Equipment Reliability

Equipment Reliability
Learning
Module
DOCUMENT NO. REVISION EFFECTIVE DATE PRINT DATE PAGE
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Learner Name
Intended Audience
Maintenance personnel in the Factory / Plant
Unit Coordinator: (Superintendent)
Unit Members: (Supervisor),
(HSE),
Thanks to the following people for their help with the development of this Learning Unit:

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UNIT OVERVIEW
Aim:
To provide artisans with the skills and knowledge to maintain, troubleshoot and set-up of the Equipment, using the required
materials, process and equipment in accordance with safety, quality and performance requirements.
Objectives:
On completion of this unit you will
 follow Health, Safety & Environmental regulations related to maintenance requirements
 identify different parts of the Plant / Equipment and understand their functions
 explain basic hydraulic symbols
 maintain the equipment to world class standards
 understand, discuss and apply advanced world class maintenance principals
 identify the appropriate maintenance documentation
 perform fault finding
 practically apply management concepts in your maintenance environment
Structure:
1 Overview .....................................................................................................................................................4
1.2 Environment......................................................................................................................................4
1.3 Health................................................................................................................................................5
1.4 Safety ................................................................................................................................................6
2 Hydraulics...................................................................................................................................................8
2.1 Basics ................................................................................................................................................8
2.2 Pumps & Motors .............................................................................................................................10
2.3 Valves..............................................................................................................................................11
2.4 Cylinders .........................................................................................................................................13
2.5 Accumulators ..................................................................................................................................14
2.6 Powerpacks .....................................................................................................................................15
3 Electrical Motors......................................................................................................................................16
3.2 Cooling Fans ...................................................................................................................................16
3.3 Bearings ..........................................................................................................................................17
4 Electrical Switches....................................................................................................................................18
4.2 Proximity Switches .........................................................................................................................18
4.3 Limit Switches ................................................................................................................................19
5 Screws & Conveyors ................................................................................................................................19
5.2 Gearboxes........................................................................................................................................21
5.3 Scrapers...........................................................................................................................................23
6 Waste Gas System ....................................................................................................................................24
6.2 AC Invertors....................................................................................................................................28
6.3 Fans & Valves.................................................................................................................................28
6.4 Dosing System ................................................................................................................................30
6.5 Pumps and Pipes .............................................................................................................................32
6.6 ESP Electrodes & Insulator.............................................................................................................33
7 Controls & Instrumentation....................................................................................................................34
OTHER THINGS I HAVE LEARNED ...........................................................................................................35
RESOURCE GUIDE .........................................................................................................................................36
ASSESSMENT PLAN .......................................................................................................................................38

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Prerequisites: Departmental Fundamentals LM, Departmental Operations LM,
Associated Units: Hydraulics LM, Instrumentation Optimization LM, Modicon PLC LM, Team Excellence LM, Asset
Management LM, Legislative LM.

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C = Critical  = No Verification required
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LEARNING OUTCOME AND VERIFICATION FORM
Each Learning Outcome must be Verified by a competent person to record that the individual has successfully demonstrated
the skills and knowledge identified. For resources available to assist in achieving these Learning Outcomes, see the Unit
Resource Guide. Critical Learning Outcomes that involve practical demonstrations must not be attempted except in the
presence of a competent person until the learner has been successfully Verified.
Ref Learning Outcomes C
Ver’d
& Date Notes
1 Overview 
1.1 Environment  Check
Carbon Fund.
1.101 As part of your 4-step safety card, you need to think about what else can go wrong
when you do something.
Talk to at least one colleague about the consequences if you place rubbish or
hazardous or chemical waste in storm water drains.
C
1.102 At Our Company we separate our waste. Discuss with your colleague the waste
handling techniques and fill in, the blank spaces provided, the waste to be disposed in
which bins.
 Black bins: ________________________________
 Brown bins: _______________________________
 Yellow bins: _______________________________
 Blue Municipal bins: ________________________
 Orange bins: ______________________________
 Blue bins: ________________________________
C ISO
14001:2000
1.103 “The distinction between contamination and pollution may be worth noting, though
they are often used interchangeably.
 Contamination is the presence of elevated concentrations of a substance in the air,
water, soil etc. not necessarily resulting in a deleterious effect.
 Pollution is the, direct or indirect, human introduction of substances into the
environment such as to harm living resources, affect human health and impair
environmantal quality. (from GESAMP, 1982). “
Apply these concepts in your work environment and list at least one material that
could potentially pollute and one material that can contaminate our natural resources.
C

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Ver’d
& Date Notes
1.104 Protecting the water table in this area is important, as it is only approximately 1 meter
deep at some places.
Discuss why maintaining equipment handling oil, chemicals or pitch is important to
protect the water table.
C ISO 14001
1.105 Discuss the measures you will take to protect your health, safety and
environment when you need to work with hazardous waste or working
in areas where hazardous waste is stored:
 spent pot linings
 re-claim areas
 oil or petroleum contaminated waste
 fluorinated waste
C ISO 14001
1.106 Talk to a colleague about the most likely things that can go wrong when you perform
maintenance tasks. You may want to use some of the following guide lines:
 introduction of contaminants to the environment or your anodes
 over lubrication
 cleaning solvents and chemicals
C
1.2 Health 
1.201 Name at least three symptoms of dehydration, also known as heat fatigue:




