located at the preferred warehouse .
c.The approved permit were signed and validated,toolbox meeting was convened at the site in the presence of all the personnel .Thereafter the recommended procedures and safety protective tapes and isolation of the processes were also performed including explosive meter test which was conducted in the presence of the client.
d.The basic requirement that defined the activity at the site was the plan, and the orientation  program which involved site precedence diagram and the nodes, and was presented to the site management of the company.It also enabled their activity planning to conformed to the requirement of the contractor. .The instrument process and loop diagram were also re-evaluated, and traced, whether there were changes from the original design. Its conformity would activates the operating plants efficiency, after the modification. It was also necessary that while the exercise of the modification was ongoing, the company provided the construction contractor their meeting plan and regular operational details and consistent re-evaluation study of the project.

HEALTH SAFETY ENVIRONMENT AND SECURITY STATEMENT OR POLICY.

In the process of the implementation of the project, the following statement shall be formed to ensure safe completion of the contractor task and effective performance and deliverance of the project.
There shall be induction courses that would be organised by the client on the system of the site operation,which will illustrate the way of the work permit in every daily activity and the method of documentation including the materials storage system and cases of emergency procedure shall also be addressed.The following steps shall be adopted:
i, To make sure that the permit to work signed every morning and the accompanied documentation          distributed to their various location.
ii.The personnel health,safety,environment and security is given the highest priority over all the other      activities
iii.Toolbox meeting shall be convened and documented prior to start the work and also addressed             associated harzards,
iv.To Provide adequate personnel and appropriate protective equipment (PPEs) to all the workmen involved in the project task.
v.There shall also be displacement of awarness posters, safety tape, sign board,at strategical position in  the event of the task execution
vi.If the work activity is not safe, do not start,but where it is started do not continue.
vii,There shall be emergency response procedures at the site of the job execution.
viii.There shall also be construction, logistics, and installation safety procedures at the site and in the event of the contract.
ix. The tag-in and tag-out procedure to the project site and in the event of the contract execution shall be given the appropriate priority and mandatory it deserved.
x. The protection of the area for welding, hydro-test,and x-ray zones with red safety tape ,and resistant tarpaulin including fire safety gas sensors to avoid the occurrence of accident and incident is mandatory.
xi. The site of the construction work shall be inspected with explosive meter prior to the job execution on each daily activity.

PROJECT RESPONSIBILITY

There are series of work that are usually performed in any project site, though not minding the classification but the programmes define the interval in which it may fall.At  present the assumption  is pump installation or reconstruction of the process loops,for instance the discharge and the suction lines modification.The mechanical Engineer responsibility may includes the following steps: i. preparation of the materials,
ii.Revision of the implementation and follow up of the modified drawings, which may includes the following details:a. Establishing and execution of modification schedule and sequence b.Control of modification documentation and drawings.
                 c, Overall site safety management.
                 d Ensure proper quality assurance QC and QA and the safety plans.
                 e. Provide as  built drawings,
Equipment and tool list that will be required in the sequence of the task and execution of various plans may involved such as stated below:
Hydrotest pump.
Air compressor
Pressure guage of various range, 0 -100 (bar), 0-150 (bar),0-250(bar) or may be calibrated in Metric range to suite the site requirement.
Vibration analyser
Lincoln welding machine
Oxy-acetylene rack and gas cylinders
Welding torch
Travelling block 10-25(tons)
Crane of about 25(tons)
Dye penetrant equipment
X-Ray equipment
Mechanical toolbox
Portable grinder
Measurement and inspection instrument,dial gauges,magnetic stand
Vernier caliper,micrometer gauges,steel rule,measuring tape .
Power drilling machines
Classified lifting belt
Battery drilling machine
Rotalign instrument

