MAINTENANCE TOOLS MAINTENANCE TOOLS &TECHNIQUES&TECHNIQUES

MAINTENANCE MANAGEMENT MAINTENANCE MANAGEMENT &TECHNIQUES&TECHNIQUES

LLFLLF CONDITION MONITORINGCONDITION MONITORING PREDICTIVE MAINTENANCEPREDICTIVE MAINTENANCE PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE SCHEDULED TURNAROUNDSSCHEDULED TURNAROUNDS STATUTORY MAINTENANCESTATUTORY MAINTENANCE PROACTIVE MAINTENANCEPROACTIVE MAINTENANCE

MAINTENANCE ACTIVITIESMAINTENANCE ACTIVITIES

PLANNINGPLANNINGRESOURCESRESOURCESMANPOWER MANPOWER SPARES SPARES TOOLS AND TACKLESTOOLS AND TACKLES

TASKSTASKSMICRO PLANNINGMICRO PLANNINGMACRO PLANNINGMACRO PLANNING

EXECUTIONEXECUTION RECORDINGRECORDING ANALYSISANALYSIS LEARNINGLEARNING

MAINTENANCE TOOLSMAINTENANCE TOOLS HAND TOOLSHAND TOOLS POWER TOOLSPOWER TOOLS MACHINE TOOLSMACHINE TOOLS LIFTING TOOLS AND TACKLESLIFTING TOOLS AND TACKLES TRANSPORTATION TOOLSTRANSPORTATION TOOLS SPECIAL TOOLSSPECIAL TOOLS MAINTENANCE FACILITIES & MAINTENANCE FACILITIES &

ACCESSORIESACCESSORIES FABRICATION TOOLSFABRICATION TOOLS

HAND TOOLSHAND TOOLS SPANNERS(OPEN/D,RING )SPANNERS(OPEN/D,RING ) WRENCHESWRENCHES HAMMERSHAMMERS PLIERSPLIERS SCREW DRIVERSCREW DRIVER CHISELCHISEL FILESFILES SCRAPPERSSCRAPPERS CENTER PUNCHCENTER PUNCH

PULLERSPULLERS

TWO LEG PULLERSTWO LEG PULLERS THREE LEG PULLERSTHREE LEG PULLERS FOUR PRONG PULLERSFOUR PRONG PULLERS HYDRAULIC PULLERSHYDRAULIC PULLERS TAILOR MADE PULLERSTAILOR MADE PULLERS

LIFTING TOOLS AND TACKLESLIFTING TOOLS AND TACKLES MANILA ROPEMANILA ROPE SYNTHETIC ROPESSYNTHETIC ROPES WIRE ROPESWIRE ROPES

-NO. OF STRANDS 6-NO. OF STRANDS 6-NO. OF WIRES PER STRAND 19-NO. OF WIRES PER STRAND 19-STRAND CONSTRUCTION 6 X19-STRAND CONSTRUCTION 6 X19-LAY(REGULAR/LANG),CORE FABRICATION (HEMP OR -LAY(REGULAR/LANG),CORE FABRICATION (HEMP OR IWRC)IWRC)STD: 6X19,6X37 ( SMALL WIRES OFFER MORE FLEXIBILITY) STD: 6X19,6X37 ( SMALL WIRES OFFER MORE FLEXIBILITY) SHARP BENDS REDUCE LOAD BY 50%SHARP BENDS REDUCE LOAD BY 50%

HANDLINES( ROPE FOR STEADYING OR HOLDING LOADS)HANDLINES( ROPE FOR STEADYING OR HOLDING LOADS) BLOCKS(SNATCH BLOCKS,PULLEY BLOCKS)BLOCKS(SNATCH BLOCKS,PULLEY BLOCKS) CHAIN FALLSCHAIN FALLS TURN BUCKLESTURN BUCKLES HOISTHOIST CRANESCRANES EYE BOLTS/D SHACKLESEYE BOLTS/D SHACKLES JACKS(SCREW JACKS/HYDRAULIC JACKS,POWER JACKS)JACKS(SCREW JACKS/HYDRAULIC JACKS,POWER JACKS) C CLAMPSC CLAMPS

SLINGSSLINGS

There are There are generally six generally six types of slings:types of slings:

chain, chain, wire rope, wire rope, metal mesh, metal mesh, natural fiber natural fiber

rope (Manila rope (Manila Rope), Rope),

synthetic fiber synthetic fiber rope, or rope, or

synthetic web. synthetic web.

