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Monday, August 28, 2017

LITERATURE REVIEW-4A


The cross - correlation of eddy current images for detection of fatigue crack propagation by MOORE and others (2001), directs that there is a need within the NDE industry to calculate the growth of damage such as fatigue cracking and corrosion over the life of a structure. Charpy impact testing was performed to determine impact test and properties as a function of temperature,in one case to verify the compliance with requirement and in other case,as part of a temper embitterment assessment. Fracture toughness crack tip opening displacement (CTOD) testing was performed to obtain the fracture toughness required in the assessment. In the remaining cases the small samples were used to obtained tensile testing specimens and to perform direct metallographic evaluation to determine the nature and extent of the degradation that the steel suffered during service.A total of twelve half size Charpy specimens were machine from the samples that were extracted. Since these samples were small to carryout the Charpy impact tests, extension taps were welded to the end of the test materials where the v-notch was machined. The absorbed energy and the transmission temperature depend on the size of the Charpy specimen and since half size specimen were used, the correlation by API RP 579 was used. For half size specimen for the absorbed energy conversion of full size was achieved by multiplying by two. The procedure is to determined the transmission temperature and then add 11oC
(12oF) to account for the temperature shift in using half size specimens. The impact results at -12oC and -1oC (10oF and 30oF) are shown in figure 2.

Saturday, August 26, 2017

LITERATURE REVIEW- 4


In statistical approach to underground corrosion carbon steel pipeline by KOGAS (2001) in field corrosion studies were that performed on polyethylene (PE ) coated carbon steel transmission pipeline laid  underground in Korea, Chemical and biochemical analysis of the soil adjacent to coating defects were performed in both fields on laboratory. The factor controlling corrosion were considered by linear regression analysis,Principal components (PCA) and multiple regression analysis,
The corrosion site had strongly positive correlation with the chemical factors such as low pH and high level of chloride,and anaerobic nature soil that promoted the growth of surface reducing bacteria (SRB). Characterized by low level of soil resistively and reduction - oxidation potential and finally on pipe to soil potential.It was proved that the statistical described results of field and laboratory works satisfactory. Finally the precision equation for the maximum corrosion depth of carbon steel and soil environment is presented. It is important that the chemical,biochemical and cathodic protection (CP) effects should be considered together for the precise prediction of corrosion behaviour i.e the environments.

Thursday, August 24, 2017

LITERATURE REVIEW -3


The presence of a network of ferrite particles in an austenitic matrix acts as a barrier to crack propagation, thus enhancing the resistance to stress corrosion of the material. This effects associated to the morphology and distribution of the phase rather than its contents welding in a direction parallel to the stress using reductively high heat input improved,the stress corrosion of the material even further. The HAZ ( heat affected Zone) of AISI 304 Steel was highly susceptible to stress corrosion in chloride solution. The presence of carbide precipitates in the austenite grain boundary deteriorated the corrosion resistance of the steel, as they promoted anodic dissolution and the development of the stress corrosion cracks .
A recent literature review by KOVACH: and others (1993) identified thirty seven publications involving MIC - micro biologically influence corrosion) and stainless steel focus on those which involved the high performance stainless and stainless steels in an effort to determined whether or not MIC poses a threat to the engineering application of these materials .It is easy to summarize the characteristics which are generally regarded as representative of MIC  and help in distinguishing MIC activity. These characteristics have been identified based on service experience and were first detailed by Tatnall (3) MIC which is characterized by:
        (a) The pressure of the distinctively shaped coloured deposits that are usually soft and easily                     deformed.
        (b) Large cavities under pinhole surface penetrations or open pitting,gouging, and stunningly.
        (c) Frequent association with welds.
        (d) Rapid rate of penetration.
However, it is important to know that these corrosion characteristics are not limited or attack by MIC.
It is generally accepted that opposite identification of MIC requires confirmation of the presence of aggressive microbial species in substantial quantities and the elimination of other possible corrosion mechanism.

Wednesday, August 23, 2017

LITERATURE REVIEW - 1

In addition the effect of sulphur on GTA weld penetration was quantitatively evaluated by considering two heat of 304 stainless steel containing 90 and 240 ppm sulphur. Sulphur, as expected increased depth with ratio by altering the surface tension gradient driven flow in the weld pool. In the study of the influence of welding on the stress corrosion resistance of AISI 304 steel ,Barbosa,and others (1997) also specified that Austenitic stainless steel to code pressure vessels in the petrochemical plants.The materials is highly susceptible to stress corrosion in chloride environment,which can endanger the weld and lead to rupture of the component.In this work the calculation of the influence of welding parameters on the stress corrosion resistance of AISI 304 Steel exposed to a magnesium chloride solution. AISI 304 steel were manually welded using three different coated electrodes (AWS E 304-16, E308L-16, 316L-16) and two heat inputs (5.0 and 9.0kj/cm).
The welded sample were analysed by tensile strength test optimal microscopy and corrosion test carried out according to ASTM G36-73 guidelines. The result show s that AWS E309-16 electrodes produced the best results due to the microstructure of the resulting weld metal.

Monday, August 21, 2017

LITERATURE REVIEW


 Series of research have been established to advance the correlation of materials selection and good performance of welded steel in construction, fabrication and welding industries including production company which could be obtained through proper experimentation and analysis.To established a good competitive edge and proper customer service,construction and  production companies must have  reliable techniques for variability of corrosion correlation data.Dependability of service is one of the best performance measures by which a company can distinguish it self.
equipment shall be kept reliable without defective components in other to remain productive and competitive.The weld pool development during GTA and laser beam welding of the type 304 stainless steel,part II experimental correlation,(Zachariah and others,1989), highlights in part one of the paper, the result of the heat flow and the fluid flow analysis were presented in part II, of the paper,predictions of the computational model are verified by comparing the numerically predicted and experimentally observed fusion zone size and shape, stationary gas tungsten are and laser beam wide were made type 304 stainless steel difference times to provide a variety of solidification condition as cooling rate and temperature gradient.Calculated temperature rolling rates are correlated with the experimentation observed fusion structure.


Saturday, August 19, 2017

SCOPE OF THE STUDY

Qualification for specification is limited to ASTM, ASME, NACE, ANSI and API standard and codes, This implies that the presentation of the research outcome shall conform to international and  professional recommendations for effective correlation acceptance and approval codes.This implies that the research confirmation  will be affected to fabrication, welding and selection of material for engineering design. The research would be limited to the test analysis of welds and parent metal reaction on sulphur reducing bacterial (SRB),critical crevice temperature (CCT) and critical pitting temperature (CPT) and preferential weld corrosion. Correlation data for welded steel will enable adequate provision of standard systems of serviceability factors.

OBJECTIVE OF THE STUDY-2

The objective propels the analysis of potential microbiological influenced corrosion(MIC) in stainless steel as a function of the resistance of stainless steel to localized corrosion as evaluated by conventional test methods.It is reasonable to explore whether or not all stainless that are equally susceptible to MIC.This is because of the wide range of pitting and crevice corrosion resistance available in stainless steels. There are many test which evaluate the resistance localized corrosion but the ferric chloride (ASTM G-68) method is one of the most widely used.This test produces acidic oxidizing condition similar to those produced by iron and manganese oxidizing types of bacteria. and as there may be some relationship between ferric chloride test data and the metal oxidizing types of bacteria. Ferric chloride testing has been used to determine pitting temperature (CPT) and critical crevice temperature (CCT) for corrosion resistance stainless steel and nickel based alloys (TATNAIL,1981).Ranking the materials by this and similar test has been helpful in making successful material selections. The correlation between the ferric chloride and a stainless steel chemical composition has been demonstrated in fig.1.Representing critical temperature are summarized on a range of stainless steel table.1, types 304 and 316 have relatively low resistance as indicated by low critical temperature,904L has moderate resistance and 6% Mo stainless steels have very good resistance, A study of Kovach and Raymond suggests that positive correlation exist between ferric chloride test and service experience(KOVACH,1995).
(1) Microbial activity almost certainly has been present in many of this applications,therefore this correlation suggest that high performance stainless steel are significantly more resistance to MIC than the standard grades.

