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MAINTENANCE TOOLS &TECHNIQUES
MAINTENANCE MANAGEMENT &TECHNIQUES <ul><li>LLF </li></ul><ul><li>CONDITION MONITORING </li></ul><ul><li>PREDICTIVE MAINTEN...
MAINTENANCE ACTIVITIES <ul><li>PLANNING </li></ul><ul><li>RESOURCES </li></ul><ul><li>MANPOWER  </li></ul><ul><li>SPARES  ...
MAINTENANCE TOOLS <ul><li>HAND TOOLS </li></ul><ul><li>POWER TOOLS </li></ul><ul><li>MACHINE TOOLS </li></ul><ul><li>LIFTI...
HAND TOOLS <ul><li>SPANNERS(OPEN/D,RING ) </li></ul><ul><li>WRENCHES </li></ul><ul><li>HAMMERS </li></ul><ul><li>PLIERS </...
PULLERS <ul><li>TWO LEG PULLERS </li></ul><ul><li>THREE LEG PULLERS </li></ul><ul><li>FOUR PRONG PULLERS </li></ul><ul><li...
LIFTING TOOLS AND TACKLES <ul><li>MANILA ROPE </li></ul><ul><li>SYNTHETIC ROPES </li></ul><ul><li>WIRE ROPES </li></ul><ul...
SLINGS <ul><li>There are generally six types of slings: </li></ul><ul><li>chain,  </li></ul><ul><li>wire rope,  </li></ul>...
Synthetic Web  SLINGS <ul><li>Synthetic web slings are commonly made of nylon, polypropylene, or polyester and have the fo...
Non Metallic SLINGS Fiber Rope and Synthetic Web   Fiber rope and synthetic web slings are used primarily for temporary wo...
Non Metallic SLINGS <ul><li>Physical Properties of Nonmetallic slings: </li></ul><ul><li>NYLON PRODUCTS STRETCH ABOUT 6% A...
REFERENCES: for SLINGS OSHA Regulations / Standard for slings. 29 CFR N 1910. 184 …   American National Standards Institut...
POWER TOOLS PORTABLE GRINDER,BENCH GRINDER, PORTABLE DRILLING MACHINE, MAGNETIC BASE DRILLING MACHINE
Regulations Covering  Hand and Power Tools <ul><li>For General Industry  </li></ul><ul><li>29 CFR.------- </li></ul><ul><u...
CRANES <ul><li>BLOCK </li></ul><ul><li>CONTAINS ONE TO EIGHT PULLEYS </li></ul><ul><li>SNATCH BLOCK-ONE PULLEY WITH SIDE O...
OVERHEAD TRAVELLING CRANES
Acetylene  Gas Cylinders <ul><li>Acetylene  cylinders are 200 to 250 psig. </li></ul><ul><li>Becomes unstable when compres...
Acetylene Cylinder The acetylene dissolved in acetone to the ratio of 400. Liquid acetylene on evaporation expands 250 tim...
 
Compressed Gas  Oxygen  Cylinders <ul><li>High Pressure – Rated at 2250 psi. </li></ul><ul><li>Must be secured at all time...
Oxy  /   Acetylene  – Use & Safety <ul><li>Equipment Setup </li></ul><ul><ul><li>Oxygen – cylinder, hose & torch threads a...
Oxy   /   Acetylene  – Use & Safety <ul><li>Hoses </li></ul><ul><ul><li>Make sure that hoses are rated for the gas being u...
Nozzle-Mixing Technology
Quick-connect, Check-valves, Backflash-preventers
 
 
Care & maintenance of the Gas Regulators The internal working parts of the regulator are precision units.  Only qualified ...
SPECIAL TOOLS <ul><li>ALIGNMENT KITS: CLAMPS,DIAL GUAGE,SCALE,LASER ALIGNMENT UNIT </li></ul><ul><li>HYDROJETTING MACHINE ...
MEASURING TOOLS <ul><li>DIAL GUAGE </li></ul><ul><li>MAGNETIC STAND </li></ul><ul><li>PLASTIC GUAGE </li></ul><ul><li>THIC...
MAINTENANCE FACILITIES AND ACCESSORIES <ul><li>WORK BENCH </li></ul><ul><li>BENCH VICE </li></ul><ul><li>LAP BED </li></ul...
