1. King Fahd University of Petroleum and Minerals Mechanical Engineering Department Coop Training : Central Heavy Equipment Department In Aramco King Fahd University of Petroleum and Minerals Mechanical Engineering Department Maintenance and Preventive Maintenance of Heavy Equipment Coop Training : Central Heavy Equipment Department In Aramco Presented by: Abdulnaser M. Al-Mesbah ID# 981908 DATE : OCTOPRER 20, 2004

2. Outline  Central Heavy Equipment Department  Heavy Equipment Shops  Cases Study  Conclusion

3. Central heavy equipment department 1111. Dhahran Equipment Pm/Field Repair Service Unit 2222. Patch & Dispatch Unit 3333. Quality Control Unit 4444. Electric Shop Unit 5555.Heavy Equipment Shops Unit

4. Heavy Equipment Shops  1. Crane Shop  2. Dozer Shop  3. Fuel Room  4. Pumps Rebuild Shop

5. Case Study 1: Portable 900KW Generator

6. Case study 1 Portable 900KW generator Physical assessment: 1. Water leak in radiator core 1. Water leak in radiator core 2. Excessive leak at oil cooler gasket 2. Excessive leak at oil cooler gasket

7.  Quality Control Unit Case study 1 Portable 900KW generator 1. Due to radiator leak, water level dropped causing the engine to over heat. 2. Automatic Shut down system failed to actuate. 3. Heavy oxidation of the engine oil that become black viscous tar. 4. Due to the oxidation of the oil, all oil lines and panes are covered/coated with the high oxidized oil.

8. Case study 1 Portable 900KW generator Material cost ($)Labor($)Invoices($)Total($) Already charged 3295822522811748 In-house engine overhaul 50001000015000 Total82951822522826748 Repair cost: Alternative #1: Repair Cost Estimate with In-House Engine Overhaul

9. Material cost ($) Labor ($) Invoices($)Total($) Already charged 3295822522811748 In-house engine overhaul 100,000100010,000111000 total103295922510228122748 Case study 1 Portable 900KW generator Repair cost: Alternative #2: : Repair Cost Estimate with External Overhaul or Replacement

10.  Alternative #1: % of Repair Cost vs. New Unit Cost: 27000/300,000 = 9%  Alternative #2: % of Repair Cost vs. New Unit Cost: 123000/300,000 = 41 % Case study 1 Portable 900KW generator Repair cost:

11. Case study 1 Portable 900KW generator Items That Have Been Repaired or Replaced:  replacing the engine starter.  Removing the old automatic shut down system and reinstall it again.  install new radiator.  cleaning the engine due to the oxidation of oil.  replacing oil ban gaskets with new ones.  Replacing the engine head gaskets.  replacing the engine governor.

12. Case Study 2: AT-750BE Crane

13. Case study 2 AT-750BE Crane Quality Control Inspection:  Steam clean unit.  Flash radiator and refill with antifreeze.  Clean all operator cap.  Reseal rear R.H.S final drive due to oil leak.  Repair or replace upper sky glass supporting cylinders.  Calibrate fuel injectors.  Replace fuel sender.  Repair air leak at the parking brake valve.

14. AT-750BE Crane Case study 2 Crane Maintenance:  R.H.S Final Drive

15. Case study 2 AT-750BE Crane All injectors have been sent to the fuel room for calibration. All injectors have been sent to the fuel room for calibration. adjusting the intake and the exhaust valves with 0.014 and 0.027 in feeler gauge respectively. adjusting the intake and the exhaust valves with 0.014 and 0.027 in feeler gauge respectively. one of the rock arms fall down inside the engine. one of the rock arms fall down inside the engine.

16. AT-750BE Crane Case study 2 Additional items: Changing oil filters Changing 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.

17. 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.

18. Re-sealing the lift cylinder Step # 1: Draining oil from the lower part of the lift cylinder Case study 3 89-0865 Forklift

19. Case study 3 Re-sealing the lift cylinder Step # 2: Removing the lock, which is in the head of the cylinder. Step # 3: Opening the piston lock.

20. Case study 3 89-0865 Forklift Re-sealing the lift cylinder Step # 4: Pulling the piston out side the cylinder using a forklift. Step # 5: changing the piston seals

21. 89-0865 Forklift Case study 3 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.

22. Case study 4 Pipe Loader Case Study 4: Pipe Loader

23. Pipe Loader Case study 4 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.

24. Pipe Loader Case study 4 New transmission pump cost: 2100 US$ New transmission pump cost: 2100 US$ The pump was sent to the welder shop The pump was sent to the welder shop  Most of the hydraulic systems use gear pump

25. Pipe Loader Case study 4 Testing the pipe loader: pipe loader capacity: 12 T pipe loader capacity: 12 T The test was to carry a 9 T The test was to carry a 9 T The pipe loader success The 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.

26. Case study 4 Pipe Loader

27. Conclusion: Value of time and commitment. Value of time and commitment. Value of team work. Value of team work. maintenance of heavy equipment maintenance of heavy equipment

28. Thank you