WORK SUPERVISION AND WORK PERMIT ORGANIZATION.
The permit to work shall be raise based on the client project work program and recommendation ,which may also conform with their schedules in the project work program. The phases with the accompanied project nodes and precedence diagram will define the work scope of activities on hourly interval and the required man hour. In some organization work permit is always prepared within 48 hours. And is one of the mandatory requirement and a certificate for the work execution and commencement.
A supervisory department shall also be informed of the project specification and the period of commencement of the activity. The necessary personal protective equipment shall  also be a mandatory requirement and shall conform to standard specification of the company or client.
On commencement of the activity pre job safety meeting and tool-box shall be conducted at the site on timely interval.The contractor first aid box shall always be available throughout the operation including the first aider .The company shall educate the contractor of the necessary steps involved in any safety alarm and other methods of tag-in and tag-out systems which will enable successful sequence in the project construction and execution. A supervisor shall be attached to the contractor to ascertain that the project is adequately supervised to conformity.The client work permit rule for validation and audit shall be applied at the site when necessary and as an intricate requirement to conformation.All the personnels on the job shall ensure good house keeping and after the job, and all the generated waste shall also be evacuated in conformity with the client management procedures and policy. No other job that will impact on the contractor will be done during the activity interval. The facility manager will approve all the necessary each work permit before the work will commence on each day.

  

VARIABLES IN MAINTENANCE WORK AND INSPECTION CULTURE

In most countries of the world there are organisations that are established for purposes of serving the public interest as well as the client by promoting the security of plants,property ,design specification and survey in a standard format. These standard are only best interpreted by the community of professionals involved in the acts and of cause an entire culture that is adopted at its best , like  a decorum..:Their primary objective are development , verification and conformity  of standards for design construction  and maintenance application and operation of oil and gas factories.and other related activities.They deals with the policy of standardization and provides quality services in support of the mission, and to response to collective needs  of the client commitment and supportive actions and services. The services can be organised as expression of quality and the pledge to monitor operational performance as an ongoing activity and to strive for continuous improvement.In recent years there has been  an increasing reliance by owners on store based personnel, for repair and maintenance of machinery on board vessel and offshore structures (ABB,2003). Planned and condition based maintenance are the two techniques presented in this project and other related activity which could be used to assist the owner of oil and gas in maintaining machinery . these techniques are used concurrently to the planned maintenance which is the setting formal schedule for maintenance and overhaul of machines running hour or calendar hour which may be used for establishing a schedule.Such schedules are generally established by the manufacturer and includes lubrication servicing, bearing and seal replacement as well as minor and major overhaul.
Condition based maintenance involved the use of diagnostic technology to monitor machine condition. this process involved establishing a based line and operating parameters , then periodically monitoring the machine and comparing any change in operating condition to the baseline. The repairs of replacement are carried out based upon the detection and fault diagnosis of the machine towards a condition of failure.The common tools used in monitoring are vibration analysis, oil analysis,ferrography, thermography,electric current, wave form analysis and stroboscopic examination. Supplemental technologist such as demodulation ultrasonic analysis, shock pulse and spike energy, HFD etc.roller bearing element condition monitoring may be used in addition to liberation analysis. Measurement are taken in periodical hours.

HEAT EXCHANGER TUBE INSPECTIONS

The inspection of heat exchanger boiler ,turbine , engine and boiler are executed by the following optimal selected technologies,

 Multiple frequency eddy current
 Magnetic base eddy current
 Remote field eddy current
 Rotascan (rotational  eddy current system).
 Iris(rotational ultrasonic system).

Continuous inspection is of utmost importance for the company and its operations and serves to achieve the following.
Detection of damages at an early stage in order to maximize the life time of the component and the cost effective planning including  the repairs.
to avoid unforeseen plant shut-down due to component damage.
Avoid secondary damage of high value components
Avoid environmental damage and distraction of the company image.
Avoid reduction of the product quality.
increase operational safety and fulfillment of authorities requirements.
Achievement of the best analysis of production or process caused damages.
Inn-inspection may involved high level of tube inspection experience and accurate defect analysis. Advanced technologies offer high defect detection capacities and accurate defect analysis .With high inspection speed and low cleaning requirement. The cost of effective inspection are able to inspect the ferromagnetic and non ferrous magnetic tubes as well as fin fan tubes..Due to its embedded of advanced and comprehensive importing software, the clients are provided with the precise and accurate condition overviews as well as the result for individual tubes .The real time result is  also available while the inspection is in progress. The inspection  overview of the various heat exchanges  and boiler  tube inspection techniques can be illustrated as follows;
 the fan inclination and declination.
 the redial displacement of bearing or fouling
 the alignment and fracture etc.
 the tubes fins and cracks including rupture and twist.etc
 vibration due to slacken fixtures. etc.