MAINTENANCE TECHNIQUES <ul><li>HEAT EXCHANGER MAINTENANCE </li></ul><ul><li>PUMP OVERHAULING </li></ul><ul><li>TURBINE OVE...
RIGGING <ul><li>GIN POLES </li></ul><ul><li>A POLE HELD VERTICAL BY ROPES AND USED IN PLACES WHERE CRANE APPROACH IS NOT P...
SCAFFOLDING <ul><li>TEMPORARY PLATFORM USED FOR WORKING ABOVE GROUND LEVELS </li></ul><ul><ul><li>FIXED SCAFFOLD </li></ul...
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47 Maint Tools & Techniques Fope06

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  • Quick connections make set-up and tear-down of torch &amp; equipment much faster. It also adds additional safety check valves
  • Quick connections make set-up and tear-down of torch &amp; equipment much faster. It also adds additional safety check valves
  • Refer to Tip Charts for proper size tip needed for the material thickness to be cut Excessive Tip Size will waste Oxygen
  • Transcript of "47 Maint Tools & Techniques Fope06"

    1. 1. MAINTENANCE TOOLS &TECHNIQUES
    2. 2. MAINTENANCE MANAGEMENT &TECHNIQUES <ul><li>LLF </li></ul><ul><li>CONDITION MONITORING </li></ul><ul><li>PREDICTIVE MAINTENANCE </li></ul><ul><li>PREVENTIVE MAINTENANCE </li></ul><ul><li>SCHEDULED TURNAROUNDS </li></ul><ul><li>STATUTORY MAINTENANCE </li></ul><ul><li>PROACTIVE MAINTENANCE </li></ul>
    3. 3. MAINTENANCE ACTIVITIES <ul><li>PLANNING </li></ul><ul><li>RESOURCES </li></ul><ul><li>MANPOWER </li></ul><ul><li>SPARES </li></ul><ul><li>TOOLS AND TACKLES </li></ul><ul><li>TASKS </li></ul><ul><li>MICRO PLANNING </li></ul><ul><li>MACRO PLANNING </li></ul><ul><li>EXECUTION </li></ul><ul><li>RECORDING </li></ul><ul><li>ANALYSIS </li></ul><ul><li>LEARNING </li></ul>
    4. 4. MAINTENANCE TOOLS <ul><li>HAND TOOLS </li></ul><ul><li>POWER TOOLS </li></ul><ul><li>MACHINE TOOLS </li></ul><ul><li>LIFTING TOOLS AND TACKLES </li></ul><ul><li>TRANSPORTATION TOOLS </li></ul><ul><li>SPECIAL TOOLS </li></ul><ul><li>MAINTENANCE FACILITIES & ACCESSORIES </li></ul><ul><li>FABRICATION TOOLS </li></ul>
    5. 5. HAND TOOLS <ul><li>SPANNERS(OPEN/D,RING ) </li></ul><ul><li>WRENCHES </li></ul><ul><li>HAMMERS </li></ul><ul><li>PLIERS </li></ul><ul><li>SCREW DRIVER </li></ul><ul><li>CHISEL </li></ul><ul><li>FILES </li></ul><ul><li>SCRAPPERS </li></ul><ul><li>CENTER PUNCH </li></ul>
    6. 6. PULLERS <ul><li>TWO LEG PULLERS </li></ul><ul><li>THREE LEG PULLERS </li></ul><ul><li>FOUR PRONG PULLERS </li></ul><ul><li>HYDRAULIC PULLERS </li></ul><ul><li>TAILOR MADE PULLERS </li></ul>
    7. 7. LIFTING TOOLS AND TACKLES <ul><li>MANILA ROPE </li></ul><ul><li>SYNTHETIC ROPES </li></ul><ul><li>WIRE ROPES </li></ul><ul><li>-NO. OF STRANDS 6 </li></ul><ul><li>-NO. OF WIRES PER STRAND 19 </li></ul><ul><li>-STRAND CONSTRUCTION 6 X19 </li></ul><ul><li>-LAY(REGULAR/LANG),CORE FABRICATION (HEMP OR IWRC) </li></ul><ul><li>STD: 6X19,6X37 ( SMALL WIRES OFFER MORE FLEXIBILITY) </li></ul><ul><li>SHARP BENDS REDUCE LOAD BY 50% </li></ul><ul><li>HANDLINES( ROPE FOR STEADYING OR HOLDING LOADS) </li></ul><ul><li>BLOCKS(SNATCH BLOCKS,PULLEY BLOCKS) </li></ul><ul><li>CHAIN FALLS </li></ul><ul><li>TURN BUCKLES </li></ul><ul><li>HOIST </li></ul><ul><li>CRANES </li></ul><ul><li>EYE BOLTS/D SHACKLES </li></ul><ul><li>JACKS(SCREW JACKS/HYDRAULIC JACKS,POWER JACKS) </li></ul><ul><li>C CLAMPS </li></ul>
    8. 8. SLINGS <ul><li>There are generally six types of slings: </li></ul><ul><li>chain, </li></ul><ul><li>wire rope, </li></ul><ul><li>metal mesh, </li></ul><ul><li>natural fiber rope (Manila Rope), </li></ul><ul><li>synthetic fiber rope, or </li></ul><ul><li>synthetic web. </li></ul>