C
1.202 One method to detect and monitor heat fatigue is to diagnose your urine.
Discuss the following stages of heat fatigue and what you will do to combat it.
 urine colour: amber
 urine colour: dark lemon
 urine colour: light lemon
C

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Ver’d
& Date Notes
1.3 Safety 
1.301 Explain the function of your PPE:
 safety hat
 gloves
 steel toe safety boots
 Vinex 2 piece overalls; long sleeves
 2 types of respirators; When & Where to use, What & How to maintain the canister
& filter
 ear protection
 safety glasses
C OHSA Part 4
1.302 Suppose one of your close family members work at Our Company. Explain to your
verifier the risk of injury or death of your family member having loose hanging hair,
jewellery or clothing and working with or close to moving or rotating machinery.
C
1.303 Demonstrate to your verifier what you will do when you hear the Evacuation Siren.
Mimic the siren or alarm.
C
1.304 According to the OHSA Section 14 it is your duty as employee to report any unsafe,
hazardous, un-reasonable or safety incident. If you do not report incidents, your
company will not know about it and can therefore not take any action. According to
this act section 38, you will be held liable if you do not report incidents to your
employer or health and safety officer, possibly facing one or all of the following:
 termination of your contract
 a fine of R 50 000
 imprisonment for period of 12 months
You might want to talk about the value of “Lessons Learned” from past experiences.
C OHSA Part 1
Sec. 14 & 38
1.4 Fire Fighting Equipment
1.401 Point out at least two things that are not
quite right in the photo, i.e. things that
will make the fire hose not functional for
fire fighting,.


C OHSA Part 1
Section 15

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Ver’d
& Date Notes
1.402 It is against the law to use fire hydrants or
hoses for anything but fire fighting. You
could face a fine and/or imprisonment for
abusing fire fighting equipment. Give one
good reason for not abusing fire hydrant
like:
 washing your car
 cleaning plant or equipment
 watering the garden
 “horse play”, fooling around
Suppose a fire breaks out and the fire
brigade needs to use the hydrants and can
not because of the above. Talk about the
consequences.
C OHSA Part 1
Section 15
1.403 Safety and good housekeeping is everybody’s responsibility. Our Company uses the
term ”a place for everything – everything has a place” Explain how this is applicable
to:
 unused fire extinguishers
 used fire extinguishers
C
1.404 Point out to your supervisor at least three fire extinguishers in your work
environment.
On identifying their location, discuss the:
 type,
 usage and
 condition
C
1.405 Point out the following and talk about aspects related to inspection of gas pipes and
connections:
 the PMs & report/feedback process
 inspection points
 inspection materials
 leakage test techniques
Demonstrate what you would do when you detect a leaking gas pipe or fitting.
Discuss the hazards and consequences in case of an explosion due to gas leakage.
C
1.5 Hoisting Equipment
1.501 Find out why you need to stay clear of the Plant / Equipment Intake Crane Area, only
entering when you have been officially authorised.
C
1.502 Slings and chains need to be adjusted while moving the fire so that the equipment is
level when transported. Talk to an operator and confirm the importance of the
equipment being level when moved.

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Ver’d
& Date Notes
1.503 With an operator, talk about the risks
involved by leaving hoisting equipment
unattended.
Suppose an incident occurred due to the
above. List at least 2 consequences:


Dicuss the additional maintenance cost
occurred while leaving the equipment
unnecessarily under load.
2 Hydraulics 
2.1 Basics 
2.101 According to ANSI B93.2.1971, contaminants are considered to be “…any material,
or substance which is unwanted or adversely affects the fluid power system or
components, or both.” Contaminants can be grouped as:
 build in: from paint chips and overspray, rust, dust, Teflon tape & other sealing
compounds, metal chips from pipe & fitting threads, sand, lint & welding slag.
 environmental: from dusty & moist air conditions & condensation
 operational: high oil velocities causing erosion & sliding friction on surfaces
causes wear
 oxidation: formation of solid carbon build-up
Talk about at least one preventive measures per group you can take to keep the
hydraulic system clean.
ANSI
B93.2.1971
2.102 Contaminants cause failure modes and can be grouped according to:
 Catastrophic failure: immediate failure of a system component mainly caused by
large particles in the hydraulic fluid.
 Degradation failure: a slow degrading process occurs daily but is not easily noticed
with time. Minute particles cause accelerated wear of close tolerance and sealing
surfaces, e.g. loss of flow & pressure, sluggish operation, sticky and irregular
movement.
Consider the two failure modes and find two applications in your work environment.

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Ver’d
& Date Notes
2.103 World class aluminium producers perform fault finding effectively, with the aid of the
following:
 hydraulic circuit diagram
 electrical circuit diagram
 operation sequence diagram
 plant layout with valve-, cylinder- & sensor-locations
 numbering and labelling of inputs, outputs, valves, cylinders & sensors
Discuss how the above documents could be used to your advantage in your own work
environment.
ISO 9001:2000, section 4.2 a quality management (QM) system is about document
control. Discuss with your group how the above documents are controlled and what
advantages good control can offer referring to:
 document release
 document evaluation
 document revision
 document availability
 document identification
 document handling
ISO
9000:2000
section 4.2
2.104 According to EN 13306:2001; Inspection can be carried out before, during and after
maintenance. Inspection is to “Check for conformity by measuring, observing, testing
or gauging the relevant characteristics of an item.”
Discuss your inspection technique and interval when:
 checking hydraulic hoses and fittings.
 checking for loose bolts or nuts on the structure.
Explain how you might use each of your senses during inspection:
 sight – (remember to wear your safety glasses)
 hearing – (remember to wear your ear protection)
 touch – (do not touch hot or hazardous materials)
 smell – (do not smell hazardous materials)
 taste – (do not taste hot or hazardous materials)
C EN 13 306
2.105 Hydraulic fluid seepage can easily contaminate a natural resource to such an extent
that it becomes polluted. One method to prevent pollution during an oil spill or leak
is to have drip trays fitted beneath hydraulic machinery and powerpacks. Drip trays
also known as “a double container” should be able to contain 1,5 times the oil volume
in the machine or reservoir.
Discuss the value of this preventive containment system and how you can help
protecting your environment by implementing this system.
C
2.106 Discuss your Isolation Procedure for the hydraulic system.
Be prepared to demonstrate your isolation, lock out, tag, de-energise and checking
procedures. Remember the Accumulators.
C