EXPERIMENTAL ANALYSIS AND RESULTS., BORESCOPE SURVEY AND EQUIPMENT

Applications and properties

pump casing
turbine bore
cylinder bore
orbital weld pipe operation
fuel injector body
pipe inspection solution
close fitting inner diameter
large cavities - multiple object distance
very close focus
ultra violent ( uv) illumination
sheating types
video equipment and light service
intersecting passages
infared application
high magnification
high temperature.

Tools and Instrument
Mechanical too box
Electrical extension cables
electrical tool box
adaptable plugs and sockets
inclinometers
printers
computer systems CCD AND LCD Monitors

Equipment and Apparatus.
milliscope 1.5(mm) diameter
                  2.5(mm) diameter
probe and micro tubes
zebra scope
4(mm) diameter
6(mm) diameter

muilti division
zebra scan
muiltscope probe
muitiweld 

PROJECT PERSPECTIVE.

The following sequence can be adopted in the process of a piping modification activity of an expedition pump,installed in an export process line ,they may includes the following steps or procedures:
Disconnect suction and discharge pipe work including the auxiliary pipe work
Clear and flush lines before any hot work.
Cut off flange after valve on suction and discharge lines
install spectacle blind and flange suction and discharge lines
Assemble suction and discharge lines and adequately supports.
Access and evaluate extent of modification work to be perform on suction and discharge lines
Tack weld suction and discharge pipes
Remove suction pipe and weld fully
Radiograph all welds.
Dye penetrant and test all welds
Hydrotest suction and discharge pipes and lines.
Remove blind flange on suction line
Reinstall suction line and fix the pump on temporary supports.
Monitor coupling alignment
Remove blind flange on discharge lines.
Reinstall discharge line and fix the pump on temporary supports.
Rerun the coupling alignment,
Finalized pipe supports.
Make up the drain lines offsets on both suction and discharge lines.
Recheck coupling alignment and reconnect auxiliary pipe works.
Confirm pump and gearbox alignment.
Conduct pre-commissioning inspection
Commission pump and hand over to production department.

PROJECT PERSPECTIVE.

The following sequence can be adopted in the process of a piping modification activity of an expedition pump,installed in an export process line ,they may includes the following steps or procedures:

ABBREVIATION

The list of abbreviation are often commonly applied in definition of standard and specification of data in a project. It illustrate the region or scope of terms in the documentation of the work.,And they are illustrated in such a system that will enable the specialist to know exactly the requirements and process of the implementation and presentation.It is important for every engineers and specialist to have good knowledge of them for reference purpose,it includes the following:
API 13,31&32 -For flushing of coolers and other systems.
API 21- flushing systems with abrasive products that are incompatible.
API 682 - Piping plan designation.
ASTM D833- Fracture mechanics,testing and inspection.
ASTM D3306 - unacceptable silicate coolant specification.
ASTM D4985 - Acceptable coolant specification
CBM - Condition based maintenance
CCF - Common cause failure.
CMMS- Computerised  management of maintenance system.
DDT - Digital data transducer.
ECM - Electronic control module.
FARADIP - Failure rate data in perspective.
FMEA - Failure mode effect analysis.
FMECA - Failure mode effect critical analysis.
IU7298 - Cooler tested specification.
LCC - Logistics cost category.
MOSAIC - Maintenance operations system and integrity checks.
LUBRICATION - NGLI 1 to NGLI 3
MRO - Maintenance repair and overhaul
MTBI - Meantime time between inspection.
MTBM - Meantime between maintenance.
NLCC - Non logistics cost category.
NPV - New present value.
O & M - Operation and maintenance.
PDM - Predictive Maintenance.
PLASMA - Plant Stimulation Analysis.
RAM - Reliability Availability  Maintainability.
RCM - Reliability centered maintenance.
ROI - Return on investment
SAEJ 1349 - Specification of machine plan rating standard.
SENIR 313D - Torque specification of caterpillar
VRU - Vapour Recovery Unit.

