How to SMASH Maintenance - Advisor

  1.      Engineering Principles for Maintainers and Operators.

1.1.               How equipment is designed to work

1.2.               Force transmission

1.3.               Stress in materials

1.4.               Clearance, fits and tolerances

1.5.               Bending stress

1.6.               Torque stress and combined loads

1.7.               Metal fatigue failure

1.8.               Lubrication

1.9.               Vibration

1.10.             Chemical and material compatibility

1.11.             Corrosion

1.12.             Fluid flow

1.13.             Cavitation

1.14.             Welding metals

1.15.             Welding plastics

1.16.             Heat transfer

1.17.             Bearing isolation and protection

1.18.             Electric motors

1.19.             Process control and monitoring

  2.       Equipment Maintenance Best Practice.

2.1.               Creative disassembly

2.2.               Bolting and gaskets in flanged connections

2.3.               Threaded connections

2.4.               Chain and sprocket drives

2.5.               Vee-belt and pulley drives

2.6.               Mechanical seals

2.7.               Soft-foot distortion

2.8.               Shaft alignment

2.9.               Pneumatic valve actuators

2.10.             Process control valves

2.11.             Isolation valves

2.12.             Roller bearings

2.13.             Oil cleanliness

2.14.             O-ring seals

2.15.             Gear box drives

2.16.             Gland packing

2.17.             Vibration control

2.18.             Nondestructive thickness checking and crack detection

  3.       Maintenance Philosophies and Methods.

3.1.               Equipment Reliability

3.2.               RCA (Root Cause Analysis)

3.3.               RCM (Reliability Centred Maintenance)

3.4.               5 Whys

3.5.               5S

3.6.               Watch keeping by operators

  4.       Maintenance Management and Asset Management.

4.1.               Equipment criticality

4.2.               Work planning and scheduling

4.3.               Preventive maintenance

4.4.               Work order instructions and history reporting

4.5.               CMMS

  5.      Fault Finding and Troubleshooting Check Lists

5.1                Shafts breaking

5.2                Bearings failing

5.3                Mechanical seals failing

5.4                Flanges leaking