Transcript King Fahd University of Petroleum and Minerals Mechanical Engineering Department Equipment

King Fahd University of Petroleum and Minerals
Mechanical Engineering Department
Maintenance and Preventive Maintenance of Heavy
Equipment
Coop Training : Central Heavy Equipment Department In Aramco
Presented by: Abdulnaser M. Al-Mesbah
ID#
981908
DATE :
OCTOPRER 20, 2004
Outline
 Central Heavy Equipment Department
 Heavy Equipment Shops
 Cases Study
 Conclusion
Central heavy equipment department
 1. Dhahran Equipment Pm/Field Repair Service Unit
 2. Patch & Dispatch Unit
 3. Quality Control Unit
 4. Electric Shop Unit
 5.Heavy Equipment Shops Unit
Heavy Equipment Shops
 1. Crane Shop
 2. Dozer Shop
 3. Fuel Room
 4. Pumps Rebuild Shop
Case Study 1: Portable 900KW Generator
Case study 1
Portable 900KW generator
Physical assessment:
1. Water leak in radiator core
2. Excessive leak at oil cooler gasket
Case study 1
Portable 900KW generator
 Quality Control Unit
1. Due to radiator leak, water level dropped causing the engine to
2.
3.
4.
over heat.
Automatic Shut down system failed to actuate.
Heavy oxidation of the engine oil that become black viscous tar.
Due to the oxidation of the oil, all oil lines and panes are
covered/coated with the high oxidized oil.
Case study 1
Portable 900KW generator
Repair cost:
Alternative #1: Repair Cost Estimate with In-House Engine Overhaul
Material cost
Labor
Invoices
Total
($)
($)
($)
($)
Already
charged
3295
8225
In-house
engine
overhaul
5000
10000
Total
8295
18225
228
11748
15000
228
26748
Case study 1
Portable 900KW generator
Repair cost:
Alternative #2:
Replacement
: Repair Cost Estimate with External Overhaul or
Material cost
($)
Labor
($)
Invoices
($)
Total
($)
Already
charged
3295
8225
228
11748
In-house
engine
overhaul
100,000
1000
10,000
111000
total
103295
9225
10228
122748
Case study 1
Portable 900KW generator
Repair cost:
 Alternative #1: % of Repair Cost vs. New Unit Cost:
27000/300,000 = 9%
 Alternative #2: % of Repair Cost vs. New Unit Cost:
123000/300,000 = 41 %
Case study 1
Portable 900KW generator
Items That Have Been Repaired or Replaced:
replacing the engine starter.
 Removing the old automatic shut down system and reinstall it
again.
 install new radiator.
 cleaning the engine due to the oxidation of oil.
 replacing oil ban gaskets with new ones.
 Replacing the engine head gaskets.
 replacing the engine governor.

Case Study 2: AT-750BE Crane
Case study 2
AT-750BE Crane
Quality Control Inspection:








Steam clean unit.
Flash radiator and refill with antifreeze.
Clean all operator cap.
Reseal rear R.H.S final drive due to oil leak.
Repair or replace upper sky glass supporting cylinders.
Calibrate fuel injectors.
Replace fuel sender.
Repair air leak at the parking brake valve.
Case study 2
Crane Maintenance:

R.H.S Final Drive
AT-750BE Crane
Case study 2
• All injectors have been sent to the fuel
room for calibration.
• adjusting
the intake and the exhaust
valves with 0.014 and 0.027 in feeler gauge
respectively.
• one of the rock arms fall down inside the
engine.
AT-750BE Crane
Case study 2
Additional items:
•
•
•
•
•
•
Changing oil filters
Lubricating the wire rope.
Repair the horn.
Repair the beacon light.
Replace wiper blade for the sky window.
Retighten suspension wear pads.
AT-750BE Crane
Case Study 3: The 89-0865 Forklift (10 T)
Quality Control Unit :
• Repair oil leak in the lift cylinder.
• Check if oil leak exist in both cylinders (forks mover) at the carriage.
• Change all hydraulic hoses that are fitted on the upright, carriage and lift
cylinder.
• Check if there is oil leak in the torque converter.
• Grease the chain on the upright.
• Change all tires.
• Flash radiator and refill with antifreeze and water (50% * 50%).
• Check and repair all beacon lights.
Case study 3
Re-sealing the lift cylinder
Step # 1: Draining oil from the lower part of the lift cylinder
89-0865 Forklift
Case study 3
89-0865 Forklift
Re-sealing the lift cylinder
Step # 2: Removing the lock, which is in the head of the cylinder.
Step # 3: Opening the piston lock.
Case study 3
89-0865 Forklift
Re-sealing the lift cylinder
Step # 4: Pulling the piston out side the cylinder using a forklift.
Step # 5: changing the piston seals
Case study 3
Piston Lock:
• Time needed: 3 hours.
• lock material is weak.
• no special tool available.
89-0865 Forklift
Case study 4
Case Study 4: Pipe Loader
Pipe Loader
Case study 4
Quality control unit:
• Repair or replace the transmission pump.
• Replace the hydraulic pump.
• Re-seal both the lift cylinders.
• Send engine injectors to the fuel room for calibration.
• Change all tires.
• Repair or replace beacon lights.
Pipe Loader
Case study 4
• New transmission pump cost: 2100 US$
• The pump was sent to the welder shop
Most of the hydraulic systems use gear pump
Pipe Loader
Case study 4
Pipe Loader
Testing the pipe loader:
• pipe loader capacity: 12 T
•The test was to carry a 9 T
•The pipe loader success
•The pipe loader had been sent to the load test to test it with 12 T.
• the pipe loader success.
Case study 4
Pipe Loader
Conclusion:
 Value of time and
commitment.
 Value of team work.
 maintenance of heavy
equipment
Thank you