  

engineering profiling

ball valves

maintainable devices , inspection and profiling

THE BELLOW ACTUATED FLOW METER

The bellow actuated flow meter of consist of the constant high pressure and,low pressure chamber that are seperated with liquids and they are classified as filled below assembly.The left hand assembly consist of calibrated range assembly whose function in conjunction with bellows movement is used to measure pressure drop across primary elements. A connecting rod is connected to the left hand of pressure bellow and extend over to the right side of high pressure bellow, at which point there is an interval called spring. This connecting rod has the upper end of the triangular shaped torque arm attached to it by a cable assembly which is always in tension. The lower end of the torque arm is connected to a torque tube.Any horizontal movement of the connecting rod is therefore converted to a rotary motion of the torque. This motion is brought from the meter body unto the instrument case as a shaft rotation and used to actuate the pen linkage. The angular rotation is approximately 8o between the flow and maximum flow,Most bellow flowmeters meters are of the same general design The bellows are hydraulically formed: those of other make are of a welded construction. The internal parts of all are available, including the bellow made of type 316 stainless steel to provide maximum resistance to corrosion..There are various types of liquid filled  that are used by a different manufacturer which covers the operating temperature  - 5717 to 232 oC The manufacturer should be consulted as regards the special available oxygen intake measurement and includes lower and higher temperature of the secondary elements and the two complete systems.
A wide range of spring is available for measuring the pressure drop across the primary element for flow measurement . In addition, to terms of meters per minutes per second are used for measuring pressure drop across process vessels. bellow activated flow meters are also available for operating pressure up to  a maximum of 5000 psig. It is imperative therefore to operate the instrumentation of the machines to form operating element of the designs.

FLOW METERS

Mechanical flow meters are classified as rate meter because they measure and record or locates the rate of flow when measuring liquid or gases, the fluid are in direct contact with the actuating elements. when steam is measured, it condenses to water in the connecting pipe at atmospheric temperature  and is in contact with the actuating elements. the rate of flow is determined by measuring the drop in pressure of the fluid flowing through a restriction in the flow line. The restriction is shown in the primary elements. The flow meter has several designed of secondary actuating elements which are available and are in used in the industries. A early design is a mercury manometer , with flow resting on the surface of the mercury  manometer , with the flow resting on the surface in one leg .of the manometer .T he flow condition changes as flow varies and by a linkage mechanism. The pen or pointer is moved to correspond with the new rate of flow.for several reasons, such lower cost and easier installation and maintenance the use of  mercury less meters is  increasing rapidly, There were two general types ,i.e  (i) differential meter for measuring  pressure drop and its motion, (ii) the other type measures the pressure drop with a capsular assembly and transmit a standard of about 3 to 5 psig pneumatic signal. Most manufacturer published an accuracy of plus minus 0.5 percent for full scale displacement, for bellow meters. If an installation require better accuracy, it could be obtained by recalibration.
The general published for pneumatic transmitter is plus minus 0.5 percent for full scale displacement. Both types could be operated up to temperature  of 232 degree centigrade of the fluid in meter body.

RECORDING INSTRUMENT.

Recording Instrument: A  relatively small numbers of recorders are used to record only the value of the process variables, a large number of these records flow with the total amount indicated by a mechanism.The majority of the recording instrument ae used for automatic control application, for this application,254(mm) to 304.8(mm) charts are the most desirable because of greater accuracy in reading and positioning the set point and a better opportunity of observing process trends. Recorder are available with one ,two, three, and four pens, Ink of different colours could be used and by using an eccentric scale which follow the time line of the chart and pointer on the pen arm .It is possible to have a combined recording and indication instrument. The use of a printer has been in used for so long that they are recently available with literally thousands of calibrations including those for a single variable and others multiple segments for two or more variables. The standard chart speed is the 24hrs revolution ,but many other speed and the required drive mechanism available. The drive mechanism may be electric, hand wound springs drive or pneumatically operated.

