Principles of Engineering Maintenance,

Installation and Commissioning

Unit 2.3
Principles of Engineering Maintenance,
Installation and Commissioning

The session outcomes and objectives

are to understand and explain the
following:

• Understand how to plan maintenance,

installation and commissioning
activities
Safety induction.

Day 1

Start & finish times

Site map

First aid personnel

Assessment

Section induction check sheets

Start & finish times

Start 9:00

Break 10:30-10:45

Lunch 12:00-12:30

Break 2:30-2:45

End 16:00
 EEF HUB – Ground Floor Fire Plan

C
Reception Smoking shelter

B
First aid room
A
First Aid Personnel
Assessment

• Project

• Create a maintenance plan and report

format for the typical automated
production line.

• You will need to be able to justify and

explain your plan including any
contingency plans.
Section induction check lists

Please complete the following:

• General rules check sheet

Maintenance Activities

Why do we carry out maintenance activities?

What is in a maintenance plan?

How do we carry out installation activities?

What needs to be done to make an area safe?

Describe the contents of a report following activities.

Maintenance

• What is Maintenance?

• Maintenance refers to all measures regarding the

preservation, evaluation and restoration of the system status.
• Why do we carry out maintenance activities?
• Objective of maintenance
– Maintain and extend operational readiness
– Protection of personnel, system and environment
Maintenance

• Keep machines or systems operating at peak efficiency

• Protect personnel and environment under legal requirements

of
• HSAW 1974
• PUWER 1998
• PSSR 2000
• HSG43 ‘Industrial Robot Safety’
• EPA 1990
Employers’ responsibilities

• Provide a safe place to work

• Provide safe plant and equipment
• Provide a safe systems of work
• Provide a safe working environment
• Provide and maintain work equipment
• Provide safe methods of handling, storing and moving goods
and materials
• Provide any PPE required to safely undertake a task
• Consult with employees, or their representatives, on H&S
matters
Types of Maintenance

• Service
– Measures to maintain required status

• Inspection
– Measures to determine and evaluate the actual status

• Repairs
– Measures to restore the required status
Service

• Preventative measures to prolong operations

• Carried out
• According to the Service Schedule
• Preventive
• Wear reducing measures
• Extending service life
Service

• Service Schedule (Service Instructions)

• Mandatory
• List
• Contains all work to be carried out
• Measurements
• Test variables
• Frequency of operations
• Additional comments
Inspection

• Wear and tear of components cannot always be detected

by eye

• Periodic check of function and condition

• To detect wear at defined intervals
• Detect and evaluate visible and audible signs of extent
of wear
• Measuring, experiencing and checking of safety
elements
• Compare against set values
Inspection

• Set by Manufacturer
• Usually combined with the Service Schedule

• Planned Preventative Maintenance (PPM)

• Combination of Service and Inspection
• Checking
• Adjustments
• Replacement
Planned Preventative Maintenance

• Replacement
• Contamination
• Component life cycle

• Component life cycle set by Manufacturer

• Based on historic or design criteria

• Hours
• Cycles
• Calendar
Planned Preventative Maintenance

• What sort of things could be checked during PPM?

• Oil and water levels

• Check for leaks and corrosion
• Check for noise and vibration
• Check clearances and wear
• Replace ‘lifed’ components
• Check operation against known parameters /
tolerances
Repairs

• Planned
• Defect limit reached
• Repair before failure

• Malfunction
• Unintentional interruption
• Fault diagnosis
• Systematic repairs
Planning Maintenance Activities
Planning Maintenance Activities

• Plan dictated by legal requirements

• Manufacturers’ recommendations

– Service schedule
– Operating parameters
– Unexpected system or machine failure
– Familiarity with machine or system
Planning Maintenance Activities

• Safe working systems

• Reduction in down time

• Rotation of off duty time of machine / system

• Factory down time

• Troughs in expected production

• Restore or maintain system peak operating efficiency

Maintenance Plan

• What is in a maintenance plan?

• Service Schedule (Service Instructions)

• Mandatory
• List
• Contains all work to be carried out
• Measurements
• Test variables
• Frequency of operations
• Additional comments
Maintenance Plan
Example
Installation and Commission

• To install an eligible installation means to build and/or put in

place the relevant plant.