Friday, August 18, 2017

OBJECTIVE OF THE STUDY


The objective of the  is to determine proper method for selection of materials.The construction of engineering project,design and structural activities may fail due to corrosion effect and fatigue failures. The selection of materials and effect of corrosion is confirmed  through experimentation and results  carried out  by engineer.Microbiological influenced  corrosion (MIC) has become accepted as form of corrosion that occurs in stainless steels.Reports during the last fifteen years have cited numerous examples of MIC as the explanation of corrosion failures in this steels.The most highly alloyed grades have been specifically designed for high resistance to localized corrosion. The high performance stainless has a long service history of successfully handling seawater in power plant condensers and in offshore drilling platform (KOVACH,1995).
 

PREFERENTIAL CORROSION DATA -AIM


The aim of the project were twofold :To evaluate the effectiveness of a rapid test which could be used after fabrication. 2. To identify a weld which is susceptable and secondly to assess the capability of the scanning vibrating probe. 3.To provide information on the corrosion of welds. Tests were conducted on three welds produced by TWI UK, and designed to exhibit specific corrosion behaviour,and on a weld that had failed in service. The rapid test conducted was the galvanostatic test whilst long time immersion test were conducted to provide reference data.Measurement of the microhardness were made to establish the extent of linkage with the corrosion behaviour.

PREFERENTIAL WELD CORROSION -2


The scanning vibrating probe is relatively new and could provide information about corrosion activity on a small scale. However, its utilization to investigate the corrosion of welds has weld limited. Pistorius  used a number of techniques including the scanning vibrating electrode to investigate the role of sulphur in the localized corrosion of welds in high manganese carbon steels (Pistorious,2000).The authors suggested that hardened microstructures within the HAZ,such as bainite and martensite,do not form galvanic couples with surrounding microstructure but the formation of the networks of sulphide in the fusion line area is the most likely explanation for grooving parallel to the weld line in corrosive environments.

PREFERENTIAL WELD CORROSION-2


There is a range of methods for testing the corrosion of property of weld and their sensitivity to preferential weld corrosion and these were reviewed by Griffiths and others(1999).These tests were generally designed to be conducted in a laboratory on a sample weld to provide confidence in the welding procedures. However in practice a welder may deviate from the specified welding procedure and produce a poor quality weld. There is a need for non-destructive techniques good for identifying a weld that is susceptible to preferential weld corrosion after fabrication .
The scanning reference electrode technique has been used to assess the preferential corrosion of weldment for use in offshore applications when freely corroding and with applied potentials. The technique was found to be sensitive and reliable compared to immersion and potentiostatic anodic dissolution tests. The results of the test were used to develop two indices for assessing susceptibility to preferential corrosion,the first index(R1) was calculated from the hardness of the  HAZ parent plate and the highest hardness of martensite that the parent form.The second index (ChE) used the copper ,nickel and silicon content of weld metal and parent plate to assess their relative nobilities.

Thursday, August 17, 2017

THE PREFERENTIAL CORROSION -1

However,Bradley(1962) concluded that the silicon content of the weld had no direct effect on corrosion of steel wedments in sea water but had low hydrogen electrodes which would give rise to enhance corrosion of the weld.In such trend hicks,(1973) suggested the use of low alloy weld steels so that the weld is always cathodic to the base plate.Nevertheless,corrosion of the HAZ could still pose some problems for some application and will be dependent on the rate of cooling and Mn level in the steel,which affect the grain size and  the extent of the martensite formation.The net effect is that the HAZ could be anodic to the parent plate.Recent work at the welding institute (TWI) UK has shown the importance of nickel content in the weld metal compared to the parent plate with higher nickel content in the weld being percieved to result in the weld acting as a net cathodic with respect to adjacent parent plate. Macroscopic anodes and cathodes will develop only if there is sufficiently conducting medium, when the conducting medium is low or the medium is in the form of a thin liquid layer,the potential drop in the solution will be shorten, the distance over which anodes and carthodes can effectively interact.In those circumstances,significant localized corrosion can occur in regions that are percieved to be net cathodic,as has been observed

PREFERENTIAL WELD CORROSION

The preferential weld corrosion has been a major problems historically and remain a significant concern for industry. The term preferential weld describes selective attack of the weld itself rather than parent plate plate but is sometimes used in a somewhat loose way to describe corrosion of other features of a weldment for example the heat affected zone (HAZ).The origin of preferential attack is usually combination of more active weld material (the weld will tend to be more susceptible o corrosion than the parent material if in isolation) together with galvanic coupling to the parent material, The influence of the coupling is accentuated by the poor area ratio, i.e a small anodic weld and large cathodic based material. The key features of preferential weld corrosion,have been reviewed by Turnbull(1982) elsewhere.
   Lundin (1967), drew the following conclusion from a detailed investigation. In the welding of C- Mn steels , the silicon are the most anodic and unkilled steels are the most anodic and the unklled steels with the silicon content are the most cathodic. Of the weld metals,the normal basic coated electrodes exhibit the anodic potential and the acid types the most cathodic,while the potentials
for the weld metal from rutile electrodes are placed in an intermediate position.

Wednesday, August 16, 2017

CORRELATION OF CORROSION DATA FOR WELDED STEEL -ABSTRACT

Three test methods,namely immersion tests, galvanostatic anodic dissolution tests and the scanning vibrating probe technique,have been evaluated as adequate methods for ascertaining the susceptibility of welds in carbon steels to preferential corrosion. The used of hardness measurement by profiling and mapping was also evaluated. Three welds were tested for which the production has been controlled to produce difference types of corrosion behaviour. In addition a weld that had failed in service was used to validate the finding of the assessment.In the immersion test lasting nine months,the tree controlled sampled welds exposed to ASTM D114 seawater behaved as expected,in terms of which region of the weld was most susceptible to corrosion.

Thursday, July 20, 2017

MY CAREER AND PROJECTION

Enhancing human performance through careers and practical sources to uplift professional understanding is one basic step that enable research application and effective supervision, the most factors that conform to dynamic realization of engineering designs,were factors developed through experimentation and analysis which involved construction,manufacturing,production,and other project details.They were the sources through which machines and its performance sequence were constructed,Although the performance of these devices enhanced needs for higher goals of technologies and human machine interface. These devices are designed to some standardization to fulfill set goals and objectives, therefore for the require needs to be appropriated,maintenance system are provided to actuate deviation irregularity from the standard.And maintenance is a way of keeping operating equipment into effective realization of its designed performance index of production value and avoidance of uncertainty.It is programmed to accommodate production needs and performed in accordance to original equipment manufacturer documentation.

Sunday, July 9, 2017

YOUR PRESENCE IN THIS SITE IS INSPIRING.


ENGINEERING CONSTITUTE SEVERAL FUNCTIONS AND ACTIVITIES,SUCH AS:
-CONSTRUCTION
-MAINTENANCE
-INSPECTION
-INSTALLATION
-SURVEYING OR SITE VISIT AND EVALUATION
-PROFILING
-NETWORKING
-ELECTRIFICATION
-INSTRUMENTATION
-AUTOMATION etc.

In view of the optimal production process and maintenance management efficiency, utilities,are examining the application of maintenance and information technology as an option to support corporate business strategies, that focus on improving service and plant systems performance as well as reducing cost of operation in maintenance management. The key issue for the improvement of the automation strategy of maintenance management is to achieved overall higher productivity and better information concerning dynamic behavior of the entire gas plant system. It will generate.
reliable automatic control concepts to maintenance control system integrity in case of multi contingency.
-The monitoring of the service condition of the physical assets e,g gas power plant ,compressors,injection pumps allow higher safety margin for operation as well as higher cost, and efficient maintenance and asset management.
-Wide area protection systems are intended to complement existing protection,control network systems and provide state of the art solution for contracting systems instabilities.
-They are designed to protect abnormal system early enough to initiate predetermined counter and secure reliable high system performance.
-The integration of the various safety information system in a high communication network allow system wide adaptive protection and real time automatic plant restoration and control.

Sunday, July 2, 2017

MAINTENANCE WORKING DRAWING.