    9. 9. Synthetic Web SLINGS <ul><li>Synthetic web slings are commonly made of nylon, polypropylene, or polyester and have the following properties in common: </li></ul><ul><li>§    Strength -  Depending upon their size, synthetic web slings can handle loads of up to 300,000 pounds. </li></ul><ul><li>§    Convenience and Safety - Synthetic web slings adjust to the load contour and hold it with a tight, non-slip grip. </li></ul><ul><li>§    Load Protection - Unlike other sling materials, synthetic web is less likely to mar, deface, or scratch highly polished surfaces.      </li></ul>
    10. 10. Non Metallic SLINGS Fiber Rope and Synthetic Web Fiber rope and synthetic web slings are used primarily for temporary work, such as construction or painting, and are the best choice for use on expensive loads, highly finished or fragile parts, and delicate equipment.
    11. 11. Non Metallic SLINGS <ul><li>Physical Properties of Nonmetallic slings: </li></ul><ul><li>NYLON PRODUCTS STRETCH ABOUT 6% AT RATED CAPACITY, POLYESTER PRODUCTS AT ABOUT 3% AND HIGH PERFORMANCE SPECIAL SYNTHETIC PRODUCTS SUCH AS SPECTRA® AND KEVLAR® AT ABOUT 1%. </li></ul><ul><li>  </li></ul><ul><li>&quot;WITH THIS BUILDING BLOCK KNOWLEDGE, THE INSPECTOR MAY DETERMINE THAT EXCESSIVE ELONGATION MIGHT BE A CAUSE OF THE ABRASION, AND SO RECOMMEND THAT A PRODUCT WITH LESS STRETCH IN COMBINATION WITH WEAR PROTECTION MIGHT REMEDY THE EFFECT OF ABRASION AND INCREASE THE LIFE OF THE SLING. </li></ul>
    12. 12. REFERENCES: for SLINGS OSHA Regulations / Standard for slings. 29 CFR N 1910. 184 …   American National Standards Institute, standard for slings. (ANSI) B-30.9-1971.   Sling Safety Guidelines. OSHA 3072 Description Std / Number
    13. 13. POWER TOOLS PORTABLE GRINDER,BENCH GRINDER, PORTABLE DRILLING MACHINE, MAGNETIC BASE DRILLING MACHINE
    14. 14. Regulations Covering Hand and Power Tools <ul><li>For General Industry </li></ul><ul><li>29 CFR.------- </li></ul><ul><ul><li>1910 Subpart P, Hand and Portable Power Tools and Other Hand-Held Equipment. </li></ul></ul><ul><ul><li>1910.241, Definitions. </li></ul></ul><ul><ul><li>1910.242, Hand and portable powered tools and equipment, general. </li></ul></ul><ul><ul><li>1910.243, Guarding of portable powered tools. </li></ul></ul><ul><ul><li>1910.244, Other portable tools and equipment. </li></ul></ul>
    15. 15. CRANES <ul><li>BLOCK </li></ul><ul><li>CONTAINS ONE TO EIGHT PULLEYS </li></ul><ul><li>SNATCH BLOCK-ONE PULLEY WITH SIDE OPEN </li></ul><ul><li>HAND SIGNAL </li></ul><ul><li>FIGURING THE RADIUS ON CRANES </li></ul><ul><li>- BOOM LENGTH AND RATING, DISTANCE OF JOB FROM CRANE,COUNTER WEIGHT OF CRANE, ATTACHMENT OF JIBS, EXTENSION OF BOOM </li></ul><ul><li>HYDRA(HYDRAULIC LIFT TRUCKS) </li></ul><ul><li>OVERHEAD TRAVELLING CRANE </li></ul><ul><li>EOT(ELECTRIC OVERHEAD TRAVELLING) CRANES </li></ul><ul><li>MONORAILS </li></ul>
    16. 16. OVERHEAD TRAVELLING CRANES
    17. 17. Acetylene Gas Cylinders <ul><li>Acetylene cylinders are 200 to 250 psig. </li></ul><ul><li>Becomes unstable when compressed in gaseous state above 15 psig. </li></ul><ul><li>Requires special porous core cylinder. </li></ul><ul><ul><li>Acetylene gas is absorbed in cylinder core by acetone to keep it stable under pressure. </li></ul></ul><ul><ul><li>Must be stored and used in upright position to keep the liquid acetone contained. </li></ul></ul><ul><li>Maximum delivery pressure is 15 psig. </li></ul>
    18. 18. Acetylene Cylinder The acetylene dissolved in acetone to the ratio of 400. Liquid acetylene on evaporation expands 250 times .
