King Fahd University of Petroleum and MineralsKing Fahd University of Petroleum and MineralsMechanical Engineering DepartmentMechanical Engineering Department

Maintenance and Preventive Maintenance of Heavy Equipment

Coop Training : Central Heavy Equipment Department In AramcoCoop Training : Central Heavy Equipment Department In Aramco

Presented by: Abdulnaser M. Al-MesbahPresented by: Abdulnaser M. Al-Mesbah

ID# 981908ID# 981908

DATE : OCTOPRER 20, 2004DATE : OCTOPRER 20, 2004

OutlineOutline

Central Heavy Equipment DepartmentCentral Heavy Equipment Department

Heavy Equipment ShopsHeavy Equipment Shops

Cases StudyCases Study

ConclusionConclusion

Central heavy equipment departmentCentral heavy equipment department

1. Dhahran Equipment Pm/Field Repair Service Unit1. Dhahran Equipment Pm/Field Repair Service Unit

2. Patch & Dispatch Unit2. Patch & Dispatch Unit

3. Quality Control Unit3. Quality Control Unit

4. Electric Shop Unit4. Electric Shop Unit

5.Heavy Equipment Shops Unit5.Heavy Equipment Shops Unit

Heavy Equipment ShopsHeavy Equipment Shops

1. Crane Shop1. Crane Shop

2. Dozer Shop2. Dozer Shop

3. Fuel Room3. Fuel Room

4. Pumps Rebuild Shop4. Pumps Rebuild Shop

Case Study 1: Portable 900KW GeneratorCase Study 1: Portable 900KW Generator

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

Physical assessment:Physical assessment:

1. Water leak in radiator core1. Water leak in radiator core

2. Excessive leak at oil cooler gasket2. Excessive leak at oil cooler gasket

Quality Control UnitQuality Control Unit

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

1.1. Due to radiator leak, water level dropped causing the engine to Due to radiator leak, water level dropped causing the engine to over heat.over heat.

2.2. Automatic Shut down system failed to actuate.Automatic Shut down system failed to actuate.

3.3. Heavy oxidation of the engine oil that become black viscous tar.Heavy oxidation of the engine oil that become black viscous tar.

4.4. Due to the oxidation of the oil, all oil lines and panes are Due to the oxidation of the oil, all oil lines and panes are covered/coated with the high oxidized oil.covered/coated with the high oxidized oil.

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

Material cost Material cost

($)($)

LaborLabor

($)($)

InvoicesInvoices

($)($)

TotalTotal

($)($)

Already Already chargedcharged

32953295 82258225 228228 1174811748

In-house In-house engine engine

overhauloverhaul

50005000 1000010000 1500015000

TotalTotal 82958295 1822518225 228228 2674826748

Repair cost:Repair cost:

Alternative #1: Repair Cost Estimate with In-House Engine OverhaulAlternative #1: Repair Cost Estimate with In-House Engine Overhaul

Material cost Material cost

($)($)

LaborLabor($)($)

InvoicesInvoices

($)($)

TotalTotal

($)($)

Already Already chargedcharged

32953295 82258225 228228 1174811748

In-house In-house engine engine

overhauloverhaul

100,000100,000 10001000 10,00010,000 111000111000

totaltotal 103295103295 92259225 1022810228 122748122748

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

Repair cost:Repair cost:Alternative #2: Alternative #2: : : Repair Cost Estimate with External Overhaul or Repair Cost Estimate with External Overhaul or ReplacementReplacement

Alternative #1: % of Repair Cost vs. New Unit Cost: Alternative #1: % of Repair Cost vs. New Unit Cost: 27000/300,000 = 9%27000/300,000 = 9%

Alternative #2: % of Repair Cost vs. New Unit Cost: Alternative #2: % of Repair Cost vs. New Unit Cost: 123000/300,000 = 41 %123000/300,000 = 41 %

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

Repair cost:Repair cost:

Case study 1Case study 1 Portable 900KW generatorPortable 900KW generator

Items That Have Been Repaired or Replaced:Items That Have Been Repaired or Replaced:

replacing the engine starter.replacing the engine starter. Removing the old automatic shut down system and reinstall it Removing the old automatic shut down system and reinstall it again.again. install new radiator.install new radiator. cleaning the engine due to the oxidation of oil.cleaning the engine due to the oxidation of oil. replacing oil ban gaskets with new ones. replacing oil ban gaskets with new ones. Replacing the engine head gaskets.Replacing the engine head gaskets. replacing the engine governor.replacing the engine governor.