A maintenance working drawing is prepared for each engineering equipment to facilitate pre-knowledge of the equipment design,
To enhance easier and possible means of assembling and dis-assembling the equipment without distortion or crack.
Every design details are made known for easier interpretation of design and can be understood by any other specialized engineer and professional. So the responsible company that owned the product may request to purchase with some presentation of data,they will be given the package design and oriented on how the equipment function. they will confirm the maintenance viability and applicability.
If it could be easier to carryout repairs of the device when malfunctioned and reinstalled in its existing bedding without much constrain.
The equipment package would fully be prepared with the attachments which may include the following ,
the related design drawing .
An instructional detail of the equipment installation in which some interpretation of hidden details in the drawing will be shown in an exclusive and explosive representation in sectional views .
 The simplification of the design detail interpretation will enable the company engineer to easily implement the design layout foundation.
The equipment dimension would be compared and measured according to the specification of the original equipment manufacturer specification, to enable the determination of the bedding size.
As soon as the measured data are able to accommodate the details or equipment the task is accomplished , and the installation would be enhanced and made available for test, thereafter it will be handed over to the department concerned. so the machine will be prepared for preliminary test and inspection, to enhance the operational performance interpretation of test results. So the equipment data will be communicated to maintenance department for study and production results outlook.

Saturday, July 1, 2017

MAINTENANCE IS A PUZZLE AND HIGHLY REWARDING..

It creates most positive outcome when all your anticipation suddenly turned to your advantage that your failed vehicle has been rectified,may be there was no good repair by your mechanic because you had suddenly lost your car service periods and were not paid.
Fortunately you were with a friend who had a workshop and you were able to witness as he repairs a Mercedes car, and you immediately assisted and in turn, you were rewarded with a gift of five thousand naira or more ,which suddenly enabled you to prepare an immediate dinner, great rewards awaits those that have such creditable profession that enable them to make changes especially when the need is required, frankly you are blessed.Another simple step can be practice in case you have no immediate money to buy parts,at least you can buy the components or materials for servicing :a simple CAR servicing can includes the following parts. i) 2x4 litres of engine oil (ii) one or two oil filters elements,(iii) fuel filters,(iv) one hydraulic can,(v) steering oil etc. These items will enable you to work on your car or if you have no working tools,or you can call mechanic to do the work in your resident.

THE ACTIVITY PROGRAMS AND TASK

It will consist of series of maintenance activities of which were performed at various operational tasked and occasioned by direct task supervision in various organizations.It may bring to mind the realization of academic projection and presentation of the tacit activities that are performed from time to time, which are mostly occasioned by years of experience and application in the program.The long term view and activation of field performance on series of maintenance work are the embodiment of its consistency in the assigned responsibility.There are essential need in this particular area of emphasis to upgrade the optimal leverage of plants and operating machinary. And because the performance of machines are essential would mean the need to obtained the responsibility and strength to fulfill such set goals,  Apparently it is through the objective and process, that the society is sustained and avenues created for emancipation and survival . It is also projected for improvement of the people and the societal requirements and development, Maintenance substance are also being mostly accomplished through recognition and application of professional instrumentation of the  process.Most countries invest greatly on the upgrading of their essential facilities and  are good in purchase of package products,whence without adequate analysis of maintenance cost the resulting of operating plant , machines, and operating equipment may not be utilized for prolong years without fracture.Therefore maintenance is best enhanced through proper replacement of parts and accessories.One basic important factor is the fact that what you google in is exactly what you will  google out.Human are Mobile machines creative and effective,and are maintained on daily basis therefore let us develop a more severe outlook on maintenance effectiveness. let our maintenance activity produce impact in the way that it will be appropriated for the equipment design life cycle, so that its impact in production can be obtained, realized and effective.It is essential to identify the operating needs of plants, its maintenance criteria and other upsurges that can be prorated for efficiency and positive work.

Friday, June 30, 2017

SITE TECHNICAL REPORT DATA SHEET


Data sheet of a task or activity are the major issues that enhance the action plan of the equipment maintenance inspection and replacement of aged accessories or parts, that are involved in its daily performance operation.Obviously there are stages involved in evaluating the equipment running hour interval which may be evaluated in either of the following schedules viz.
-weekly running hour,
-monthly running hour ,
-three monthly hour rating ,
-sixth monthly hour rating,
-and yearly or annually hour rating.
These aforementioned stages of equipment for maintenance are programmed to suite existing site needs and operational priority.And each equipment has its definition of maintenance accessories which are documented as the work program .It has the system of application and the reportage of inspection data and falls under various stages and approach . The program is guarded with different steps invariably for fulfilling the expected program or task. Some Task in most of the weekly action plan are programmed on preventive and predictive basis and are prioritized to conform with the phase of activity in the site.

Saturday, June 24, 2017

ENGINEERING PROJECT MATERIALS AND STATISTICS.: INSPECTION /OVERHAUL PROCEDURE FOR ENGINE/COMPRESSOR/PUMP. CONTINUE;

Engineering materials are selected based on the nature of task being performed ,so in a preventive activity,the following measures may be very necessary:
-The tooling required and the nature of activity being performed.
-Equipment inspection may be defined to the scope of work.
-The procedure that is required must be clearly stated.
-Stages of task defined in a clear and simple document
-A work permit needs to be signed in accordance to what work that is to be done in the site.
- A toolbox meeting is also mandatory because of the hazards that needs to be identified prior the task.
-Everyone involved in the work may also be required to sign the documentations.
-It is also necessary to apply the procedure according to the definition of the tasks.
- There after a summary report be written and summit to site representative.

Monday, June 5, 2017

MATERIALS DATA COLLECTION



  • Too difference in cost may influence selection of commercially available units or components of work performed.In determining how most of the company maintenance work are being performed is actually necessary, consideration frequently is given on to obvious problems - and the number of hours spent on them., since the work require are but clerical and engineering time as production equipment demands. But all those factors would later mean more or less need for maintenance depending on the quality of original equipment chosen.Also contributing to the needs of maintenance work is deviation from the acceptable operation practices,quality of separate components within a larger equipment system and continuing quality  of maintenance. Quinn (1995) comment that there are many reasons why maintenance work is needed,initial decision established to some extent that amount of maintenance work that would be required,such designed may be based on reliable data,past experience and /or opinions. as well as the actual hour of repair,these must be evaluated too and the whole expenditure considered with collection and analysis of considerable data .

Friday, June 2, 2017

MAINTENANCE PROCEDURE,TEST AND MEASUREMENT.


All operating cylinder valves inspection should be performed with an instrument such as feeler gauges,in accordance to specification and should be replaced with spare parts where test is unsuccessful or unsatisfactory.
-Adequate inspection should be conducted on journal bearing for wear,crack,pitting,using appropriate instruments,(micrometer,dial, vernier, internal micrometer,external gauges and dial gauges,comparator etc) with an accompanied data plan that could details their operational interval,such data are evaluated to determine their operational lag and performance..
-Malfunctioned devices or instrument should be discarded to eliminate re-usage hence avoidance inconsistent maintenance operation.
-All connecting rods/gudgeon pins, end caps should be inspected to specification
-A metrology/measurement should be conducted on the crank rods/ancillaries,and other malfunctioned items should be replaced
-All component and materials received for the maintenance of machines should be carefully inspected for quality,machining error,defects and other shot falls in accordance to API 1104,or ASTM.
-All actuators and valves (ball and gates) with prismatic operated devices,including relief valves should be maintained, inspected,and  calibrated.,other faulty devices be kept to standard through adequate re-calibration and in accordance to oil mineral code 1963 and BS code 229

Wednesday, May 31, 2017

PROCEDURAL STEPS IN MAINTENANCE INSPECTION.AND QUALIFICATION OF THE PROCEDURE.

-Inspection of drive end and radial bearing be monitored at regular interval in every operational devices and machines. 
-stuffing box be adequately inspected and lubricated and care be taken to avoid excessive lubrication otherwise it will result to distortion and temperature increase,which can lead to failure of the equipment.
-observe filter elements for cleanliness to enable effective and efficient performance of operable device or machines.
-Main drive shaft of operational machines.pump,engine and compressor should be regularly inspected on a face plate to determine the parallelism ,concentricity,axial deviation, etc
-
B. The above procedure will be qualified as follows:
-Enhancing maintenance operation on the specified engine,pump, and compressor
-Enhancing the following series of test;

* maintenance power test
*maintenance metro-logy and measurement
*maintenance instrumentation and measurement,calibration and test.
*Component quality and inspection.