    19. 20. Compressed Gas Oxygen Cylinders <ul><li>High Pressure – Rated at 2250 psi. </li></ul><ul><li>Must be secured at all times. </li></ul><ul><ul><li>Must be capped to transport in motor vehicle or not in use as per statutory rules. </li></ul></ul><ul><li>Grease & Oil must not come in contact with component of Oxygen System. </li></ul><ul><ul><li>They can ignite & burn violently in presence of pure oxygen. </li></ul></ul>
    20. 21. Oxy / Acetylene – Use & Safety <ul><li>Equipment Setup </li></ul><ul><ul><li>Oxygen – cylinder, hose & torch threads are Right-Hand. </li></ul></ul><ul><ul><li>Acetylene - cylinder, hose & torch threads are Left-Hand. </li></ul></ul><ul><li>Main Cylinder Valves </li></ul><ul><ul><li>Inspect cylinder valve seating surfaces & threads for dirt and damage. </li></ul></ul><ul><ul><li>Always crack valve prior to attaching regulator – helps remove any loose dirt or debris. </li></ul></ul><ul><ul><li>Stand to the side of the valve port and make sure no one is standing in front of it when you crack it. </li></ul></ul>
    21. 22. Oxy / Acetylene – Use & Safety <ul><li>Hoses </li></ul><ul><ul><li>Make sure that hoses are rated for the gas being used and the tip size. </li></ul></ul><ul><ul><li>Hoses are often exposed to abuse and must be inspected for cracks, burns, etc. </li></ul></ul><ul><ul><li>Keep clean and free from oil or grease. </li></ul></ul><ul><ul><li>Hoses are color coded and threaded differently </li></ul></ul><ul><ul><ul><li>Oxygen is blue with Right-Hand threads. </li></ul></ul></ul><ul><ul><ul><li>Fuel Gas is Red with Left-Hand threads. </li></ul></ul></ul><ul><ul><ul><li>Fuel Gas hose nuts have a V groove on outside to indicate Left-Hand threads. </li></ul></ul></ul><ul><ul><li>Purge both hoses at about 3 psi to clear any foreign objects prior to attaching torch. </li></ul></ul>
    22. 23. Nozzle-Mixing Technology
    23. 24. Quick-connect, Check-valves, Backflash-preventers
    24. 27. Care & maintenance of the Gas Regulators The internal working parts of the regulator are precision units. Only qualified technicians should clean or repair a regulator <ul><li>The Inlet Connections </li></ul><ul><ul><li>Oxygen are right hand thread / Acetylene are left hand thread </li></ul></ul><ul><ul><li>Keep free of oil, grease, & dirt. </li></ul></ul><ul><li>The Pressure adjusting screw </li></ul><ul><ul><li>Turning clockwise allows the gas allows to flow. </li></ul></ul><ul><ul><li>Turning counterclockwise reduces or stops the gas flow. </li></ul></ul><ul><li>The High pressure gauge </li></ul><ul><ul><li>Indicates the pressure from tank. </li></ul></ul><ul><li>The Low pressure gauge </li></ul><ul><ul><li>Indicates the delivery pressure to the hoses & torch. </li></ul></ul>