Case Study 2: AT-750BE CraneCase Study 2: AT-750BE Crane

Case study 2Case study 2 AT-750BE CraneAT-750BE Crane

Quality Control Inspection:Quality Control Inspection:

Steam clean unit.Steam clean unit. Flash radiator and refill with antifreeze.Flash radiator and refill with antifreeze. Clean all operator cap.Clean all operator cap. Reseal rear R.H.S final drive due to oil leak.Reseal rear R.H.S final drive due to oil leak. Repair or replace upper sky glass supporting cylinders.Repair or replace upper sky glass supporting cylinders. Calibrate fuel injectors.Calibrate fuel injectors. Replace fuel sender.Replace fuel sender. Repair air leak at the parking brake valve.Repair air leak at the parking brake valve.

AT-750BE CraneAT-750BE CraneCase study 2Case study 2

Crane Maintenance:Crane Maintenance:

R.H.S Final DriveR.H.S Final Drive

Case study 2Case study 2 AT-750BE CraneAT-750BE Crane

• All injectors have been sent to the fuel All injectors have been sent to the fuel room for calibration.room for calibration.

• adjusting the intake and the exhaust adjusting the intake and the exhaust valves with 0.014 and 0.027 in feeler gauge valves with 0.014 and 0.027 in feeler gauge

respectively.respectively.

• one of the rock arms fall down inside the one of the rock arms fall down inside the engine.engine.

AT-750BE CraneAT-750BE CraneCase study 2Case study 2

Additional items:Additional items:

• Changing oil filtersChanging oil filters

• Lubricating the wire rope.Lubricating the wire rope.

• Repair the horn.Repair the horn.

• Repair the beacon light.Repair the beacon light.

• Replace wiper blade for the sky window.Replace wiper blade for the sky window.

• Retighten suspension wear pads.Retighten suspension wear pads.

Case Study 3: The 89-0865 Forklift (10 T)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.

Re-sealing the lift cylinderRe-sealing the lift cylinder

Step # 1: Draining oil from the lower part of the lift cylinderStep # 1: Draining oil from the lower part of the lift cylinder

Case study 3Case study 3 89-0865 Forklift89-0865 Forklift

89-0865 Forklift89-0865 ForkliftCase study 3Case study 3

Re-sealing the lift cylinderRe-sealing the lift cylinder

Step # 2: Removing the lock, which is in the head of the cylinder.Step # 2: Removing the lock, which is in the head of the cylinder.

Step # 3: Opening the piston lock.Step # 3: Opening the piston lock.

Case study 3Case study 3 89-0865 Forklift89-0865 Forklift

Re-sealing the lift cylinderRe-sealing the lift cylinder

Step # 4: Pulling the piston out side the cylinder using a forklift.Step # 4: Pulling the piston out side the cylinder using a forklift.

Step # 5: changing the piston seals Step # 5: changing the piston seals

89-0865 Forklift89-0865 ForkliftCase study 3Case study 3

Piston Lock:Piston Lock:

• Time needed: 3 hours.Time needed: 3 hours.

• lock material is weak.lock material is weak.

• no special tool available.no special tool available.

Case study 4Case study 4 Pipe LoaderPipe Loader

Case Study 4: Pipe LoaderCase Study 4: Pipe Loader

Pipe LoaderPipe LoaderCase study 4Case study 4

Quality control unit:Quality control unit:

• Repair or replace the transmission pump.Repair or replace the transmission pump.

• Replace the hydraulic pump.Replace the hydraulic pump.

• Re-seal both the lift cylinders.Re-seal both the lift cylinders.

• Send engine injectors to the fuel room for calibration.Send engine injectors to the fuel room for calibration.

• Change all tires.Change all tires.

• Repair or replace beacon lights.Repair or replace beacon lights.

Pipe LoaderPipe LoaderCase study 4Case study 4

• New transmission pump cost: 2100 US$New transmission pump cost: 2100 US$

• The pump was sent to the welder shopThe pump was sent to the welder shop

Most of the hydraulic systems use gear pumpMost of the hydraulic systems use gear pump

Pipe LoaderPipe LoaderCase study 4Case study 4

Testing the pipe loader:Testing the pipe loader:

• pipe loader capacity: 12 Tpipe loader capacity: 12 T

•The test was to carry a 9 TThe test was to carry a 9 T

•The pipe loader successThe pipe loader success

•The pipe loader had been sent to the load test to test it with 12 T.The pipe loader had been sent to the load test to test it with 12 T.

• the pipe loader success.the pipe loader success.

Case study 4Case study 4 Pipe LoaderPipe Loader

Conclusion:Conclusion:

Value of time and Value of time and commitment.commitment. Value of team workValue of team work.. maintenance of heavy maintenance of heavy equipmentequipment

Thank youThank you