-Power accessories dismantling procedure and should be performed to conform with ISO 
9001 code for caterpillar plant.The test should conform to the specification and include
-maintenance confirmation test for synchronization of the governor.
-maintenance  confirmation test for performance of the ignition system(digital testing apparatus).
maintenance performance test for navigation of the machine architecture in  case of  failure.
Maintenance confirmation test for energy pulsation and power (tachometer and oscilloscope)
.-.
-

Tuesday, May 30, 2017

INSPECTION /OVERHAUL PROCEDURE FOR ENGINE/COMPRESSOR/PUMP. CONTINUE;

- Gas cooler/heat exchanger should be properly inspected and the fans inclination up dated for effective performance and efficiency.
-Impeller/Shaft should be properly maintained to ascertained that their concentricity through regular maintenance inspection and updates,to avoids deflection and buckling.
-Wear rings must be inspected from time to time especially when there is need to conduct replacement of malfunctioned components,such as bearing or mechanical seals.
-observe and infrared the drive end and non drive end bearings for malfunction and temperature rating.



Monday, May 29, 2017

PROCEDURE FOR ENGINE/COMPRESSOR/PUMP.

The specification and procedure for performing effective maintenance in a plant are mentioned below:

-Spare parts replacement and gasket materials for the maintenance should be duly inspected to standard.
-The effective areas of replaceable part reference and service procedure be clarified to manufacturer reference and systems.
-Grades and types of lubricants be clearly identified to standard specification.
-Bearing,oil seals,glands,lip seals references be clearly written and identified to standards.
-Types of coupling,alignment,shimming and their applicable instrument be defined to specification.
-Visual inspection of foundation bolts and their design factors is imperative.
-Mechanical seals standard and specification varies,though they may serve same motive,but check manufacturer design and orientation.
-visually inspect crankshaft journals,crank-web and main bearing ends or seating.
-Note that electronic control module (ECM) of an engine can develop a failure report,therefore often conduct an inspection calibration,to confirm its status.
-Always perform visual inspection on your engine spark plugs and transformers to avoid sudden shut-down or abnormal vibration etc.
Filter cart-rages for air compressors and engine should be inspected and cleaned always to avoid sudden shut-down.

Sunday, May 28, 2017

MAINTENANCE SPECIFICATION AND STANDARD



The maintenance standard specified for this work are as follows: 
The maintenance metrology and measurement.
Maintenance instrumentation test and measurement.
Maintenance inspection and components quality.
Maintenance calibration and test.
The areas as mentioned above are considered to either of the following codes.


Maintenance metrology and measurement codes
                  ASTM, ASME codes
Maintenance calibration testing code.
                    ASTM and oil mineral regulation 1963.
Maintenance and components quality codes
                      API 104,BSEN AND ISO 9001
                       ASTM A216,215,316
                       ANSI CLASS 150,AND 300,DIN24960
                        ASTM 300-350


ACTIVITIES


CONNECTING ROD AND ASSEMBLING SYSTEMS                                       DURATION
- Torquing of crank of crankshaft.
-The connecting rod nuts and bolts.                                                                      ----------1 WK
-The end main bearing to appropriate to appropriate specification (24ib/wts)

The PROCESS OF COMPONENTS ASSEMBLING OF ENGINE (G399/3512)           1 WK
-installation of top cylinders/valves
-installation of valves,tappers,rockets,springs, push-rods,
-calibration of valves,inlet/exhaust (30/45 degrees) to designer/manufacturer.
-installation of transformers,and installation of other main accessories.
-installation electric module
-installation of turbo changers,governors and other components                           -      --- 1 WK      
-Add all necessary oil and water.

RE-INSTALLATION OF ENGINE,SURVEY AND PERFORMANCE TEST
-Painting and re-installation,
-lifting equipment and tranferring media
-tightening of nuts and bolts
-perform alignment of engine,gearbox and pump .--------------------------------                   1 WK
-perform other instrumentation,electronic process installation
Test run engine                            

Saturday, May 27, 2017

PR0JECT ACTIVITIES


ITEM 4.0                                                                   ACTIVITIES                                          Duration
                                                                                   
Process of inspection of instrument.                        - Placement of components on
pressure testing,metrology or measurement,             appropriate work benches for    
of engine cylinders,liners,hydro-testing oil                assembling the gudgeon pins
coolers, and heat ex-changers.                                     with the pistons
                                                                                   -Assembling the connecting rod to
                                                                                   crankshaft case in-conjunction with the  ---1week
                                                                                    crankshaft.
                                                                                 
                                                                                    -Assembling the journal bearings
                                                                                    -Timing the engine chain and sprocket      
 Journal bearing and other internal assembling.          - inspection of installed accessories       --2week
Connection rod assembling and torquing                       -Torquing of the crankshaft
                                                                                       connecting rod bolts and nuts
                                                                                        the end and main bearing to appropriate
                                                                                        specification 24ibs/wts      

Friday, May 26, 2017

PROGRAMME OF ACTIVITIES


ITEM No.ONE.                                              Activities/            Duration ---------------------- 1 wk  
                                                                       Preparation for dismantling,
                                                                     -Disassembling of G399/G3512 Cat engine
Preparation of storage equipment and         -procedure and specification containing the
dismantling of accessories,                          -process materials and tools.
                                                                     -lifting devices and positioning structures                                                                                                   fabrication.
                                                                      -transporting and transferring of plant to                                                                                                      W/Shop.

No..TWO.                                                           Activities         Duration   --------------------------- 1wk
Component and Material  procurement           procurement for malfunctioned parts/components
                                                                          and other accessories.

No. Three.                                                            Activities    Duration---------------------------  3wks    Process of metro-logical Inspection                   Preparation and assembling.
Pressure testing and of cylinders                       i) measurement of crankshaft journals
- hydro-testing of cylinders                                 ii) measurement of ovality and inspection
- hydro-testing of oil coolers                               iii)measurement of connecting rod
-inspection and test of heat exchanger                iv)placement of components on appropriate work  instrument on benches                                            benches for assembly and selection

Monday, May 8, 2017

MAINTENANCE PROJECTION GOALS.

-Metrics chosen should give evidence of the goals already established
-A wide assortment metrics should be used with when you are certain that they are meaningful.
-It will enhance fulfillment of  the economy of the program
-As it increase or expand it will be possible to evaluate the present position.
-Look towards the process of automation to provides much of the data collection  for effective results.
-Understand that the process of obtaining viable information is cumbersome .
-Delay in taking corrective action will result to negative outcomes.
-Collect data through automation because it is faster,affordable in each day because it consist of wireless sensors,smart sensors and neutral nets and various other expert systems etc,
-Excessive and unnecessary automation will lead to higher cost thus longer return on investment (ROI).
-Never increase cost of program unnecessarily because it will lead to its demise.
-Evaluation of optimization require consistent evaluation program and it enhance the best alternative choice.
-Optimization of maintenance program can best be practice through induction of training.
- Refresher reviews to keep management informed of the successes associated with the program.
--Ensure to monitor cost saving, avoidance and track them in comparism with the expenditures.
-Ascertain how tracking towards our break -even point time and return on investment (ROI) will improve the effectiveness of the program
-

EQUIPMENT MAINTENANCE IMPLEMENTATION PLAN.

Measures or Steps
-Set of measures that can be utilized to accomplished plan.
-To evaluate the effectiveness of the program in concert with established goals.
--The features that will accomplish the goal and create changeability for effectiveness to the overall plans.
-The overall goals should be seen as necessary because management personal sometimes change and  new management often need justification for all activities under their responsibility.
- Periodic program reviews be conducted after six months and then be projected on annual basis.
- Periodic effectiveness reviews provides management with information necessary to ensure continuation of monitoring activities.
The typical metrics are: cost benefit analysis
                                      -O and M reduction and avoided production losses.
                                       -Saving from the reduced preventive maintenance tasks
                                       -cost per work order
                                       -Emergency maintenance order on critical equipment.
                                       -individual component maintenance cost.
                                       -Equipment availability
                                       -Overtime (OT) hours reduction.
                                       -Unplanned outages.
                                       -

Sunday, May 7, 2017

WORK PROGRAMME

ITEMS
-Preparation of equipment.
-storage facility for dismantled  accessories,
-components, and materials procurement
-process of metrological inspection,
-testing of cylinders
-hydro-testing of oil coolers and heat ex-changers
-journal bearing and other internal accessories,
-connecting rod assembling, and torque
-process of components  assembling of the engine.
consideration and recommendation of the original engine manufacturer OEM series,G3512,G399.
-Inspection of necessary accessories recommendation from OEM compliance.
-Re-installation of the engine
-Engine survey
-Engine performance test to conformity
-Inspection of leftover accessories if any
-Test run
-monitoring.