MECHAN-TRONICS VARIABLES

Mechanical instruments provides an accurate and economical means of measuring the status of nearly all process system. The instrument that measure all critical performance of process system are essential for all predictive and plant improvement programs. The information derived from process are used in-conjunction with vibration monitor,parameter infrared, interrogator to monitor predictive maintenance instrument, and other devices.  Mechantronics provide means for maintenance experts to liaise effectively  in any technical challenge and the method to enhance appropriate troubleshooting. and optimize the process. And the instrumentation aspect is divided into two variables i)Monitoring and Control..
 Process Monitoring: Mechanical instrument are mostly used to measure, record and trend variation in process parameters, such as pressure, low or temperature. In most cases the instrument convert mechanical displacement or movement of its sensor into corresponding proportional movement of a pen or gauge. These instrument generally transfer actual value of the measured parameter by means of a linkage mechanism,to a graph or displacement that is a part of the unit.
Process Control: The principle of the instruments are identical to those for the purposes of monitoring.In this instance, the instrument will translate the actual mechanical displacement into a proportional output, either pneumatic or electrical, that is used by the system control logic to adjust the process parameters.
Most process variable could be measured with mechanical instruments and may include the following:i. flow, ii. pressure iii. temperature iv.level and v. positions.The limitation are few, e.g pressure in micron range , temperature above 537.8 oC, and analysis of fluids.New designs and  materials for actuating element provides acceptable accuracy and sensitivity that are suitable for most applications These factors in addition to ruggedness include low cost and ease of maintenance,have resulted in an increasing use of mechanical instrument.for both monitoring and control of process system.In the industry they are classified by case size,type of recorders or indicators and form of charts or scales,In addition to the record or indication for the process variable instrumentation could provide automatic control integration of flow and adjustable alarm or signals for abnormal operating conditions.
Recording Instrument:A relatively small number of recorders are used to record only the value of the process variable,  A large number of flow with the total amount indicated by a mechanism.The majority of the measuring instrument are used for automatic control application.For this applications, 254 (mm) to 308.4 (mm) charts are the most desirable because of greater accuracy in reading and positioning the set point and a better opportunity of observing process trends .  Ink of different colors could be used and by using eccentric scale which follow the time line of the chart,and a pointer on the pen arm. It is possible to have a combined recording and indicating instrument. The use of  printer has been in used , for  so long that, they are recently available with literally thousands of calibration,including those for a single variable and others having multiple segment for two or more variable. The standard hour chart speed is the 24 hours revolution but many other speed and the require mechanism are available. The drive mechanism may be electric, hand worn spring drive or pneumatic operated.

MAINTENANCE STORE AND INVENTORY CONTROL MANAGEMENT

There are various factors which affects the department ability to control cost. Among these are the age and the condition of the equipment, the skill of the labour force;the amount and the quality of information available to make decision, The size and the value of the store inventory to mention but a few.The inventory is a costly segment of the maintenance department budget, that until recently has not  much attention. In most company any reference to inventory usually implies production, work in progress or finished goods inventory, all of these are recognized as an asset in the general ledger. As an item on the general balance sheet they are continuously scrutinized and managed. Maintenance inventory on the other hand is less dynamic and often tend to be material shelved  to insurance purposes.Typically the maintenance  inventory when purchased is recorded as an expense and rarely shows up as a financial report this occurs despite the fact that its values in some larger plant could be several million dollars, (Ann,1995). In order to manage this inventory effectively, it is necessary to know its content and values.It is equally important to plan department actively similar to the way the production manager anticipate a production schedule. In such condition parts and supply are available when needed and not sitting for months even years before hands.In addition timing is critical when preparing production equipment in order to meet the goal of maximum availability. The maintenance planning system could be a microcosm of the overall business. these should be equivalent to order entry, production and bills. At the same time history records production improvement and cost  reduction programs should be recurring.The cornerstone of any maintenance planning is the work order.It serves as historical records and includes material cost and labour expense.Too often in some country history the work order,upon completion, is discarded or filed and never seen again ,thereby housing valuable information.More importantly the completion of a work order represent accumulated history of a piece of equipment,By analyzing these data, it is possible to anticipate repair practice preventive maintenance and avoid costly lost production potential poor quality.In addition with the many of the new technologies available, equipment can be diagnosed and until failure can be predicated.

