Servicing and or maintenance

Servicing and/or maintenance of equipment is an important aspect of keeping your assets protected. It can also be a source of tragedy if not approached properly. This means your company needs proper lockout/tagout procedures. 

Servicing and/or maintenance takes place during normal production operations in which... 

Without proper training, an employee might not be able to recognize a hazardous condition, or might create a hazardous condition that could lead to injury. Proper maintenance of all electrical equipment is an important part of the injury and incident prevention process. Routine maintenance programs are a must for any industrial operation. Anyone associated with electrical service and/or maintenance must be knowledgeable and authorized to perform the duties. 

A successful BEWS is relatively inexpensive. In the calculation of costs the purchase price may not be the dominant factor, however. Running costs for maintenance and servicing, including consumables and staff costs, will in the end determine the cost effectiveness. Often the frequency of servicing and/or the replacement of organisms will be the dominant cost factor, especially if this is on a weekly basis. 

Close communication with customers/users The maintenance organization should have periodic communication with the users to ensure that the analyzer data are being used correctly. The users should be notified when the analyzer is being serviced, and the maintenance group should be notified when the data are suspicious or erroneous. 

G6 Close Project (CP) Agree on closing the project and handover the product to manufacturing and/or service for mass production and/or maintenance. 

Reliability-centered maintenance (RCM) focuses on analysis of potential failures. RCM methodology, such as used with aircraft, involves failure modes related to serviceable and/or replaceable components. This process helps predict an impending failure of a component. Complex systems can experience a large number of maintenance requirements, as identified by failure analysis. 

Preventive maintenance includes inspection, servicing and adjustment with the objective of preventing breakdown of equipment. This is appropriate for highly critical equipment where the cost of failure is high, or where failure implies a significant negative impact on safety or the environment. This form of maintenance can be scheduled on a calendar basis (e.g. every six months) or on a service hour basis (e.g. every 5,000 running hours). 

Table 1 is condensed from Handbook 44. It Hsts the number of divisions allowed for each class, eg, a Class III scale must have between 100 and 1,200 divisions. Also, for each class it Hsts the acceptance tolerances appHcable to test load ranges expressed in divisions (d) for example, for test loads from 0 to 5,000 d, a Class II scale has an acceptance tolerance of 0.5 d. The least ambiguous way to specify the accuracy for an industrial or retail scale is to specify an accuracy class and the number of divisions, eg. Class III, 5,000 divisions. It must be noted that this is not the same as 1 part in 5,000, which is another method commonly used to specify accuracy eg, a Class III 5,000 d scale is allowed a tolerance which varies from 0.5 d at zero to 2.5 d at 5,000 divisions. CaHbration curves are typically plotted as in Figure 12, which shows a typical 5,000-division Class III scale. The error tunnel (stepped lines, top and bottom) is defined by the acceptance tolerances Hsted in Table 1. The three caHbration curves belong to the same scale tested at three different temperatures. Performance must remain within the error tunnel under the combined effect of nonlinearity, hysteresis, and temperature effect on span. Other specifications, including those for temperature effect on zero, nonrepeatabiHty, shift error, and creep may be found in Handbook 44 (5). The acceptance tolerances in Table 1 apply to new or reconditioned equipment tested within 30 days of being put into service. After that, maintenance tolerances apply they ate twice the values Hsted in Table 1.

Economy of time and resources dictate using the smallest sized faciHty possible to assure that projected larger scale performance is within tolerable levels of risk and uncertainty. Minimum sizes of such laboratory and pilot units often are set by operabiHty factors not directly involving internal reactor features. These include feed and product transfer line diameters, inventory control in feed and product separation systems, and preheat and temperature maintenance requirements. Most of these extraneous factors favor large units. Large industrial plants can be operated with high service factors for years, whereas it is not unusual for pilot units to operate at sustained conditions for only days or even hours. 

Granular materials are shipped raw or calcined and usually have been ground to a specified screen si2e or si2e distribution. The additives depend on the apphcation and service conditions. These materials are used in constmction, repair, or maintenance of furnaces and vessels. Refractory mortars are used to lay brick of the same composition. These are manufactured wet premixed or dry. 

In selec ting the machines of choice, the use of specific speed and diameter best describe the flow. Figure 10-67 shows the characteristics of the three types of compressors. Other considerations in chemical plant service such as problems with gases which may be corrosive or have abrasive solids in suspension must be dealt with. Gases at elevated temperatures may create a potential explosion hazard, while air at the same temperatures may be handled qmte normally minute amounts of lubricating oil or water may contaminate the process gas and so may not be permissible, and for continuous-process use, a high degree of equipment rehability is required, since frequent shutdowns for inspec tion or maintenance cannot be tolerated. 

Very few industrial pumps come out of service and go into the maintenance shop because tlie volute casing or impeller split down the middle, or because the shaft fractured into four pieces, d he majority of pumps go into the shop because the bearings or the mechanical seal tailed. 

Does the authorized employee verify that isolation and deenergization of the machine or equipment has been accomplished before servicing or maintenance of the machine or equipment is begun [OSHA Reference. 147(d)(6)]... 

In addition, test and maintenance activities can contribute significantly to unavailability by components being out of service for test or maintenance. The amount of unavailability from this cause depends on the frequency and the duration of the test or maintenance act. 

Normally Unoccupied Remote Facility - A facility that is operated, maintained, or serviced by workers who visit the facility only periodically to check its operation and to perform necessary operating or maintenance tasks. No workers are regularly or permanently stationed at the facility. Such facilities are not contiguous with, and must be geographically remote from, all other buildings, processes, or persons. If workers spend more than 1 hour at a facility each day, that facility is not considered to be normally unoccupied. 

When equipment or plant is taken out of service, either for maintenance or for repair, it should not be re-introduced into service without being subject to formal acceptance tests that are designed to verify that it meets your declared standard operating conditions. Your procedures need to provide for such activities and for records of the tests to be maintained. 

Service reports are reports from service or maintenance personnel identifying the nature of faults, the components replaced, and time taken. They are required in clause 4.19. 

Regarding service reports, these should be collected from the servicing or maintenance personnel and analyzed for repetitive problems. The data can also be used to compute the actual reliability, maintainability, and many other characteristics of the products. 

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