ACTIVITIES.
-Preparation for dismantling and disassembling of the engines G399 and G3512 caterpillar engine.
-Engine procedure and recommendation of the manufacturer specification.
-Enclose documentation and tooling for the dismantling and disassembling process,materials and tooling.
-Lifting device preparation,inspection and color coding.
-fabrication for positioning of structures and means of transferring plant to workshop.
-The setting will be presume for one week planning or more.


Saturday, May 6, 2017

ALIGNMENT,MATERIAL QUALITY ,CRACK DETECTION AND INSTRUMENTATION.

Coupling Alignment;
- Laser alignment kit (exigo)
- measuring tape
-vernier caliper
-dial gauges
-charts
-steel rule, micrometer screw gauges
-Set of tool box.

Metrological Data Analysis.
-Dial gauge
-Internal micrometer
-External micrometer
-Vernier height gauge
-Vernier caliper D500 (mm) L/09-30288
-Data book
-Ovality comparator

Material Quality
-Weight indicator
-manufacturer reference data
-Computer system
-Measuring accessories

Crack Detection
-Compressor
-Hoses
-Complete mechanical tool box
-Detection powder
-Clamps
-Blind flange (RTG 2 X 250#)
-Nuts and bolts
--manometer guages

INSTRUMENTATION
-Vibration monitoring meter.
-Visual inspection
-Vibro-meter, vibration analyser.
-Speed and temperature
-Tachometer
-thermometer
-Infrared
-cylinder pressure analyser
-
PRESSURE VERIFICATION
-Calibrator
-manometer
-pressure safety valve calibrator
-carbon monoxide monitor

POWER
-Turbo-scope
-lamp detector
-failure mode architecture
-instrument loop test
-smoke detector
-instrument loop test verification
-pressure safety valve (psv), calibrator
-



-
-


PRESSURE TESTING OF CYLINDERS/ VALVES / HEAT EX-CHANGER.



  The pressure testing task were performed in the following:
   -cylinder heads,
    - valves.
    - heat ex-changers
    - coolers
The pressure test conformed to the specified codes of the oil and gas producing companies and oil mineral regulation Act 1963, And the specimens involved the following:
     - Cylinder head
     -  Valves
     -  Heat ex-changers
     -  Oil coolers
  Experimentation of  the aforementioned specimens were best conducted in a standard industry with good workshop/laboratory to enhance good results.

Optimization of activities
The activities involved in the sequence of the maintenance work of the engine and steps taken were optimized to enhanced the viability of the job. The process conformed to established standard in all institution of operational research management.The specimen were the activity involved in the overhaul of G3512 engine.s

overhaul equipment
overhaul equipment involved the following
tool wrenches
valve pullers
complete mechanical toolbox
lifting devices
Vee blocks
Vee stand
Crane

COUPLING ALIGNMENT:
Laser alignment kit
Measuring tapes.
Vernier caliper
Dial gauge
Chart
Shim boxes
Complete sets mechanical toolbox
Data book

Tuesday, May 2, 2017

SHAFT CONCENTRICITY AND CRACK DETECTION TEST


COMPONENT METROLOGICAL ANALYSIS OF DATA.
The specimens for the metrological analysis of data were the connecting rod,crankshaft,liners,pistons,and journal bearings.The inspection conformed with the reference code of the manufacturer specification or designers recommendation. The components were examined visually for casing, pitting,cracks,tear, and other defects before the inspection of the of the metrology commenced. The measurement  was conducted on a bench in the workshop.


A shaft concentricity and crack detection was conducted on the gearbox rotating shaft and the engine driving shaft  The driving shaft of the engine and the rotating shaft of the gearbox were inspected prior the test was conducted. An inspection was also conducted on the equipment before the alignment of the coupling commenced. It was performed to prevent unprecedented failure of the equipment. However crack detection test was also conducted on the engine casing. The specimen was the casing of the engine and it was performed in the workshop.The process conformed with the inspection code of the designers or the original manufacturer of equipment.specification, which also conformed with the ASTM, ASME,NACE,etc,and oil mineral regulation acts 1963.

Thursday, April 27, 2017

SAMPLING LOCATION



The criteria used in selecting the overhaul and experimental work area are mostly selected by availability of experimentation features, and such work area shall include the following: I) the proximity to industrial area, ii) accessibility to good mechanical workshop, iii) availability of measuring instruments and iv) other tools that could be used to produced good technical performance of the project activities.

EXPERIMENTAL WORK:
The experiment was performed by assembling of engine in the workshop and carrying out overhaul on G399 caterpillar engine or G3512 engine and the following series of test and inspection were conducted.
i)    Carrying out coupling alignment.
ii)   Carrying out component metro-logical analysis of data.
iii)  Carrying out material quality inspection.
iv)  Carrying out optimization of activities.
v)   Carrying out pressure testing of top cylinders and valves.
vii) Carrying out hydro-testing or pressure testing of heat exchanger and oil cooler.

COUPLING ALIGNMENT:
The specimens for the alignment were the coupling of the driving shaft of the engine and the gearbox  driving shaft.It was subjected to axial torque and load on rotation in-conjunction with the flywheel of the engine,.The torque and the speed were conformed with the requirement of the engine and gearbox specification, depending on the type of coupling.The process involved knowledge of the allowable tolerance range of the manufacturer and the designer specification.



Thursday, April 20, 2017

OPTIMIZATION IMPLEMENTATION PLAN -CONTINUE 1


The implementation plan should also include a set of measures that can be utilized to evaluate the effectiveness of the program in concert with the established goals.The features of the program is a key to success.This evaluation is necessary because management personnel sometimes change and new managers often need justification for all the activities under their responsibility. A periodic program review should be conducted after six months and then at least on an annual basis.This periodic effectiveness review provides management with the information necessary to ensure the continuation of monitory activities (Digiovanni, 2003).Example of typical metrics are  improvement:
---Cost benefit analysis
---O&M reduction and avoided production losses
---Saving from reduced preventive maintenance tasks.
---Cost per work order
---Emergency maintenance orders on critical equipment.
---Individual component maintenance cost
---Equipment availability.
---Overtime (OT) hours reduced.
---Unplanned outages.
It is important that the metrics chosen support and give evidence to the goals that have been established.There is a wide assortment of metrics that may be used, but it is important to ensure that they are meaningful since they provides the economic justification for the program.

MAINTENANCE IMPLEMENTATION PLAN.