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Ver’d
& Date Notes
2.107 One case study, see above, show the frequency of occurrence of 8 various failure/fault
types (left hand graph) and a Plan of Action with 5 main measures to improve a
hydraulic system reliability (right hand graph). The most frequent fault is due to
“Faulty Pressure”. The most frequent preventive measure is “Part Rebuild &
Exchange”.
As a team, consider your hydraulic system. Set-up, from your experience and by
group discussion, your own Pareto chart with your selected failure or fault types like:
 leaking cylinder neck seal
 leaking connection
 valve not switching
 limit made, but not responding
 ….also, us you SAP system to find other frequent hydraulic system fault types
Set-up another Pareto chart showing your plan of action to control the failure or fault
types.
You might want to apply the 20/80 rule and consider the following:
 frequency of the fault/failure occurrence,
 severity of the fault/failure and
 the probability of detecting the fault/failure
2.2 Pumps & Motors 
1)_d_ 2)___ 3)___ 4)___ 5)___ 6)___

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Ver’d
& Date Notes
2.201 The above ISO 1219 symbols represent pumps and motors. Match the above symbols
with their descriptions below:
a) pump – variably capacity, two directional flow
b) pump/motor – variable capacity, two directional flow
c) motor – fixed capacity, one directional flow
d) pump – fixed capacity, one directional flow
e) motor – variable capacity, two directional flow
f) pump/motor – fixed capacity, one directional flow
ISO 1219
2.202 For a pump to function the direction of rotation must be correct.
Talk about why the pump rotation can be incorrect and the damage it could cause if
not quickly detected.
2.203 Hydraulic motors can be:
 gear type; low torque & high revolution
 vane type; low torque & high revolution
 axial piston type; medium torque & medium revolution
 radial piston type; high torque & low revolution
Discuss at least two reasons why motors or pumps might cavitate and present
solutions or preventive actions. Talk about the type of damage cavitation may cause.


2.204 Your powerpack is fitted with three electrical motors connected to hydraulic pumps.
One motor is planned for redundancy or backup, but is actually operational due to the
large ram cylinder not travelling fast enough.
Discuss how you can use accumulators to solve the same problem.
Team work
2.3 Valves  ISO 1219

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Ver’d
& Date Notes
2.301 Valve symbols can be:
 single block – pressure control types
 double block – flow control type
 triple block – flow control type
Discuss the following:
 number or ports; 4, 2, 3
 port naming; P, A, B & T
 actuation types; lever, pilot, manual push button, servo, solenoid, roller, plunger
 spring return vs. indentation
 valve positions in normal and energized states
 flow direction
Explain the valve naming convention:
 3/2-way, normally open, hand actuated, spring return
 4/3-way, directional control valve, hand operated, notched/indented
2.302 The following valves are also used in your Plant / Equipment:
a) Directional Control Valve (DCV), 4/3 way, spring central return, solenoid
activated.
b) DCV, 4/2 way, spring return, solenoid activated
c) shut-off valves, normally open (n/o)
d) flow control valves, variable with nrv (throttle one way)
e) non return valves (nrv), spring loaded,
f) non return valves (nrv), piloted to open
Match the above description with the ISO 1219 hydraulic symbols. Discuss their
functions:
 number or ports; 4, 2, 3
 port naming; P, A, B & T
 actuation types; lever, pilot, manual push button, servo, solenoid, roller, plunger
 spring return vs. indentation
 valve positions in normal and energized states
 flow direction

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Ver’d
& Date Notes
2.4 Cylinders  ISO 1219
2.401 Double acting type cylinders are mainly in use at the Plant / Equipment.
From the ISO 1219 symbols above select the double acting cylinder type and discuss
at least another two cylinder types.
2.402 One of the 5 TPM pillars are; Housekeeping and Cleanliness. Point out and discuss
the practical application of the BAOS 5s system, focus on “Shine”.
Discuss at least 2 methods to keep the cylinders clean, preventing dirt entering your
hydraulic system.
2.403 Cylinder neck seals must be well maintained, else leakage will occur. Discuss the
following and the effects it have on the seal life:
 clean and smooth (no grooves or scratches) cylinder rod
 radial forces and misalignment of cylinder rods ends, especially when extended
outward.
Talk about preventive methods to maximize the neck seal lifespan.
2.404 Suppose your piston seal is not sealing
properly due to wear.
Refer to the image to discuss how you can
check or confirm if the seal is not
functioning, using a manometer.
Bear in mind that:
 the inward flow must be fully throttled
to avoid shock and sudden piston
movement
 the initial test pressure should be very
low, full pressure should not be used.
C

