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.

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)

                                                             

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.,

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..   .

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).

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.

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.