DIGIOVANI, (2003), Ephasied that once the assessment is completed,the benefit of the optimization program are defined and the technologies are selected, then it will enters the second phase, in other to establish implementation strategy. This strategy will include the assignment of a leader and the establishment of the data base for monitoring the impact of the program (metrics).
when implementing new maintenance program and processes,it may be best to start with a small effort and expand it over time, however,the current situation may not allow for this path. Therefore,in other to ensure there is a well organised implementation plan. The plan may be structured to accomplished the following:
---Built optimization program awareness and the entire plant support is required for success.
---Readiness to overcome resistance to:
                                                             Change of philosophy or maintenance strategy.
                                                             New technologies
                                                             New lines of communication
---Blueprint of the activities
---Be well defined to avoid mistakes.
To ensure success of implementation, a training program must be planned and resources be provided
for execution of the program and various types of training are recommended for proper implementation,and should be structured to provide the following:
---Maintenance strategy definitions
---Plant and facility personnel cultural change
---Program buy-in by the entire plant
---Program coordination.
---Technology level of awareness
---Technology data collection
---Technology data analysis
For technology to be implemented,training should be specific,to start the implementation rapidly, hand on training must be recommended.Due to the nature of these technologies, proficiency with equipment grows with experience.However, annual training budget should be provided in other to extend the technical knowledge of the personnel responsible for the monitoring tasks,and to train new personnel.All of these information should be provided in a training matrix (Emerson, 2003)

                                                             

Tuesday, April 11, 2017

COLLECTION AND ANALYSIS OF DATA


Quinn (1995) comments that there are many reasons why maintenance work is needed initial decision establish to some extent, the amount of maintenance work that would be required, such design decision may be based on reliable data,past experience and or opinions,.Too difference in cost may influence selection of commercially available units or component of production equipment. But all those factors will latter mean or less need for maintenance depending on the quality of the original equipment chosen. Also contributing to the needs of maintenance work is deviation from acceptable operation practices, quality of separate components within a larger equipment system and the continuing quality of maintenance workmanship or work performed.. In determining how most of the total  maintenance work being performed is actually necessary,consideration frequently is given daily to obvious problems - and the no of hours being spent on them. Since this work require both clerical and engineering,time as well the require hour of repair,this must be evaluated too and the whole expenditure considered.In doing this a basic requirement is collection and analysis of considerable data.It also necessary to establish that expenditure for engineering time and investment involved in correcting problems and or improving condition are justified,that individually they are sound business  preposition (Lewis,2001).For maintenance work and production information requires a considerable amount of basic information or data for analysis and preventive planning,including:
-Sufficient maintenance - cost information
- Adequate equipment repair history
-Knowledge of production capability and requirements.
   In addition, it is necessary to analyse tasks,which usually require staff engineering time consult assistance,or a combination of both,because of the cost involved in engineering work It is specifically important to establish return on investment for engineering time.,

Monday, April 10, 2017

PROPER OPERATION OF MAINTENANCE-CONTINUE


Maintenance is basically, a cause and effect condition rather than treat the effects with the company down time for production equipment, and it is better to try eliminate the cause economically.In such a preventive maintenance program both planned and unplanned work should be considered. This means carrying out regular preventive schedules and performing several such tasks when a machine is in repair for another reason.In such reduction of the need manufacturers recommend,at either six months or every year.Actually depending on the grease used and the condition of the coupling, re- lubrication periods could be longer or shorter (Gomorous and Zalous,2004).
In some application the equipment to which a coupling is installed cannot be stopped when a re- lubrication is scheduled. while this cause no problem in lubricating the equipment bearings,it prevent coupling lubrication. It is then possible that the coupling is not serviced until the next scheduled maintenance


COLLECTION AND ANALYSIS OF DATA:
Quinn (1996) Comments that there are many reasons while maintenance work is needed, initial decision established to some extent the amount of maintenance work that would be required, Such design decision may be based on reliable data passed experience and or opinions.Too differences in cost may effect selection of commercially available units or components of production equipment. But all those factors will later mean more or less need for maintenance,depending on the quality of the original equipment chosen. Also contributing to the needs of maintenance work is deviation from acceptable operation practices,quality of separate components within a larger equipment system and continuing quality of maintenance workmanship or work performance standard, The work culture of the group including the stability of the systems,and  good team spirit. will uplift personnel performance, upgrade production plan and the workmen..   .

Thursday, April 6, 2017

PROPER OPERATION AND MAINTENANCE

Calistral and Boltimor (1989), comment that service of gear couplings can be achieved by understanding the principle of wear, how lubricants functions and proper maintenance.proper lubricant selection greatly increase the life of gear couplings,Once proper installed periodic lubrication is the only maintenance required..In other to select proper lubricant, the principle of gear wear and lubricant properties must be understood. Maintenance is assume in disadvantage of gear couplings,,they are popular because of the proper reasoning and the principal reasons are: Gear coupling are forgiving, even when improperly installed or mishandled, It continue to perform than  most other types of couplings and gear coupling are  reliable and safe.Their main cause of failure is teeth wear,which is a gradual rather than abrupt. Even when the teeth wear out completely,the only effect is its loose of power without coupling flying apart. Coupling in general can be divided into low and standard and high speed or high performance coupling.Maintenance requirement, if the two types are very different.The article will describe maintenance of the standard type.
An objective in many maintenance operations is to improve condition through more effective performance.of maintenance work. Although this be worthwhile, it should first be established that the work being done is necessary.The reduction effective maintenance can bring about in the need for maintenance work can  in many cases significantly improve both the output of the manufacturing facility and the unit cost of the product in addition to reducing the maintenance cost (Fast,1920).

Wednesday, April 5, 2017

PROPER OPERATION AND MAINTENANCE

Caterpillar SEBU 6336, (2002), SEBU 5678 (2003),Recommends that, proper operation and maintenance are a key factor in obtaining the maximum life of the engine. The direction in the above series of manuals lower the operating cost. The time needed for the engine to reach the normal mode of the operation is usually less than the time taken for a walk around the inspection of the engine.After the engine is started and the cold low idle operation is completed, the engine can be operated with rated speed and low power, the engine will reach the normal operating temperature faster when operated at rated speed and the low power demand than when ideal at no load..Typically the engine will be up to operating temperature in a few minutes. Range reading should be observed and data recorded frequently while the engine is operating. Comparing the data over time help determine will help determine the normal reading for each gauge and help detects normal operating development, significant changes in the reading should be investigated. The maintenance guide illustrates the equipment care, steps and instructions, they are grouped by servicing intervals, items in the lubrication and maintenance chart, use the service to determine servicing period,.calender intervals may also be used instead of service intervals. They provide more convenient servicing schedules and approximate the indicated service hour meter reading.
Recommended service should always be performed at the intervals that occur first.

Tuesday, April 4, 2017

REPLACEMENT PARTS.

Quality caterpillar replacement parts could also be obtained through available caterpillar dealers  through out the world. Their parts are up to date and include all parts normally required to protect your environment in caterpillar engine.The actual operating environment of the engine also govern the operating schedule under extremely severe dusty or liquid operating condition, Lubrication and maintenance checks are more frequent than those specified in the maintenance schedule.It is recommended by caterpillar  that ongoing maintenance records be kept to document engine service.
Whitton Technology Inc series C1249 (1980) observed, that equipment used in the construction of some has been selected for its proven long life and reliability in special application.I the maintenance of the low screw compressor 4 - 9 bar is specified by whitton technology Inc that routine maintenance may not be necessary due to equipment precision and manufacture,but may be considered worth while periodically to check the suction strainer for cleanliness.Any other maintenance, to adjust repair or of the replace any components, or replaced as required to prevent necessary breakdown.Maintenance of the motor or drive coupling may be carried out by removing the motor from the unit, however,access will be required to the side of the mounting plate..Maintenance of adjustment to the pump, relief valve and suction strainer will require the unit to be removed from the reservoir. Instrument manufacturer, FISHER AND EMERSON Process management designer of series 630 pressure regulator states that maintenance of parts are subjected to normal wear and must be inspected and replaced as necessary. Frequency of inspection depends upon severity of service condition.

Friday, March 31, 2017

COST OF INSTALLATION AND MAINTENANCE

Roberson (2005) commented on any means of reducing the cost of installation and maintenance while making the best use of skilled labour can produce a competitive advantage..The cost of fines, suspended operations,can far out weights the cost of a leak tubing system and continued by stating that,effective preventive maintenance must be employed on all equipment concerned with emission  controls,including monitoring and compliance of vapour recovery unit (VRU).
He continued that for the environmental reasons, It is essential that vapour recovering equipment be maintained at its optimum performance, and any process equipment as VRU needs regular attention to ensure levels, temperature and flow rates are within normal ranges, Usually a planned  maintenance system is implemented covering details inspections and checks at three,six and twelve months intervals together with daily checks on performance by the operators.

Thursday, March 30, 2017

LIMITATION

There were constrains in countered in the process of proper implementation of optimization of maintenance in the oil and gas producing industry and other company. viz:

In the optimization of maintenance cost,effects were observed by non proactive planning and sequence of logistics.
The cost of operation also affected the optimization of maintenance through community integration and environmental quality standard.
The optimization cost was inhibited by lack of orientation and learning and impractical incentive proposition.
The accuracy of the optimization depends on the materials,cost of implementation,instrumentation,but the organizational management was affected by of tooling and incessant delays.
There were limitation to discussions on finding of some inconsequential profiling and testing, which were performed outside the environment.