    25. 28. SPECIAL TOOLS <ul><li>ALIGNMENT KITS: CLAMPS,DIAL GUAGE,SCALE,LASER ALIGNMENT UNIT </li></ul><ul><li>HYDROJETTING MACHINE </li></ul><ul><li>HYDRAULIC BOLT TENSIONER </li></ul><ul><li>BOLT HEATER </li></ul><ul><li>LIFTING BEAMS </li></ul><ul><li>TAILOR MADE TOOLS TO TURBINES/PUMPS/GEARBOXES </li></ul><ul><li>PLASMA CUTTING MACHINE </li></ul><ul><li>BEVEL CUTTER </li></ul>
    26. 29. MEASURING TOOLS <ul><li>DIAL GUAGE </li></ul><ul><li>MAGNETIC STAND </li></ul><ul><li>PLASTIC GUAGE </li></ul><ul><li>THICKNESS TESTER </li></ul><ul><li>SLIP GUAGES </li></ul><ul><li>VERNIER CALIPERS </li></ul><ul><li>MICROMETERS </li></ul><ul><li>HEIGHT GAUGE </li></ul><ul><li>BEVEL PROTRACTOR </li></ul><ul><li>GEAR TOOTH VERNIER </li></ul><ul><li>FILLER GUAGE </li></ul><ul><li>HARDNESS TESTER </li></ul><ul><li>SPIRIT LEVEL/MASTER LEVEL </li></ul><ul><li>STRAIGHT EDGE </li></ul><ul><li>PIANO WIRE </li></ul><ul><li>VIBRATION METER </li></ul><ul><li>THREAD GAUGE </li></ul><ul><li>TONGUE TESTER </li></ul><ul><li>VOLTMETER </li></ul>
    27. 30. MAINTENANCE FACILITIES AND ACCESSORIES <ul><li>WORK BENCH </li></ul><ul><li>BENCH VICE </li></ul><ul><li>LAP BED </li></ul><ul><li>HYDRAULIC PRESS </li></ul><ul><li>TOOL BOX </li></ul><ul><li>HAND TROLLEYS </li></ul><ul><li>LUBE CART </li></ul>
    28. 31. MAINTENANCE TECHNIQUES <ul><li>HEAT EXCHANGER MAINTENANCE </li></ul><ul><li>PUMP OVERHAULING </li></ul><ul><li>TURBINE OVERHAULING </li></ul><ul><li>SPADING/DESPADING VALVE MAINTENANCE </li></ul><ul><li>GEARBOX MAINTENANCE </li></ul><ul><li>FANS AND BLOWERS </li></ul>
    29. 32. RIGGING <ul><li>GIN POLES </li></ul><ul><li>A POLE HELD VERTICAL BY ROPES AND USED IN PLACES WHERE CRANE APPROACH IS NOT POSSIBLE </li></ul><ul><li>TRIPODS </li></ul><ul><li>REMOVING SAFETY VALVES FROM TALL COLUMNS </li></ul><ul><li>DAVIT ARM,SNATCH BLOCK,WINCHES </li></ul><ul><li>SMALL WOOD SKIDS </li></ul><ul><li>SKIDS AND ROLLERS USED TO MOVE HEAVY OBJECTS </li></ul><ul><li>MOVING PUMPS </li></ul><ul><li>MOVING ELECTRIC MOTORS </li></ul><ul><li>RUNNING PIPE </li></ul><ul><li>PULLING AND REPLACING EXCHANGER BUNDLES </li></ul>
    30. 33. SCAFFOLDING <ul><li>TEMPORARY PLATFORM USED FOR WORKING ABOVE GROUND LEVELS </li></ul><ul><ul><li>FIXED SCAFFOLD </li></ul></ul><ul><ul><li>SWINGING SCAFFOLD </li></ul></ul><ul><ul><li>TYPES: </li></ul></ul><ul><ul><li>HORSE TYPE </li></ul></ul><ul><ul><li>BUCK TYPE </li></ul></ul><ul><ul><li>CANTILEVER </li></ul></ul><ul><ul><li>HANGING </li></ul></ul><ul><ul><li>TANK BRACKET </li></ul></ul><ul><ul><li>COMBINATION SCAFFOLD </li></ul></ul><ul><ul><li>TUBELOX SCAFFOLD-PATENTED METAL SCAFFOLD MADE OF TUBULAR STEEL CONSTRUCTIONS </li></ul></ul>
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