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Ver’d
& Date Notes
2.405 Hydraulic cylinders must be secured properly. The photo shows:
 2 loose bolts & nuts
 2 out to 4 bolts & nuts were missing (one shown in ellipse)
Make a list of the consequences for not replacing ALL screws, bolts and nuts when
maintaining equipment in general.
2.5 Accumulators  ISO 1219
2.501 Discuss the risks involved working with
accumulators.
Explain your safety measures to prevent
any injury when working with
accumulators.
ISO 1219 Symbol: Diaphragm Type
Accumulator – Gas Charged
C
2.502 Accumulators can be grouped:
Group II: p > 1 bar & p1 ≤ 200 bar (loaded)
Group III: p > 1 bar & 200 bar < p1 ≤ 1000 bar
Group IV: p > 1 bar & p1 > 1000 bar
Group IV accumulators need to be internally inspected every 5 years and pressure
tested every 10 years.
Determine in which group your accumulators will fall and discuss their maintenance
procedures.
10 missing screws
Loose bolt & nut
Missing bolt & nut

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Ver’d
& Date Notes
2.503 Discuss your accumulators, operation &
the following:
 shut-off valve, normally closed (n/c)
 manometer
 piston type
 operating pressure
 gas charged pressure & gas type
 charging procedure
2.6 Powerpacks 
The ISO 1219 symbol for a powerpack
shows the following items:
 a pressure reducing valve (PRV)
 a reservoir
 a hydraulic pump
 an electrical motor
Point out the items on the sketch and
discuss their functions in detail.
2.601 Your Powerpack consists of the following items:
 electrical motors x3
 hydraulic pumps x3
 reservoir
 manometer
 level control
 thermometer
 filtration system
 piping, valves and fittings
Point them out and discuss the function of every item.
2.602 Studies have shown that over 60% of all
hydraulic system’s down time can be
attributed to untidy maintenance and lack
of the proper filtration. A good filtration
system work at 98% efficiency, i.e.
allowing 2 particles per 100 to pass
through the filter.
Discuss the function of the “Kidney Pack”.
Talk about the purpose of the pressure
differential gauge. Be prepared to
demonstrate a filter change, if clogged.
ISO 1219 Filter Symbol
by The Hycon
Corp.

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Ver’d
& Date Notes
2.603 The above table is used in a SAE standard to classify the levels of hydraulic system
cleanliness. From your oil analysis, determine your cleanliness class by matching the
results with the table above.
Talk about methods to improve (if needed) or maintain your hydraulic system
cleanliness.
SAE, see
ISO 4406,
NAF? as
alternative
methods
2.604 Find and discuss a resent oil analysis, mentioning the following:
 type of wear metals
 particle count/ml & size
 viscosity
Talk about the advantage and use of having good historical data to aid your predictive
maintenance strategy.
3 Electrical Motors 
3.101 It is good practice to protect electrical motor from overload. Discuss the electrical
protection methods to prevent electrical motors from burn-out:
 drive control settings
 current overload limitation
3.102 Discuss operational and maintenance methods to prevent damage to bearings and
other electrical connections due to heat exposure. Explain the effects of electrical
motors being exposed to high temperatures for periods.
3.2 Cooling Fans 
3.201 Discuss at least two purposes of fan motor housings (cowling).



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Ver’d
& Date Notes
3.202 Electrical motors are normally cooled down when running by the fan and cooling fins.
Studies showed a drop in operating temperature when the electrical motor, cooling
fins, cowling and cooling fan were kept clean. The small drop in operating
temperature extended the motor life span dramatically.
With your verifier and a Plant / Equipment Operator/Cleaner, talk about autonomous
maintenance by using “inspection & cleaning of electrical motors” as an example.
3.3 Bearings 
3.301 The graph shows the typical trend for a
lubricant viscosity-temperature ratio.
Another function of a lubricant is to
maintain a thin separating film between
two wearing surfaces.
Talk about the importance of selecting and
using the correct lubricant, suitable for the
relevant operating conditions:
 normal lubricant = 0 to 70C
 synthetic lubricants = -20 to +350C
Remember that some synthetic lubricants
can cost 30-50 times more than mineral
lubricants, but it might prevent a
breakdown costing 10 000 times more.
Point out your high temperature working
areas and talk about methods to effectively
lubricate machinery.
You may want to use the Exhaust
Manifold or Cooler Bridge electrical
motor ball bearings as examples.
3.302 The following scenarios could cause a dry or cold start:
 If a bearing has been exposed to high temperature while standing, the lubrication is
most likely to settle at the lowest point.
 Bearing exposed to high temperature and caused the lubricant to fail.
 Bearing exposed to high temperature causing seals to leak, loss of lubricant.
Discuss in a group preventive measures to avoid the above scenarios.
3.303 Grease basically consists of the following:
 oil basis – mainly mineral oil
 thickener – mainly soup or mineral based
 additives – viscosity, corrosion, temperature enhancing materials
The oil is absorbed by the thickener and is dispersed again to lubricate when the
grease is pressurised or placed under load. One disadvantage of grease is that dust
and dirt particles will collect and stick to the grease, causing more problems.
Talk about the importance of firstly cleaning greased areas removing old grease with
impurities prior to re-greasing.
Discuss the reasons for enclosing greased areas, i.e. the exhaust manifold screws, you
may want to recommend enclosing improvements.