JUSTIFICATION AND SIGNIFICANCE

To establish a competitive edge and to provide a good customer service.companies must have reliable equipment that respond to customer demand when needed. Equipment must kept reliable without costly work, stoppage and repair, if a company is to remain productive and competitive.
Maintenance is an important factor in quality,which is another basis for successful competition. Inconsistency in equipment leads to variability in products and defective parts that fail to meet the established specification. Beyond just preventive breakdowns,companies must keep equipment operating within specifications that will produce a high level of quality (Milowitz and Madanat,2000),
Most highly trained maintenance workers are required, and the cost of replacement is higher. Poor care of equipment and facility can be very expensive.It allows large investment to deteriorate and  breakdown, To reduce the return that could be earned on the investments.Many challenges make sound maintenance management important to competitive, productive operations.

Sunday, March 26, 2017

MONITORING SYSTEM

The plant monitoring system is one common factor that exist in maintenance operations and performance. Jari (2002), emphasised that the maintenance includes various condition and health monitoring systems that monitor both individual field equipment and entire processes,
The method vary with the target to be monitored,condition monitoring system for rotating machines can be used as good early time warning system, for example, a fault in the bearing may cause a malfunction in the turbine.
The comprehensive measurement can be used to monitor turbine and other rotating gas compressors and observe for leakages in areas such as the sumps,bearing and mechanical seals and captured in advance.The integration of data provided by different methods into a power plant information system creates the best possible information foundation for the optimization of plant wide maintenance operations.it will mean that the information supplied must have strong understanding of the power components processes..
Recent experience suggest that nearly all plant encounter irregularities in either their main or sub process machinery.Measurement data ca be used to initiate regulatory actions quickly in the right places and to ensure that operation starts up as planned..

THE OPTIMIZATION MODEL.



The optimization model optimize for a single metric, namely cost,the greater the mean time between maintenance (MTBM) for a given asset,the less the preventive maintenance is being done.Hence the lower the preventive maintenance at same time,the greater the MTBM,the greater the probability of failure,and thus the greater the maintenance repair and replaced cost (Berger,2005).
Berger(2005),illustrates that optimization on the basis of reliability or availability might show that an alternative policy is superior, which might be compared with difference condition based maintenance (CBM) policies that differ in terms of mean time between maintenance.
the condition based maintenance may differ in terms of conditions that trigger a maintenance type(minor versus major) and at which stage of deterioration.Thus a good maintenance program compares policies, from single - runt failure to online continue condition based maintenance, all in the multiple matrices,more sophisticated modeling tools allow progressive outlays of greater and greater functionality, which continuously improves the optimal solutions.The user should be able to:
      - Experiment with effect on several key metrics of changing the maintenance of a given component, equipment, line facility or line of business.
      - Determine the post and benefit of outsourcing one or more maintenance tasks.
      - Understand the trade of in adding hand held or online condition monitoring devices.
      - Determine the effect of changing the maintenance technician skill level.
      - See the effect of giving policy on product quality(damaged or lost items) at different degradation levels.
       -Perform sensitivity analysis to understand the effect of adjustment of various variables, so that strategic trade-offs can be understood.


  

LITERATURE REVIEW.

Several research work have been conducted to enhance the reliability of maintenance and good performance of plants in the companies, industries, and other production facilities.Some service companies such as airline,production, manufacturing, maintenance experts and many other parastatal  such as petrochemical industry,  oil refinery and production have very high investment in equipment that is vital both for safety and success of the business.Dependability of service is one of the four performance measures by which a company can distinguished itself.
(Robbert,1993) highlights that many manufacturing companies particularly those with just in time inventory or programme (JIT), are operating inventory so low as to offer no protection in the invent of a lenghty equipment failure beyond the cost of idle  equipment, and lost sales that can result from a breakdown. There is a of permanently market shear to a company that are more reliable therefore, It is very important that companies should work very diligently to prevent breakdown.

Friday, March 24, 2017

BACKGROUND OF THE STUDY.



It is important that organization properly map their path to maintenance optimisation or they find themselves inversed in a data, lacking information and direction and find themselves returning to the old maintenance strategy..The project describes a process which may be used to identify the existing resources and to specify advance technology necessary to implement an integrated optimisation of maintenance cost in producing oil and gas company.
The successful implementation of optimisation cost coupled with systematic process change will enable organization to optimise their maintenance programs. The success of this optimisation will lead to reduce maintenance cost and operational outages (Augustine,2003). In today competitive global business climate industries and enterprises are under increasing pressure to reduce cost in order to meet tougher performance and production goals with maximum return on asset investment.
unplanned equipment down time greatly affect the earning of any enterprises and must be minimised, risk should also be minimised as well as the cost of keeping those risks low. Asset maintenance is a significant cost factors for companies to improve and maintain the availability during the asset life cycle. Maintenance is a key factor in succeeding in asset management (BQR,2007).
Asset management is an expert system for maintenance optimisation which allow manufacturer service provider and maintenance repair and overhaul (MRO) organisation to scientifically analyses, improve and optimise all relevant aspect of maintenance strategies.
These strategies involved planning and execution of the following factors:
- Repair or discard
-Corrective, Preventive, and Predictive Maintenance.
-Spare Part Allocation and Procurements
-Support and Test Equipment
-Tools and Materials.
 

MAINTENANCE RESPONSIBILITY.



It is obvious and important that responsibilities assigned to the maintenance department be clearly defined and that the limits of authority and responsibility be established on all concerned.
Maintenance is to ensure installed equipment remains fit for purpose throughout the designed life. It provides maximum overall availability without on hygiene, safety and environment. And it also enhance cost effective operations, optimum use of manpower with less fatigue and more output. It provides means of adequate work preparation, appropriate tools procedures, professionalism and good state of mind. Maintenance is divided into various categories, but the basic concept are:
1.Preventive and 2.Corrective. The preventive maintenance concepts is conducted to reduce either the  probability of failure of an item on the deterioration of a required function. While the corrective maintenance concept are performed after a complete failure had occurred. Others are schedule or periodic, predictive, involving predetermined interval of time, number of operational mileage.

INTRODUCTION: PLANT MAINTENANCE OPTIMIZATION


    Maintenance optimisation is a process that attempts to balance the maintenance requirement (Legislative, Economic, and Technical) etc.and the resources used to carryout the maintenance programme.(peoples,spares,consumptions,equipment; etc.).The goal of the maintenance optimisation is to select the appropriate maintenance technique for each piece of equipment within a system and identifying the periodicity that the maintenance technique should be conducted to achieved availability and cost.(Digiovanni,2003). It is obvious that when maintenance is effectively implemented it will, i)Improve  system availability, ii) Reduce operation maintenance cost iii),Improve equipment reliability and system safety.
The maintenance optimization process will effectively blend predictive,proactive and, corrective maintenance strategies often through the use of reliability centred maintenance techniques. This will allow system maintenance to move from a reactive approach or preventive approach to a planned approach..The planned approach conducts maintenance at the most optimum time, which is often before the equipment fails. Optimising maintenance often seems to be a catchall for many odd activities that no other single department can or wants to handled, but care must be taken not to dilute the primary responsibilities of maintenance with the secondary services. Maintenance must be carefully tailored to suite existing technical, geographical and personnel situations. Basic organizational rules due exist, however, there are some general rules covering specific conditions that govern how the maintenance department is to be structured. It is usually essential that some recognised, formally established relationship exist to layout firm lines of authority and responsibility, Such an organization laced with universal truths, trimmed to fit local structures, and staff with people who interact positively and with a strong spirit of cooperation is the one, which is mostly to succeed, such is the case that exist in most of the professional organization, where the maintenance department is taken as an adhoc implementation and planning department of the organisation or company..  

Wednesday, March 15, 2017

CORROSION FORMS AND DEF.ECTS.



