COLLEGE OF ENGINEERING AND TECHNOLOGY

MODULE
MAINTENANCE AND RELIABILITY

COURSE CODE
INME 511

ASSIGNMENT 1 NAME: KETSHEPHAONE KEISANG

ID: 14001131

PROGRAM: BEng ENERGY

DATE OF SUBMISSION: 23 JAN 2019

Company Attached to: Morupule B Power Plant

Department- Mechanical Maintenance Section

Main Activities Carried out:

Power Generation

Transmission & Distribution of Electricity to the final consumer

3 Types of engineering equipment found at the plant:

Main Components

Boiler

Turbine

Air Cooled Condenser Fans

Feed-water Pump

Other Components(Auxilliaries)

Generator

Compressors

Transformer

Electric Motors

Hydraulic Coupling

Different pumps depending on application e.g. condensate extraction pumps

4 Maintenance Challenges

I. Assigning and managing work orders efficiently while improving workflow with scheduling and
work history.
II. Old equipment and machines, these are not only outdated their inability to cope with
production challenges
III. Acquisition of spare parts is very much a headache as some of the equipment are no longer in
the market
5 PREVENTATIVE MAINTENANCE(PM)

Maintenance is carried basing on principle “prevention is better than cure”. Maintenance activities are
planned and scheduled in advance. These are carried out at predetermined intervals or corresponding
to prescribed criteria and intended to reduce the probability of failure or the performance degradation
of an item.
PM is achieved by application of these elements;
1.Inspection

2. Servicing

3. Installation

4. Testing

5. Calibration

6. Adjustment

7. Alignment

This type of maintenance has several benefits including but not limited to:

 Equipment downtime is decreased and the number of major repairs are reduced

 Better conservation of assets and increased life expectancy of assets, thereby eliminating
premature replacement of machinery and equipment

 Reduced overtime costs and more economical use of maintenance workers due to working on a
scheduled basis instead of a crash basis to repair breakdowns

 Timely, routine repairs circumvent fewer large-scale repairs

 Improved safety and quality conditions for everyone

6 Air Compressor Maintenance

Air compressor owners often forget that an ounce of prevention is worth a pound of cure. Maintaining
your air compressor can save you both time and money down the road. By performing the following
checks each time, you operate your air compressor, you are saving yourself a world of pain in the future.
Air Compressor Preventive Maintenance Checks

Checking Compressor Pump Oil Level

Unless your air compressor is an oil free compressor, do not operate without lubricant or with
inadequate lubricant. Manufacturers and the company from whom you bought it from cannot be
responsible for failure due to inadequate lubrication.

1. Ensure unit is off and disconnect from the power source

2. Ensure compressor is on a flat and level surface

3. Remove fill cap / plug

4. Inspect the oil in the crankcase assembly and look for dirt or debris

5. Oil should not exceed the halfway point of the sight glass

Changing Compressor Pump Oil

Remember, the compressor pump head and surrounding parts are HOT!

1. Ensure unit is off and disconnect from the power source

2. Ensure compressor is on a flat and level surface

3. Remove fill cap / plug

4. Place collection container underneath the oil drain cap.

5. Remove the oil drain cap, and let the oil drain out.

6. Replace the oil cap and be sure to tighten this nut securely. White plumbers tape (PTFE) is
generally a good idea to help create a tighter seal. Fill crankcase with appropriate oil, be sure it
does not exceed the halfway point.

Checking the air filer element

For the more common reciprocating air compressors.

1. Ensure unit is off and disconnect from the power source

2. Allow compressor pump to cool off.

3. Unscrew the filter top from the filter base by turning (generally) counter-clockwise.

4. Separate the filter top cover from the base.

5. Remove the element from the filter base

6. Blow out dust and debris from the filter element.

7. Replace element if needed.

8. Reconnect filter top to the base and secure filter.

Checking the air filer element

For the more common reciprocating air compressors.

1. Ensure unit is off and disconnect from the power source

2. Allow compressor pump to cool off.

3. Unscrew the filter top from the filter base by turning

Provisional maintenance schedule for the compressors system

General Preventative Maintenance Schedule
Procedure Daily Weekly Monthly Annually
Check Pump oil level 
Oil leak inspection 
Drain water in tank 
Check for abnormal noise & vibrations 
Inspect all air leaks 
Inspect drive belts 
Check air filters, clean or replace 
Check safety relieve valve 
Check and tighten all bolts 
Service pump or engine 
Check connections for leaks 