Synthetic WebSynthetic Web SLINGS SLINGS

Synthetic web slings are commonly Synthetic web slings are commonly made of nylon, polypropylene, or made of nylon, polypropylene, or polyester and have the following polyester and have the following properties in common: properties in common:

§    Strength -  Depending upon their §    Strength -  Depending upon their size, synthetic web slings can handle size, synthetic web slings can handle loads of up to 300,000 pounds. loads of up to 300,000 pounds.

§    Convenience and Safety - Synthetic §    Convenience and Safety - Synthetic web slings adjust to the load contour web slings adjust to the load contour and hold it with a tight, non-slip grip. and hold it with a tight, non-slip grip.

§    Load Protection - Unlike other sling §    Load Protection - Unlike other sling materials, synthetic web is less likely to materials, synthetic web is less likely to mar, deface, or scratch highly polished mar, deface, or scratch highly polished surfaces.     surfaces.     

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.

Non Metallic SLINGSNon Metallic SLINGS

Physical Properties of Nonmetallic slings:Physical Properties of Nonmetallic slings:

NYLON PRODUCTS STRETCH ABOUT 6% AT NYLON PRODUCTS STRETCH ABOUT 6% AT RATED CAPACITY, POLYESTER PRODUCTS AT RATED CAPACITY, POLYESTER PRODUCTS AT ABOUT 3% AND HIGH PERFORMANCE ABOUT 3% AND HIGH PERFORMANCE SPECIAL SYNTHETIC PRODUCTS SUCH AS SPECIAL SYNTHETIC PRODUCTS SUCH AS SPECTRA® AND KEVLAR® AT ABOUT 1%.SPECTRA® AND KEVLAR® AT ABOUT 1%.

    "WITH THIS BUILDING BLOCK KNOWLEDGE, "WITH THIS BUILDING BLOCK KNOWLEDGE,

THE INSPECTOR MAY DETERMINE THAT THE INSPECTOR MAY DETERMINE THAT EXCESSIVE ELONGATION MIGHT BE A CAUSE EXCESSIVE ELONGATION MIGHT BE A CAUSE OF THE ABRASION, AND SO RECOMMEND OF THE ABRASION, AND SO RECOMMEND THAT A PRODUCT WITH LESS STRETCH IN THAT A PRODUCT WITH LESS STRETCH IN COMBINATION WITH WEAR PROTECTION COMBINATION WITH WEAR PROTECTION MIGHT REMEDY THE EFFECT OF ABRASION MIGHT REMEDY THE EFFECT OF ABRASION AND INCREASE THE LIFE OF THE SLING. AND INCREASE THE LIFE OF THE SLING.

REFERENCES: for SLINGSREFERENCES: for SLINGS

Std / NumberStd / Number DescriptionDescription

OSHA 3072OSHA 3072 Sling Safety Guidelines. Sling Safety Guidelines.

  

(ANSI) B-(ANSI) B-30.9-1971.30.9-1971.

American National Standards Institute, American National Standards Institute, standard for slings.standard for slings.

  

29 CFR N 29 CFR N 1910. 184 …1910. 184 …

OSHA Regulations / Standard for OSHA Regulations / Standard for slings.slings.

POWER TOOLSPORTABLE GRINDER,BENCH GRINDER, PORTABLE DRILLING MACHINE,MAGNETIC BASE DRILLING MACHINE

Regulations Covering Hand and Power Tools

For General Industry

29 CFR.------- 1910 Subpart P, Hand and Portable Power

Tools and Other Hand-Held Equipment. 1910.241, Definitions. 1910.242, Hand and portable powered tools

and equipment, general. 1910.243, Guarding of portable powered tools. 1910.244, Other portable tools and equipment.

CRANESCRANES

BLOCKBLOCKCONTAINS ONE TO EIGHT PULLEYSCONTAINS ONE TO EIGHT PULLEYS

SNATCH BLOCK-ONE PULLEY WITH SIDE OPENSNATCH BLOCK-ONE PULLEY WITH SIDE OPEN

HAND SIGNALHAND SIGNAL FIGURING THE RADIUS ON CRANESFIGURING THE RADIUS ON CRANES

-- BOOM LENGTH AND RATING, DISTANCE OF JOB BOOM LENGTH AND RATING, DISTANCE OF JOB FROM CRANE,COUNTER WEIGHT OF CRANE, FROM CRANE,COUNTER WEIGHT OF CRANE, ATTACHMENT OF JIBS, EXTENSION OF BOOMATTACHMENT OF JIBS, EXTENSION OF BOOM