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Ver’d
& Date Notes
3.304 Bearing fitment plays a cardinal role in the bearing’s future life. A bearing
improperly fitted or damaged during fitting will most probably not have a normal life
expectancy.
Talk about at least four aspects to consider when replacing a bearing.




3.305 Conveyors wheels use (SKF 607?) ball bearings. With other team members, using
your RCA process, discuss methods to reduce frequent bearings replacements.
not “forever
young”
3.306 Clevis bearings on hydraulic cylinders often wear. Explain how you will determine if
the bearings are still good for use.
4 Electrical Switches 
4.101 Due to vibration electrical switches and brackets need to be checked & tightened if
needed.
Point out the following electrical switch inspection points on site:
 intake system
 exit system
 exhaust manifold
Talk about the “PM”:
 inspection interval
 preventive or corrective action to be taken, if any
4.102 Talk about the different types of electrical switches and their application:
 proximity switches
 pressure switches
 limit switches
 photo optical sensors
Consider the electrical switches in your plant. Talk about the possibilities using
different switches to improve the operational reliability without increasing the plant
maintainability. You could also mention spare part standardisation or rationalisation
methods.
4.2 Proximity Switches 
4.201 Proximity switches need to be kept clean, especially the photo optical type.
Discuss the inspection “PM”:
 inspection interval
 preventive or corrective action to be taken, if any

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Ver’d
& Date Notes
4.3 Limit Switches 
4.301 Limit switches are mainly fitted with antennas, but still can be bumped and damaged
during operation.
Suppose your verifier is a new maintenance electrician and that there is a breakdown
in the plant. Explain to him, as you would explain to a new artisan, how you would
trace a fault, e.g. a damaged limit switch.
Cost Accumulation
R 750 R 1,500
R 50,000
R 0
R 10,000
R 20,000
R 30,000
R 40,000
R 50,000
R 60,000
1 2 3
Cost
4.302 With your verifier & a Plant / Equipment Operator discuss the following. Suppose
they are new Plant / Equipment operators and they accidentally knocked over or
damaged an electrical switch during operation.
Explain by referring to the graph above, as you would explain to new Plant /
Equipment Operators, the consequences of the incident. Calculate the following three
variable costs:
1. cost for replacing the damaged part – assume a cost of R 750
2. cost of maintenance downtime – assume a rate of R 500/hour down for 3 hours
3. cost due to loss of production – assume a rate of R 10 000/hour down for 5 hours
Remember to talk about how these costs will affect the operator’s BAOS system &
performance. Consider the “ripple effect” of an incident, i.e. how a small incident can
have a dramatic effect on other people and departments.
C 4 Safety Steps
5 Screws & Conveyors 
5.101 Discuss the function of the wear guides, e.g. how you can determine the state of wear.
Talk about other complications the wear guides may cause when not properly
fastened.
5.102 Talk about the consequences of getting foreign metal parts in the conveyor screw.
How can a maintenance artisan or production operator prevent foreign material
entering the screw? Talk to an operator about the reporting procedure and action to
take when a foreign object was accidentally dropped into the conveyor screw.
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Ver’d
& Date Notes
5.103 Discuss the process, step by step, to
remove and replace the screw. Point out
the Standard Operation Procedure.












5.104 “My sister lost her right hand, more than 4 years ago, when her hand was caught in a
screw conveyor. The doctors could not sew her hand back on again as the ligaments,
fingers and muscles were ripped and crushed beyond recognition. We had to support
her during her rehabilitation period. Only then, I noticed how much she had to learn
again by doing everything with her left hand. It was very difficult for her and she
often broke down in tears because of pain and frustration, feeling very helpless. At
one point the doctors considered removing some of her toes and fit it to her hand so
that she can use her hand again. She could not even do simple things like slicing
bread, opening a bottle or peeling an orange, any more. This accident also caused a
lot of trauma to the rest of our family for several years after the accident.”
The screw conveyor is considered, rotating & moving machinery. Demonstrate the
Lock Out Tag Out process and talk about how you will prevent getting your hand
caught in any other moving or rotating machinery.
Tell your verifier; how you would feel if one of your family members gets badly hurt
while working unsafely and ignoring safety procedures?
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Ver’d
& Date Notes
5.2 Gearboxes 
5.201 The table shows potential problems that
one can experience with gearboxes.
This is a great method of using and
combining different matrix tables.
The warning signs and wear mechanisms
will give an indication to the cause and
effect leading to a failure.
Discuss the application of this table in
your work environment.
Use this method to develop your own
maintenance troubleshooting matrix in an
area of your preference.

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Ver’d
& Date Notes
Various maintenance strategies exist for various reasons. Gearboxes can be
maintained at regular time intervals, based on history of environmental conditions.
This strategy is known as “Time Based Maintenance”(TBM). TBM is scheduled &
performed at predetermined time intervals and falls under Preventive Maintenance.

Another method is known as “Condition
Based Maintenance” (CBM). CBM is
where the condition of technical
equipment is monitored, and maintained
according to the data collected. CBM falls
under Predictive Maintenance. Parameters
monitored can be:
 temperature
 performance
 efficiency
 lubrication
 wear
 vibration
 pressure

5.202 Discuss at least one advantage of both
CBM & TBM:
 CBM-
 TBM-
Select one of the maintenance strategies
and talk about how you apply it to
maintain a gearbox or an electrical motor
in your work area.
Talk about one disadvantage
of both CBM & TBM:
 CBM-
 TBM-
5.203 We lost a gearbox. Discuss how CBM,
i.e. Vibration Analysis or Bearing
Temperature Monitoring might have
helped to early detect the failing gearbox.
Suppose a bearing failed. Talk about the
“ripple effect” i.e. due to a bearing failure
caused damage to the shafts, pinion (drive
gear), driven gear, gearbox housing, shaft
coupling and possibly the electrical motor.
Present at least two ideas on how this can
be prevented in future.


