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JAO PMG Flywheel Preventive Maintenance Plan

PMG-X.X.X.X-X-A-PLA Status: Draft 1 April 25, 2013

Printed versions of this document are For Reference Only. The latest released electronic version is located in the ALMA Electronic Document Management (EDM) system accessible through the internet at: http://edm.alma.cl

Change Record
Revision A Date April 25, 2013 Affected Paragraphs(s) All Reason/Initiation/Remarks Initial release.

TABLE OF CONTENTS
1 Introduction ..................................................................................................................................... 3 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 Purpose.................................................................................. Error! Bookmark not defined. Scope ..................................................................................... Error! Bookmark not defined. Responsibility ......................................................................... Error! Bookmark not defined. Applicable Documents List (ADL) .......................................... Error! Bookmark not defined. Reference Documents List (RDL) .......................................... Error! Bookmark not defined. Abbreviations and Acronyms ................................................. Error! Bookmark not defined. Terms and Definitions ............................................................ Error! Bookmark not defined.

Plan ................................................................................................ Error! Bookmark not defined. 2.1 2.2 2.3 2.4 2.5 Cleanliness ............................................................................................................................ 1 Re-lubrication of the Bearings ............................................................................................... 1 Helium Supply ........................................................................................................................ 1 Air Filters ................................................................................................................................ 1 Summary................................................................................ Error! Bookmark not defined.

INTRODUCTION

EQUIPMENT TREE

The generic maintenance equipment tree for the flywheels is shown in the following picture:
POWER DISTRIBUTION SYSTEM

System Level

Equipment Level Component Level

PILLER UNIBLOCK UPS

Flywheel

Motor/Generator

Control System

EQUIPMENT LIST

The list of the Piller Uniblock UPS equipments in responsibility of theMG is shown in the following table:

Equipment Uniblock UPS XLA Uniblock UPS XLB Uniblock UPS XLC Uniblock UPS XLD

CMMS tag PUP-A PUP-B PUP-C PUP-D

Table 1: Equipment List

4
# 1 2

MAINTENANCE PLAN
Maintenance Task Description Monthly General Inspection Quarterly Maintenance Freq (Days) 30 90 Skills OPER MECH 1 ELEC1 Personnel Qty. 2OPER 1MECH1 1ELEC1 Equipment Condition Running Shutdown Typ e PM PM Est. Time (hrs) 5 7

Table 2: Maintenance Plan

Cmo indico que las actividades 4, 5 y 6 podrn gatillar una accin correctiva?

The Piller UNIBLOCK Flywheels are largely maintenance free, nevertheless, the operations shall be carried since they contribute to trouble-free operation and increase service life of the installation. Following the maintenance tasks are described; all of them are based on recommendations from Piller. 4.1

Monthly general inspection

A general inspection shall be performed by the operators ..

4.2 4.2.1

Quarterly Maintenance
Cleanliness

The environment around the plant must be free of dust, metal swarf, lubricants, etc. A quarterly check of all the air inlets and outlets must be performed to verify that they are free of dust or any other blocking objects. Air inlet openings must be sucked. No compressed air shall be used, since this can blow dust particles into the set and cause malfunctions 4.2.2 4.2.3 Tightening Re-lubrication of the Bearings

The UNIBLOCK-T Diesel UPS is equipped with two independent automatic greasing pumps that are using two different kinds of lubricants, which cannot be mixed with other lubricants. The grease type is written on the plate of the grease pump. The refilling must be performed when the grease container is totally empty, condition that will trigger an alarm. Also, the grease has a life of 3 years without loss of quality, so at that time it must be always replaced by new. Also, a quarterly check to the grease pipes shall be performed for detecting leakages and to the bearings in order to detect undue noise. Squealing noise can be caused by inadequate lubrication, scrapping or rumbling noises can be caused by dust or a faulty bearing.

4.2.4

Helium Supply

A Helium bottle is used to reduce working temperature, the pressure of this bottle is monitored by the Flywheel and as soon as is 3 bar or lower and alarm is triggered indicating to change the Helium bottle. Replacement doesnt require the machine to be shut down. The purity of the helium in bottle has to be 99,996% or better.

4.2.5

Air Filters

The UNIBLOCK-T is equipped with two different air inlet filters, which are being monitored by the Flywheel and an alarm will trigger in case they are contaminated. Nevertheless, they must be inspected monthly, and replaced if it is necessary. 4.3

Spare Parts List


Description Manufacturer Part Number Part Number Vendor Contact Information Time to get Replacement Task Associated

Grease Helium Bottle Air Filter Table 3: Spare parts list

SUMMARY
Hour Type OPER MECH1 MECH2 ELEC1 ELEC2 CONTRACTOR TOTAL SHUTDOWN JAN 30 0 0 0 0 0 30 0 FEB 30 0 0 0 0 0 30 0 MAR 30 21 0 21 0 0 72 9 APR 30 0 0 0 0 0 30 0 MAY 30 0 0 0 0 0 30 0 JUN 30 21 0 21 0 0 72 9 JUL 30 0 0 0 0 0 30 0 AUG 30 0 0 0 0 0 30 0 SEP 30 21 0 21 0 0 72 9 OCT 30 0 0 0 0 0 30 0 NOV 30 0 0 0 0 0 30 0 DEC 30 21 0 21 0 0 72 9 ANNUAL 360 84 0 84 0 0 198 36

Table 4: Monthly and Annual Hours

Hour Type Grease Helium Bottle Air Filter

JAN 0 0 0

FEB 0 0 0

MAR 1 1 1

APR 0 0 0

MAY 0 0 0

JUN 1 1 1

JUL 0 0 0

AUG 0 0 0

SEP 1 1 1

OCT 0 0 0

NOV 0 0 0

DEC 1 1 1

ANNUAL 4 4 4

Table 5: Monthly and Annual Spare Parts

Cost Type Oper Mech1 Mech2 Elec1 Elec2 Contractor Grease Helium Bottle Air Filter Total

JAN 1000 0 0 0 0 0 0 0 0 1000

FEB 1000 0 0 0 0 0 0 0 0 1000

MAR 1000 1000 0 1000 0 0 100 100 100 3300

APR 1000 0 0 0 0 0 0 0 0 1000

MAY 1000 0 0 0 0 0 0 0 0 1000

JUN 1000 1000 0 1000 0 0 100 100 100 3300

JUL 1000 0 0 0 0 0 0 0 0 1000

AUG 1000 0 0 0 0 0 0 0 0 1000

SEP 1000 1000 0 1000 0 0 100 100 100 3300

OCT 1000 0 0 0 0 0 0 0 0 1000

NOV 1000 0 0 0 0 0 0 0 0 1000

DEC 1000 1000 0 1000 0 0 100 100 100 3300

ANNUAL 12000 4000 0 4000 0 0 400 400 400 21200

Table 6: Monthly and Annual Costs (US$) Work Order Type Operations Maintenance Total JAN 1 0 1 FEB 1 0 1 MAR 1 1 2 APR 1 0 1 MAY 1 0 1 JUN 1 1 2 JUL 1 0 1 AUG 1 0 1 SEP 1 1 2 OCT 1 0 1 NOV 1 0 1 DEC 1 1 2 ANNUAL 12 4 16

Table 7: Monthly and Annual Work Orders