HYDRA(HYDRAULIC LIFT TRUCKS)HYDRA(HYDRAULIC LIFT TRUCKS) OVERHEAD TRAVELLING CRANEOVERHEAD TRAVELLING CRANE EOT(ELECTRIC OVERHEAD TRAVELLING) CRANESEOT(ELECTRIC OVERHEAD TRAVELLING) CRANES MONORAILS MONORAILS

OVERHEAD TRAVELLING OVERHEAD TRAVELLING CRANESCRANES

AcetyleneAcetylene Gas Cylinders Gas Cylinders

AcetyleneAcetylene cylinders are 200 to 250 cylinders are 200 to 250 psig.psig.

Becomes unstable when compressed in Becomes unstable when compressed in gaseous state above 15 psig.gaseous state above 15 psig.

Requires special porous core cylinder.Requires special porous core cylinder. Acetylene gas is absorbed in cylinder core Acetylene gas is absorbed in cylinder core

by acetone to keep it stable under by acetone to keep it stable under pressure.pressure.

Must be stored and used in upright Must be stored and used in upright position to keep the liquid acetone position to keep the liquid acetone contained.contained.

Maximum delivery pressure is 15 psig. Maximum delivery pressure is 15 psig.

Acetylene CylinderAcetylene Cylinder

The acetylene dissolved in acetone to the ratio of 400.Liquid acetylene on evaporation expands 250 times .

Compressed Gas Compressed Gas OxygenOxygen CylindersCylinders

High Pressure – Rated at 2250 psi.High Pressure – Rated at 2250 psi. Must be secured at all times.Must be secured at all times.

Must be capped to transport in motor Must be capped to transport in motor vehicle or not in use as per statutory vehicle or not in use as per statutory rules.rules.

Grease & Oil must not come in Grease & Oil must not come in contact with component of Oxygen contact with component of Oxygen System.System. They can ignite & burn violently in They can ignite & burn violently in

presence of pure oxygen.presence of pure oxygen.

Oxy Oxy // AcetyleneAcetylene – Use & Safety – Use & Safety

Equipment SetupEquipment Setup Oxygen – cylinder, hose & torch threads are Right-Oxygen – cylinder, hose & torch threads are Right-

Hand.Hand. AcetyleneAcetylene - cylinder, hose & torch threads are Left-- cylinder, hose & torch threads are Left-

Hand.Hand. Main Cylinder ValvesMain Cylinder Valves

Inspect cylinder valve seating surfaces & threads Inspect cylinder valve seating surfaces & threads for dirt and damage.for dirt and damage.

Always crack valve prior to attaching regulator – Always crack valve prior to attaching regulator – helps remove any loose dirt or debris.helps remove any loose dirt or debris.

Stand to the side of the valve port and make sure Stand to the side of the valve port and make sure no one is standing in front of it when you crack it. no one is standing in front of it when you crack it.

OxyOxy // AcetyleneAcetylene – Use & Safety – Use & Safety

HosesHoses Make sure that hoses are rated for the Make sure that hoses are rated for the

gas being used and the tip size.gas being used and the tip size. Hoses are often exposed to abuse and Hoses are often exposed to abuse and

must be inspected for cracks, burns, must be inspected for cracks, burns, etc.etc.

Keep clean and free from oil or grease.Keep clean and free from oil or grease. Hoses are color coded and threaded Hoses are color coded and threaded

differentlydifferently Oxygen is blueOxygen is blue with Right-Hand threads. with Right-Hand threads. Fuel Gas is Fuel Gas is RedRed with Left-Hand threads. with Left-Hand threads. Fuel GasFuel Gas hose nuts have a V groove on hose nuts have a V groove on

outside to indicate Left-Hand threads.outside to indicate Left-Hand threads. Purge both hoses at about 3 psi to clear Purge both hoses at about 3 psi to clear

any foreign objects prior to attaching any foreign objects prior to attaching torch. torch.

Nozzle-Mixing TechnologyNozzle-Mixing Technology

Quick-connect, Check-valves, Backflash-Quick-connect, Check-valves, Backflash-preventerspreventers

Care & maintenance of the Gas Care & maintenance of the Gas RegulatorsRegulators

The internal working parts of the regulator are precision units. The internal working parts of the regulator are precision units. Only qualified technicians should clean or repair a regulatorOnly qualified technicians should clean or repair a regulator

TheThe Inlet Inlet ConnectionsConnections

Oxygen are right Oxygen are right hand thread / hand thread / Acetylene Acetylene are left are left hand threadhand threadKeep free of oil, Keep free of oil, grease, & dirt. grease, & dirt.