Damage

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Module
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Ver’d
& Date Notes
5.204 According to DIN 50 320, the following
wear mechanisms can be present in
gearboxes:
 Adhesive type wear
 c,
 Abrasive type wear
 d,
 Surface damage wear
 f,
 Tribological-chemical wear
 l,
Match the following indicators
with the wear mechanisms:
a) holes
b) wave patterns
c) material deposit
d) pitting
e) scratches
f) grooves
g) cracks
h) dimples
i) corrosion
j) material seizure
k) ridge formation
l) material washed out
DIN 50 320
5.3 Scrapers 
5.301 Discuss with a Plant / Equipment Operator and your verifier the allowable/acceptable
wear or wear limit of scrapers. Explain how you will determine if the function of the
scrapers is still acceptable.
Double Lock Nut
Wear

Learning
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Ver’d
& Date Notes
5.302 Vibration in the exit system could cause bolts and nuts to rattle loose.
Ways to combat this are:
 eliminate vibration
 make use of “Nylock” nuts
 make use of double locking nuts
 make use of “Loctite”
Talk about the purpose of following regular continuous inspection PM.
Brainstorm with your colleagues to determine other vibration elimination methods.
Go onsite while the plant is running and determine which equipment induces shock
and vibration into the system.
Set-up a Pareto chart to help you prioritize the severity and frequency of the vibration,
e.g:
 anode tilting table – 2x 260 times per day
 ram cylinder – 260 times per day
6 Waste Gas System 

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Ver’d
& Date Notes
6.101 Refer to the image above and explain how air pollution takes place.
Discuss the importance of maintaining your Waste Gas System.
Make a list of the consequences if your Waste Gas System do not function properly,
refer to our natural resources:
 soil/ground
 water
 air
 animal wild life
Talk about what will happen to you and your family over a period of time when
exposed to polluted air.
6.102 The Cooling Tunnel and the ESP is placed outside, main equipment. Discuss the
Waste Gas Cleaning process. Refer to:
 the inward and outward flow of materials
 function of the tunnel
 function of the ESP
6.103 Talk about the risk related to environmental, health and safety aspects if:
 the tunnel is not functioning properly due to incorrect maintenance
 the ESP is not functioning properly due to incorrect maintenance
C

Learning
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Ver’d
& Date Notes
6.104 Inside the Plant is the Exhaust Manifold. Suppose that the seals require more frequent
replacement than before. Talk about possible causes and preventing solutions.
Discuss the effect of the different seal compression.
Seal Compression
New Seal Fitted
Uncompressed

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Module
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Ver’d
& Date Notes
6.105 One way to think about troubleshooting is to use what is known as an Ishikawa
(fishbone) diagram. In this the “problem/failure/error” is shown on the right hand
side and the factors that could lead to the problem are identified on the left hand side
of the diagram. The possible causes can then be grouped per factor. Factors can be
known as the 4M´s:
 Man: what could a person (operator or maintainer) have done or not done that
could lead to the problem?
 Machine: what aspect of machine function could have caused the problem
 Material: sometimes faulty material causes problems in the production process
 Method (System): often the method of manufacturing or control could be
inconsistent, causing problems.
The following cause “Pitch flue causes clogging” and the possible effects/failures are:
 valves to function improperly, i.e. opening & closing difficulty
 instrumentation equipment being inaccurate
 screw threads getting stuck
 valve gates getting stuck & not sealing
Select a team, choose one of the above failures and discuss the possible causes.
Suggest a potential solution. As a “Team Effort” draw an Ishikawa, Failure, Cause &
Effects, diagram – Considering the 4 M´s; Man, Machine, Material and Method
(System).
6.106 With the information gathered above, use
your Risk Assessment process to prioritize
the consequences and risks.
This method could help you decide where
to focus your maintenance activities to
make a big difference.

Learning
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Ver’d
& Date Notes
6.2 AC Invertors 
6.201 AC invertors are used with electrical motors obtaining soft start & speed control.
Refer to the Safe Work Procedure for the set-up of new drives, used through-out your
plant! With the aid of the process picture maps discuss the set-up process.
6.202 Discuss how you can use an AC Drive to
prevent gearbox damage. Identify what
the correct current setting would be.
Talk about the cost to install an AC drive
compared with the cost to repair or replace
the gearbox & motor, as well as the cost
due to possible loss of production.
6.3 Fans & Valves 
Broken Gear Teeth

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Module
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Ver’d
& Date Notes
6.301 Products and equipment are often designed with Redundancy. This is normally done
to reduce the risk in case of a catastrophic failure or an unplanned breakdown. The
designed Redundancy helps to quickly change over to an alternative method. A
simple example is the spare-wheel of your car. It is redundant, stored in the car’s
boot, until you have a flat tyre, which can happen at any time. Here Redundancy is
designed and allows you change over to an alternative, the spare wheel. Think about
Redundancy as; “Plan B”.
What will happen if your redundant alternative is not functional or reliable, i.e. the
spare wheel is also flat/deflated or has a slow puncher?
With new technology Redundancy can be eliminated without increasing the risk by
using advanced Condition Based Monitoring (CBM) techniques.
Identify possible redundant equipment and discuss how CBM can be implemented.
If feasible, drive the initiative to implementation stage using your BAOS system.
6.302 To open or close some valves you might need to climb on top of plant equipment.
Discuss with your HSE co-ordinator and an operator the safety procedures to work at
heights.
C OHSA Part 4
6.303 Discuss in a group to find the best practise on how to open or close a stuck valve.
Brainstorm to find implement-able methods on how can you prevent the valves from
getting stuck, i.e. to improve the valve reliability?

