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)
.-.
-

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.

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.

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                            

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      

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

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.
                                       -

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.

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

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.