MAINTENANCE PLANNING

Material and Parts Received: As the material and parts are received , they are  changed to work order , but when all the parts are received then the work order status is changed  from pending materials and parts in the backlog files.
All materials, parts and tools  are tagged to identify the work location and supervisor that would be responsible for the work, would  planned the work order accordingly. The planned work order status is changed to the appropriate ready to run category and it is placed into the back log file.
The work order is plotted from the backlog file with the  weekly schedule that be will handled by the work Supervisor..Effective planning requires observing planned job progress to eliminate potential delays or the problems that may arise.The planner should occasionally observe planned work in progress with the intention of improving his pre planning expertise.
During the follow - up process,the planner may address problem areas which are common to planning functions.These areas are:
Ensure that the communication is clear and adequate for all personnel involved on the job.
Ensure the planner time is properly utilized.
Ensure the translation of the job plan - is clear and understandable terms.
Remember the goal of planning is to eliminate the cause of the job and to eliminate the job in the future. To repair quickly is not the basic goal. The reason for maintenance planning is to eliminate the cause while overcoming the effects efficiently.

OPERATING A GOOD CHARACTERISTICS OF A GOOD MAINTENANCE MANAGEMENT SYSTEM

One of the prime characteristics of a good good computerized maintenance management system is that it has on-line inquiring and provide screen reviewing for the areas of work orders, materials and equipment.The work order is the controlling document in any maintenance management control program.When viewing the work order on a screen in a computerized program, the following information should be readily available ,
---The equipment in which such job could be done.
---The description of the work to be done.
---The level of the job priority
---The responsible charging centre for the cost incurred.
---The date the work order was written and the last date of the job and completion.
---The work backlog current status.
---The time required by craft in which the work could be completed.
---The work backlog current status.
---The time required by craft in which the work could be completed.
---The cost of labour required and material that is charged against the work order.
These are the information that may be desired but the forgoing are necessary for good maintenance management.It should also be a program that would be able to select and bring up work order for observation.However the selection criteria shall include the following:
- Cost area
- Equipment number
- Dates written,issued, completed or last worked.
- Priority level.
- Backlog status
- Cause or action taken
- Trade for instance medical,electrical,mechanical,instrument, .
- Supervisor
- Planner.
The section shall also have the ability to view
- Vendors performance specification
- Maximum and minimum qualities.
- Costs
-Recorder quantities
- Usage information on a periodic basis
Equipment --- the third level of a good maintenance management programme concerns equipment.Screen viewing for the selection includes.
-  Equipment list
- A work order list for this piece of equipment..
 

---

COMPUTERIzED MAINTENANCE MANAGEMENT

Organizational for implementation  of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows: The performance of the maintenance function planning and scheduling.

A. The performance of the front - end load semi permanent information such as cost centre,   employed list ,parts list and equipment list, cause code ,action code, budget or other information that is not changed on a daily and weekly basis, The definition of sequence necessary for the loading of this data are also included.

B. The system of maintenance of the files on a daily and weekly basis involves several persons such         as: i) A planner to load work orders. ii) A time clerk to load employees time sheets , iii). A store room clerk to load material requisition or any other appropriate combination. It is advisable to have individual information flowchart for streamlining of the system information ..

C, The performance of the security that is going to be part of the system, The definition and the procedure that should  be established as to who could enter and or modify information in the system various segment and reports updates.

D. Th performance form of data entry should also be designed for data entry, they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
 The orientation of the various people concerned with the new computerized maintenance  management program is most important step after the organization.  This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff. The detail of the maintenance appropriate for the various  groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different. The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program. The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures  for correct data inputs.
---Appropriate maintenance personnel planners and supervisors  etc plans on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance  management is a demanding task, the benefit are normally significant, but it will enhance the following :Better labor utilization., 5 to 23%
                                                                        Equipment utilization 1 to 5%
                                                                        Stores inventory reduction 10 to 20%, (Richard,2005).