The research  in prevention of anti corrosion in maintenance and control of industrial facility, Robert et al, discussed on different types of corrosion and emphasied, that a uniform corrosion is characterised by a literally constant speed of corrosion. typical examples are given by the atmospheric corrosion of galvanised steels - the thicker the zinc coating, the longer the service life or the chalking of paint, which are degraded uniformly by radioactive oxidation in air.Erosion corrosion, uniform corrosion may proceed faster when there is a flow. the flow rate velocity will locally reach high value if turbulent situation occurs, which will prevent the formulation of protective layer on the metals. Abrasive practice in a stream of gas or liquid may mechanically distrupt  the protective surface film and thus enhance corrosion often in a non uniform, localized way.
cavitation  corrosion implies formulation and collapse of tiny gas bundle in a liquid stream, which implies that it can mechanically destroy any protective layer, causing localized corrosion, erosion and cavitation corrosion are control by proper design selection of materials and may help in special case. Galvanic  corrosion often occurs when two different materials are in contact etc. 

Tuesday, March 14, 2017

CORROSION CAUSES CAN BE CONTROL AND ENVIRONMENTAL SAFETY ENHANCED,

It is obvious  that most corrosion causes can be control, the environmental  safety enhanced and quality improved by means of control measures ,and analysis of factors through dissemination of knowledge, and use of monitoring temperature techniques. A model of interconnection of all groups in the oil and gas production industry with the aim of diminish corrosion risk. Recall that anti corrosion management policy,and quality includes design, manufacture, improvement and control at all stage.

HUMAN FACTORS IN CORROSI0N FAILURES

The human factor is one of the main reason for corrosion failures, anti- corrosion management must be designed in such a manner that human potentials are improved for performance and correct decision. Example of wrong application and use of corrosion prevention measures, such as control of inhibition types and concentration, alloy, coat and technological regime. Insufficient and sometimes  inadequate corrosion monitoring methods may result to ineffective method of controlling corrosion. Ecological impact is one of the indirect cause of corrosion on the environment,because of expensive chemicals, a contamination of technological streams by corrosion product.
less of efficiency, overdesign and shutdown, the corrosion risk is related to environmental pollution by hazardous chemical, fuel and gases, resulting to impossible fire and explosion, damage to people, animal, plant, air, soil and water the causes  of corrosion damage of over-ground storage tank,pipes, heat exchangers, and  other  equipment as well other preventive are analysed.                                                                                           

Monday, March 13, 2017

THE PROBLEM STATEMENT


Many corrosion problems have occured with related process change within the several years of the existence of the oil and gas and refining industry. It is obvious that many corrosion damages or work occured at some of the oil facility, In some oil operating company, corrosion  affects most of their operating facility, and several professional are also provided maintenance work for the upkeep and treatment of the plants. The effluent water and oil/gas are tested for its constituent and are treatment for the best production outcome. The water injection booster pump in one of the oil operating company was inspected by some experts from some of the institutions,which conducted the following case study on water injection unit. Also there are many corrosion experts, and chemical analyst, corrosion magazine, and conferences that are held yearly to eliminate the effect of corrosion and its related damages. A lot of company, manufacture of difference materials and equipment for corrosion control and monitoring had discussed and presented several instructions of this epidemic called corrosion but  the impact of corrosion still persist inspite of numerous trials. It remain one of the main danger to the oil and gas refining and production industry and other operating facility. The main purpose of this work is to conduct the survey of the corrosion situation in the oil and gas industry during the past four years to quantify or estimate cost of corrosion, to define the reason of corrosion  problems and to find the effective measures to solve them, a result to improve their reliability, availability, and the profitability in the oil and gas,  production and manufacturing industry. Every industry and their plant has difference distribution and propagation of corrosion phenomena  that occurs at different interval and frequency, For example distribution of corrosion damages, that occur during the four years and the solution of their preventative measures and methodology. About 75% of all the corrosion failures occurs because of insufficient information and knowledge, as well as adequate interpretation among difference groups responsible for the  acceptance and approval of anti-corrosion discussion.

Saturday, March 11, 2017

COATING - 3


In case of fire-stops,a melting burning plastic pipe must be squeezed together and shut so that there would be no opening for fire to propagate to an otherwise rated wall or floor assembly while the intumescent application is used to achieve passive fire protection for such application as fire stopping,proofing,gasketing,and window casing.But it is important to note that some intumescent are substable to environmental influences such as humanity which reduce or negate their ability to function.protection casing also has some method of evaluating the life prediction of coating and their ability to predict service life real environment and are discussed in the contest of degradation process of coating systems. other experimentation that are conducted to determined the following includes:
1.The ingress of reactants into the steel and coating surface.
2,Accelerated test for performance evaluation ASTM B117 standard practice for operating salt    spray(fog) apparatus.ISO 7253,Testing standard ASTM B117-1939 and B117-1997.
3.Accelerated test for performance evaluation ASTM. G85,standard practice for modified salt spray(fog), testing which includes the following:
-Continuous acetic and acid salt spray test
-Cyclic acidified salt spray test.
-Cyclic sea water acidified test.
-Cyclic So2 salt spray test.
-Dilute electrolyte cyclic fog dry test.
The last item of the modification,the dilute electrolyte cyclic fog dry test was reported to give best correlation without door exposure test and uses a much diluted electrolyte (0-0.5%sodium chloride)
with small amount (0.35%)of ammonium sulphate to represent industrial atmosphere.The test cycle alternate between one hour of fog and one hour of dry off and in each fog drying cycle the fog will gradually increased thus exposing the samples to a water range of salt concentration ASTM D9894 - 96 practice for cyclic salt fog/uv exposure of painted metal.

COMMON USE OF INDUSTRIAL COATING

The most common use of industrial coating is for corrosion control of steel structure such as offshore platforms bridges and underground pipelines.The function of coating industries includes intumescent coating for fire resistance,and polymer which are also used in industrial structure such as polyurethane,epoxy and moisture cure urethane, and fluoropolymer.The process of coating also consist of the following inorganic zinc,phosphate, xylan and PVD coating.Coating also exist in two different types such as soft and hard char being produced with sodium silicates and graphite.And the product are suitable for use in plastic pipe fire-stops as well as exterior fire proofing and structure steel such as in fire-stops pillows and it has low expansion pressure.

RISK ASSOCIATED WITH HUMAN HEALTH TOXICITY ASSESSMENT.-2

Human health benchmark for chronic oral and inhalation exposures were needed to conduct risk assessment characteristics. This section represents the one cancer and cancer benchmark based to evaluate human health effects,that may result to exposure to consistent modeled risk assessment.Human health benchmarks and their sources are discussed.etc

Friday, March 10, 2017

RISK ASSOCIATED WITH HUMAN HEALTH TOXICITY ASSESSMENT

The risk associated to human exposure to the constituent of chemical toxicity information to each chemical stored in the facility or in our operational base,or being used for operations is integrated with the result of the exposure assessment interval.Its ability to cause adverse health effect depends on the toxicity of the chemical.The route of exposure to an individual( either through digestion or inhalation),the duration or extent of exposure,and the dosage(the amount that a human ingests or inhales).The toxicity of a constituent is defined by human health medical analysis  for each route of exposure  and is referred to as the risk assessment.Imperatively medical analysis is a quantitative data,valued on categorization of the medical data analysis and derived from data based on animal  studies or human epidemiological strives.A dose response estimate of adverse health effect to exposure dose are commonly represented by benchmarks. This is because individual chemical causes different heath effects at different doses and the chemical is the benchmark.For further details consult NACE International.

Thursday, March 9, 2017

ABSTRACT ON INDUSTRIAL COATING.



Coating work is usually conducted in various areas of the industry periodically to eliminate the formation of oxide on a metallic,and nonmetallic surfaces. The terrain in which such work can be performed include the following activities , industrial flow process ,drilling operation, flowstation,manufacturing industry,and flowlines,machine component and other operating facility.And to eliminate these corrosive or oxides,an industrial coating operation is normally conducted periodically, and the formation of corrosion or oxide on the surface of the pipe emanates through the reaction of oxygen,and moisture.  There are experimental examination that are conducted to determined the extent or integrity of the effect which will enable the specialist company or organization to apply the media or methods of  the composition suitable for the effected surface.
.Although corrosion prevention  coating is  performed to improve the operational life cycle of engineering materials, and there are various steps that are employed in the  application which differs from one location to the other.