• To ”commission” a plant means to carry out all necessary

tests and procedures required by industry standards to
show that the plant is able to deliver the purpose for which it
was installed.
Installation Activities

• Must be done properly

• In accordance with Manufacturer’s Instructions
• Nothing makes it unsafe
• No risk to health
• Employees and operators
• Site or equipment
• Non-employees
Installation Activities

• Installers may have additional responsibilities

• May become the ‘manufacturer’ and ‘duty holder’ of new
machine
• PUWER 1998
• Supply of Machinery (Safety) Regulations 2008
• HSG43 ‘Industrial Robot Safety’

• Person installing product responsible for

• Conformity Assessment
• Meet essential requirements
• CE marking
Installation Activities

• Person installing product has

• An obligation under HSAW 1974 to conduct work safely

• Report any safety concerns to manufacturer and user (in
writing)
• Connect or disconnect to make safe (gas)
• Report issues to the relevant authority
• Sub-contractors work under main contractor who has
responsibility for conformity etc.
Installation Considerations

• What are the considerations when installing equipment?

• Site conditions / preparation / access

• Minimise disruption to other work
• Tools / specialist equipment
• Provision of services
• Water
• Drainage
• Electricity
• Compressed air
Installation Considerations (continued)

• Storage of parts and materials

• Security of attachment
• Floor bolts
• Structural integrity
• Alignment
• Connections to services
• Working clearances
• Guards and emergency stop switches
Installation Considerations

• What are the considerations after installation?

• Commissioning
• Performance testing
• Monitoring
Installation and Commission

• To install an eligible installation means to build and/or put

in place the relevant plant.

• To ”commission” a plant means to carry out all necessary

tests and procedures required by industry standards to
show that the plant is able to deliver the purpose for
which it was installed.
Installation and Commission

• For smaller scale installations, installation and commissioning

may happen on the same day.

• At the larger scale there is usually a significant testing period,

so the date of installation and date of commissioning may be
different
Commissioning

• What is commissioning?

• Commissioning is to effect the safe and orderly handover

of the unit from the constructor to the owner, guaranteeing
its operability in terms of performance, reliability, safety
and information traceability
Commissioning

• Commissioning activities, in the broader sense, are

applicable to all phases of the project, from the basic and
detailed design, procurement, construction and assembly,
until the final handover of the unit to the owner, including
sometimes an assisted operation phase
Commissioning

• Think safety!!!!

• Ensure system is set in a safe condition

• Check security of attachments

• Check mechanical connections

• Check pipe work and connections

• Check electrical connections

Commissioning

• Start up system / machine slowly

• Continue to build up to full operating pressures, loads,

speeds and ranges

• Compare established system / machine to required

operating and manufacturer’s specifications
Think Safety

• Most Industrial Plant has the ability to maim or kill

• Legislation (HSAW and associated regulations) dictates
employers and employees responsibilities
• Think of the implications of what you are about to do
• Think about danger areas
• Permits to work
Managing Danger Areas

• Warning signs (in appropriate positions)

• Barriers / tapes
• Lock off switches / valves / etc
• Inform nearby or affected personnel
• Clean up work areas
• Spillage plan
• spill kit
• absorbent material
• detergents and solvents
Managing Danger Areas

• Safe waste disposal

• Fire equipment
• Risk assessments
• COSHH assessments
• Safety personnel
• Competent personnel
• Supervision
Report Content

• Documentation required to satisfy

• HSAW 1974
• PUWER 1998
• PSTGR 1989
• EPA 1990

• What key things should be included in a maintenance or

installation report?
Report Content

• Location of work

• Work undertaken (planned and unplanned)

• Dates and times of work

• Parts and consumables used

• Safety practices followed (Permits to Work)

• Tests carried out and data collected

Report Content

• Details of design and construction

• Rated conditions of operation

• All foreseeable faults and operation of safety devices

• Maintenance Schedule

• Latest periodic report of examination

• Previous reports linked to safety issues

• Details of all faults and modifications

Report Content

• List of machine malfunctions

– Most shift staff see approx. quarter of faults

• Record of work carried out

• Personnel involved

• Technical file for new system or machine

Technical File

• The technical file contains:

• Information on design, construction

• How essential requirements have been met
• Conformity Assessment Procedure
• Conformity Certificate
• User Instructions
• Relevant research and test results
• Quality systems for a series of products
Maintenance Activities

• Why do we carry out maintenance activities?

• What is in a maintenance plan?
• How do we carry out installation activities?
• What needs to be done to make an area safe?
• Describe the contents of a report following activities.
Project (Assessment)

• From the supplied manufacturers’ data, you will need to

create a maintenance plan and report format for the
typical automated production lines supplied.

• You may need to research the internet for additional

information in support of your plan.

• You will need to be able to justify and explain your plan to

the tutor and the group, including any contingency plans.
Principles of Engineering Maintenance,
Installation and Commissioning

Unit 2.3