COMPUTERIzED MAINTENANCE MANAGEMENT

Organizational for implementation  of a computerized maintenance management program is one of the job of project team. Its implementation system and definition of the items would have to be stated as follows:The performance of the maintenance function planning and scheduling.

A. The performance of the front - end load semi permanent information such as cost centre,employed list ,parts list and equipment list, cause code ,action code,budget or other information that is not changed on a daily and weekly basis,The definition of sequence necessary for the loading of this data are also included.

B.The system of maintenance of the files on a daily and weekly basis involves several persons such         as: i) A planner to load work orders. ii) A time clerk to load employees time sheets,iii). A store room clerk to load material requisition or any other appropriate combination.It is advisable to have individual information flowchart for streamlining of the system information ..

C,The performance of the security that is going to be part of the system, The definition and the procedure that should  be established as to who could enter and or modify information in the system various segment and reports updates.

D. Th performance form of data entry should also be designed for data entry,they should be computer-able with the computer entry format and include work time sheets and materials acquisition, (Richard,2005).
 The orientation of the various people concerned with the new computerized maintenance  management program is most important step after the organization.This may take place as part of the organizing.. The orientation will be necessary from the highest levels of the facilities organization.to the lowest and including production staff as well as maintenance staff.The detail of the maintenance appropriate for the various  groups would be the cause element different. It is also appropriate to have concise progress review session as the information takes place. The orientation and the training are similar but there is some different.The orientation is informing people of what is going to be done or what is being done while training is instructing people on how to do something.
The training of personnel are the critical aspect of implementation of a computerized maintenance management program.The training minimally should includes the following:
---How to write a work request.
---How to follow up the priority system.
---How all data could be entered and the necessary procedures  for correct data inputs.
---Appropriate maintenance personnel (planners,supervisors etc) on how to retrieve information.
---Maintenance management and supervision and appropriate maintenance production management on how to read and interpret reports and other available information.
In summary ,computerization maintenance  management is a demanding task,the benefit are normally significant,but it will enhance the following :Better labor utilization., 5 to 23%
                                                                        Equipment utilization 1 to 5%
                                                                        Stores inventory reduction 10 to 20%, (Richard,2005).

MAINTENANCE REPORTING SYSTEM , CONTINUE -1

The maintenance department will  assigned the service number as it received the work order and will then multiply the two numbers to achieve a priority number in each work order.,The lowest priority is then the number 2 and the highest priority is 90, the work order with highest priority number should be schedule first. A portion of the maintenance hour available,starting from 10 to 30 percent should be assigned to priority work lower than 30. This priority considers potential failure costs and keeps low priority equipment and department operating. The control aspect of PS is two fold The average PS by craft, identifies how important the backlog is for each craft and for maintenance in total.The average PS number by production department and or in the case of multiple plants provides knowledge of  the average level of maintenance.The PS number and man hour weighted average involved for each craft and each production involvement is calculated.The constrains of the activity can also be determined through the man hour of activity nodes and network evaluation data .Therefore the lower the man hour of any activity the  easier to approach, but in most maintenance activity there is always a case sensitive and priority.,For instance, compare two jobs,one has a PS number of 90 and requires 3 man hours of work by an electrician or mechanic,Another has a PS number of 30. and requires 1 man hour of work by an electrician. The weighted average would be :
90 PS x 3 man hour = 270
30 PS x 1 man hour =   30
addition of the man hours is equal to 300 man hour divided by the total man hour,would results to ,75 average.The minimum use of a system will easily identify acceptable control limits for many things, for example:
1.Authorize overtime for a work order with a PS number of 42 and higher
2.Sub- contract or add man hour in a craft with an average number of PS number of 56 or higher for more than 4 weeks and a constant trend up.
3.Transfer assigned manpower from lower priority to higher priority departments until the average PS number in the department reaches 42 or lower.                                    ---------