The Pressure adjusting screwThe Pressure adjusting screw

Turning clockwise allows the gas Turning clockwise allows the gas allows to flow.allows to flow.

Turning counterclockwise reduces Turning counterclockwise reduces or stops the gas flow.or stops the gas flow.

The High pressure The High pressure gaugegauge

Indicates the Indicates the pressure from pressure from tank.tank.

The Low The Low pressure pressure gaugegauge

Indicates Indicates the the delivery delivery pressure pressure to the to the hoses & hoses & torch.torch.

SPECIAL TOOLS

ALIGNMENT KITS: CLAMPS,DIAL GUAGE,SCALE,LASER ALIGNMENT UNIT

HYDROJETTING MACHINE HYDRAULIC BOLT TENSIONER BOLT HEATER LIFTING BEAMS TAILOR MADE TOOLS TO

TURBINES/PUMPS/GEARBOXES PLASMA CUTTING MACHINE BEVEL CUTTER

MEASURING TOOLS

DIAL GUAGE MAGNETIC STAND PLASTIC GUAGE THICKNESS TESTER SLIP GUAGES VERNIER CALIPERS MICROMETERS HEIGHT GAUGE BEVEL PROTRACTOR GEAR TOOTH VERNIER FILLER GUAGE HARDNESS TESTER SPIRIT LEVEL/MASTER LEVEL STRAIGHT EDGE PIANO WIRE VIBRATION METER

THREAD GAUGE TONGUE TESTER VOLTMETER

MAINTENANCE FACILITIES AND ACCESSORIES

WORK BENCHBENCH VICELAP BEDHYDRAULIC PRESSTOOL BOXHAND TROLLEYSLUBE CART

MAINTENANCE TECHNIQUESMAINTENANCE TECHNIQUES

HEAT EXCHANGER HEAT EXCHANGER MAINTENANCEMAINTENANCE

PUMP OVERHAULINGPUMP OVERHAULING TURBINE OVERHAULINGTURBINE OVERHAULING SPADING/DESPADING VALVE SPADING/DESPADING VALVE

MAINTENANCEMAINTENANCE GEARBOX MAINTENANCEGEARBOX MAINTENANCE FANS AND BLOWERSFANS AND BLOWERS

RIGGINGRIGGING GIN POLESGIN POLES

A POLE HELD VERTICAL BY ROPES AND USED A POLE HELD VERTICAL BY ROPES AND USED IN PLACES WHERE CRANE APPROACH IS NOT IN PLACES WHERE CRANE APPROACH IS NOT POSSIBLEPOSSIBLE

TRIPODSTRIPODS

REMOVING SAFETY VALVES FROM TALL REMOVING SAFETY VALVES FROM TALL COLUMNSCOLUMNSDAVIT ARM,SNATCH BLOCK,WINCHESDAVIT ARM,SNATCH BLOCK,WINCHES

SMALL WOOD SKIDSSMALL WOOD SKIDSSKIDS AND ROLLERS USED TO MOVE HEAVY SKIDS AND ROLLERS USED TO MOVE HEAVY OBJECTSOBJECTS

MOVING PUMPSMOVING PUMPS MOVING ELECTRIC MOTORSMOVING ELECTRIC MOTORS RUNNING PIPERUNNING PIPE PULLING AND REPLACING EXCHANGER PULLING AND REPLACING EXCHANGER

BUNDLESBUNDLES

SCAFFOLDINGSCAFFOLDING

TEMPORARY PLATFORM USED FOR WORKING ABOVE TEMPORARY PLATFORM USED FOR WORKING ABOVE

GROUND LEVELSGROUND LEVELS

FIXED SCAFFOLDFIXED SCAFFOLD

SWINGING SCAFFOLDSWINGING SCAFFOLD

TYPES:TYPES:

HORSE TYPEHORSE TYPE

BUCK TYPEBUCK TYPE

CANTILEVER CANTILEVER

HANGINGHANGING

TANK BRACKETTANK BRACKET

COMBINATION SCAFFOLDCOMBINATION SCAFFOLD

TUBELOX SCAFFOLD-PATENTED METAL SCAFFOLD MADE OF TUBELOX SCAFFOLD-PATENTED METAL SCAFFOLD MADE OF

TUBULAR STEEL CONSTRUCTIONSTUBULAR STEEL CONSTRUCTIONS