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Ver’d
& Date Notes
6.304 According to SAE JA 1011, the essence of reliability in maintenance is described in the
following:
A Breakdown is defined as the inability of a technical device to execute, or
perform a function, as expected by the owner or operator of that technical
device, at a required quality and performance level.
Example: A shut-off valve’s function is to open and close. The seal is suppose to be
airtight. When it can not perform it’s function at the expected performance level,
then it is not reliable and considered to be in a functional breakdown state.
When the valve closes but partially leaks it is not performing at the expected quality
or performance level and can be considered not reliable and is in a potential
breakdown state.
Talk to at least two of your colleagues about ideas on how you can improve
equipment reliability, referring to a valve’s:
 breakdown
 expected function
 quality level
 performance level
SAE JA 1011
6.305 Rotating equipment, like fans, should at least be “statically balanced”. Discuss the
consequences effects for running unbalanced equipment.
Refer to the effects it will have on:
 bearings
 machine casing
 other equipment in close vicinity
List at least two causes for equipment being unbalanced:


6.4 Dosing System 
6.401 Discuss the function and purpose of the dosing system. You might want to use the
following guidelines:
 pH level – actual/current value vs. permissible dumping value (5,5-9,5)
 flue soot level
 fire prevention
Explain the environmental and safety consequences if the correct levels are not
maintained.
How will the system detect if the operational standards are not met?
C SABS
241:1984
6.402 Point out the three most critical dosing equipment and discuss the maintenance
requirements.




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Ver’d
& Date Notes
6.403 At the dosing area identify and explain to your verifier the hazardous “Material Safety
Data Sheet”. Talk about:
 the chemical and environmental hazards if spilled
 the consequences if swallowed & the appropriate first aid measures
 the consequences if vapour is inhaled & the appropriate first aid measures
 the consequences if eye contact occur & the appropriate first aid measures
 the consequences if skin contact occur & the appropriate first aid measures
 the manufacturer contact details
 fire fighting and handling procedures, e.g. PPE requirements
 waste disposal procedures
C
6.404 Talk about the purpose of hazardous material signage. With your verifier, identify
other hazardous materials and look for:
 signage and demarcation
 Material Safety Data Sheet
C
6.405 It is good Environmental protection to use
a double container system when using
hazardous materials.
Explain why for the black container
should be at least 1,5 times the volume of
the blue container.
Find at least another container holding or
storing hazardous material.
C
6.406 Discuss with an operator the function of
this filter.
Suppose the operator is new at the Plant /
Equipment. Point out the filter to the
operator and explain how he will know
when it is needed to clean the filter.
The operator needs to be prepared to
demonstrate.

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Module
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Ver’d
& Date Notes
6.5 Pumps and Pipes 
6.501 Point out at least two pumps, Furnace and explain how you will bleed the pumps.




Mention the purpose of bleeding pumps. Be prepared to demonstrate if your verifier
requests.
6.502 Suppose this effluent pump and motor
have been making strange vibrating noises
for a while.
Make a list of at least 4 possible root
causes.




For every cause list one corrective action
and one preventive action.
6.503 Discuss your maintenance actions when you notice a pump is leaking while in
operation. Talk about when some leakage could be useful to cool the pump bearings.
6.504 Describe the different noises an effluent
pump or motor can make due to:
 cavitation
 a faulty pump bearing
 a worn motor bearing
 a blocked or restricted suction pipe
 a closed or restricted delivery pipe
 the motor turning in the wrong direction
Explain what you will do in each case.
6.505 What actions will you take if you notice a
water leak, as shown in the photo?




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Ver’d
& Date Notes
6.506 Rubber hoses, firstly harden, then perish
and crack when they are exposed to high
temperature for extended periods of time.
Cracking can also occur then the hoses
age, called “aging”.
Places where cracks normally occur are:
 where hoses are bent
 close to fittings
How will you determine when the hoses
need to be replaced?
Cracked hoses might eventually burst
when pressurised.
Discuss the consequences when a hose
burst. Your verifier might request you to
demonstrate your emergency actions, be
prepared to demonstrate.
Find alternative hoses that will not crack
and compare the costs.
C
6.6 ESP Electrodes & Insulator 
6.601 Discuss the function of the insulator. Demonstrate how you will inspect the condition
of an insulator.
6.602 One way to check the ESP & Cooling tunnel efficiency is to look at the gas exhausted
at the stack.
Discuss at least two disadvantages this “regressive-”, “fire fighting-” or “corrective-“
maintenance method presents:


The ESP’s “milli-Amps” is monitored by the SCADA system. Talk about at least two
advantages of how this data can be collected over time and used to predict and
schedule the optimal maintenance tasks:


You might want to talk about the risks & consequences and the importance of having
a time buffer to plan, react and execute maintenance.
6.603 Point out on the SCADA system the ESP “milli-Amps”. Discuss the current value
compared to the planned value.
From the trend line, predict the ideal maintenance date.
6.604 Electro Static Precipitator (ESP) electrodes often get damaged or broken during
routine high pressurised water jet cleaning process. Talk about preventing methods.
You may want to, as a group, investigate the root cause for the routine cleaning
process or discuss a best practise for cleaning the electrodes.

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Ver’d
& Date Notes
6.605 Good maintenance practice is to conserve
our natural resources.
While cleaning the electrodes, water is
wasted at approximately 5 l/min., 8 hours
a day, 15 days every 4 months, 2 ESPs =
216 000 l/year; enough water to last a
South African family of 4 people, for 13,5
years.(15 l/d/p)
Consider the photo, talk about the best
practice to save water when cleaning the
ESP.
Find alternative cleaning means.
C
6.606 With your colleauges, select a topic and brainstorm to find ideas on how you can
improve the following from a maintenance perspective:
 ESP efficiency
 operational effects causing breakdown
 operational effects causing poor anode quality
 pitch type variation
 pitch content in green anodes
7 Controls & Instrumentation  awaiting a new
upgrade
7.101 In your control room, use your plc/scada system to look at the Plant & Equipment.
Discuss at lease three different screens, mentioning:
 plc inputs
 plc outputs
 location of cylinders, electrical switches & valves, on site.
7.102 Suppose that G01 is not functioning or responding. Explain how you will identify the
fault using the plc/scada system.

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Module
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OTHER THINGS I HAVE LEARNED
Ref Learning Outcomes C Ver’d Date Notes

Learning
Module
1. Recommended
2. Relevant
3. Supporting

Manuals

Multimedia/
Intranet

Procedures/
Regulations
Process Picture
Maps

Video/Film Other

Specialist
Persons
36 of 38
RESOURCE GUIDE
Competent people at the workplace are a key resource you may use to help you achieve the Learning Outcomes in this Unit.
This Resource Guide provides a list of additional flexible learning resources you may also use.
Reference Rating / Type Resource Location
1 Overview
Management 1  Leadership & Teamwork, Innovation,
Kaizen, 5s, Risk Assessment,
BTC
OHSA Part 1; section 14, 15, 38
OHSA Part 4;
2  Employee Duty, Misuse of Equipment,
Penalties.
Regulations relating to General Aspects
BTC
DIN 31 051 3  Definition of Wear Internet
VDI 2246 3  Reliability, Maintainability & Availability
Relationships
Internet
EN 13 306 3  Maintenance Concepts Internet
http://www.fdl.uea.ac.uk/airpol/modules/de
finition.asp
3
 University of East Anglia Internet
SABS 0228 2  Identification and Classification of
dangerous substances and goods.
SABS
Department of Health 3  Malaria Roll back Plan.
Berufsgenossenschaft 3  Hazard Material Identification & Symbols §15 Abs 1 GefStoffV
Berufsgenossenschaft fuer Electrotechnik 3  Dr.Ing. J. Juhling; Cologne
InWent, Carl Duisberg Gesellschaft;
www.cgd.de
2
 Change-, Innovation- Management,
Leadership Development, Team
Dynamics
Internet
Clear Air Association 2
 Air Pollution & Monitoring
2 Hydraulics
ISO 1219 1  Fluid Power; Hydraulic Symbols BTC
ISO 4406 3  Hydraulic Fluid Analysis BTC
ISO 9001:2000 2  ISO Quality Management BTC
ANSI B93.2.1971 3  Hydraulic Fluid Contaminants
5 Screws & Conveyors
DIN 50 320 3  Wear Mechanisms

Learning
Module
1. Recommended
2. Relevant
3. Supporting

Manuals

Multimedia/
Intranet

Procedures/
Regulations
Process Picture
Maps

Video/Film Other

Specialist
Persons
37 of 38
Reference Rating / Type Resource Location
6 Waste Gas System
PM-PC-001 2 Replacing & Setting AC Drives/Invertors Attached to this LU
OHSA Part 4 Regulation 6 1  Work in Elevated Positions BTC
SAE JA 1011 3  Reliability Centred Maintenance
SABS 241:1984 2  Water Specifications BTC
Guide completing MSDS 2  Department of Labour, Chief Directorate
of OHS
HSEC

Learning
Module
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ASSESSMENT PLAN
Successful completion of this Learning Module requires each step of the Assessment Plan to be successfully completed and
signed off by the Assessor(s). Assessment is carried out by competent Assessors.
Learner Name: ____________________________________ Learner ID: ___________________
Assessment Step Assessment Result Date Assessor Signature
1. Learning Outcomes (all 129) Verified?  Yes
 No
2. Critical Outcomes re-verified to 100%?
(attempt and pass all 46)
 Yes
 No
3. Random selection of 10% of remaining
(non-critical) Learning Outcomes to 80%
competency? (attempt 8, pass at least 7)
 Yes
 No
4. Integration/problem solving exercise?  Yes
 No
Please sign to confirm that assessment was performed in a fair and competent manner and that the results are accepted.
Assessor Learner Observer
Name _______________________ _______________________ _______________________
Signature ______________________ ______________________ ______________________
Date _______________________
Learner Feedback: Learning Outcomes and general feedback (additions, changes, resources used, etc.)
 Check this box if Learner Feedback is provided on back of this sheet.

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