ASEC Academy

Coal Handling & Safety

Sinai Grey

Wael A.M. El-Noby

ASEC Academy

Layout of The Course

Subjects
o Introduction
o Maintenance Philosophy and Why is it done
o Atox Vertical mill Design and function
o Fire fighting
o ATEX Directive
o Bag house filter and coal filter
o Pfister and coal feeder
o Safety precauions for Maintenance & inspection
o Exercise and Discussion
ASEC Academy

What is Maintenance

Maintenance involves keeping the workplace, its structures,

equipment, machines, furniture and facilities in good repair and
operating efficiently and safely. It includes many tasks including
repairing, replacing, servicing, inspecting and testing. The term
could also be used in relation to the importance of keeping your
staff safe, fit and healthy.
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Maintenance Types

There are two main types of maintenance work.

Routine/preventative maintenance
is usually planned and includes scheduled inspections repairs
and replacement to make sure everything continues to work. It
can be compared to an annual service on your car.
Corrective maintenance
is needed when things go wrong or break downs occur
demanding reactive action to be taken to get things up and
running again. It can be compared to having a repair carried out
on your car after a part has failed.
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Maintenance and
Why Is It Done

Regular maintenance is essential to keep premises, equipment,

machines and the work environment safe and reliable. It helps to
eliminate workplace hazards. Lack of maintenance or inadequate
maintenance can lead to dangerous situations, accidents and
health problems.
It is important that a planned maintenance programme is in place
and that all maintenance work is risk assessed before beginning
the task
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Maintenance and Risk

Who is affected/ most at risk?

Everyone is affected. Those who carry out maintenance work are
at risk if the tasks have not been assessed and adequate controls
are in place to keep them safe but others would be affected if
maintenance work was not carried out as they could be working
with or around dangerous equipment or within a dangerous
environment.
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Maintenance and Risk

Contractors brought in to carry out maintenance work can be

particularly at risk as they may be unfamiliar with the
workplace and the procedures in place for working safely.
Maintenance can be dangerous, it is estimated that, between
25 and 30% of all manufacturing industry deaths in Britain
result from maintenance activity.
This doesnt include the long-term health problems associated
with maintenance. One example of this is the recent HSE
campaigns highlighting the numbers of workers exposed to
asbestos during maintenance work in buildings where
asbestos is present.
ASEC Academy

Maintenance and Risk

What are the main risks?

Maintenance work can in itself be hazardous. It can also make the
workplace more hazardous while the work is being carried out. A
risk assessment will be needed to identify suitable control
measures to manage the maintenance work effectively.Some of
the main problems associated with maintenance work are:
working at height (risk of falls or falling tools and equipment)
gaining access to the equipment (confined spaces or harsh
environments)
ASEC Academy

Proactive Maintenance

electrical hazards (shocks, burns if not isolated)

equipment (injuries from moving parts if not isolated)
musculoskeletal disorders (exerting force, poor access or working
in a cramped space)
exposure to asbestos fibres (not always identified and marked?)
exposure to harmful chemicals (used in the machine being
maintained?)
exposure to dust (again, through the machine being maintained?)
exposure to legionella (in water systems and air conditioners)
exposure to noise (working on or using noisy equipment)
ASEC Academy

Proactive
Maintenance
It is also known as Prevention Maintenance.
This philosophy based on tracing all failures to their root cause.
Each failure is analyzed and proactive measures are taken to
ensure that they are not repeated.
It utilizes all of the predictive/preventive maintenance techniques
discussed above in conjunction with root cause failure analysis
(RCFA).
RCFA detects and determines the problems that cause defects.
It ensures that appropriate installation and repair techniques are
adopted and implemented.
It may also highlight the need for redesign or modification of
equipment to avoid recurrence of such problems.
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2 Check List

Always use a checklist when performing an inspection.

The checklist may be of your own design, one provided by the
manufacturer of the equipment being inspected, or one obtained
from some other source.

3 Routine and Required Inspections

Performing these inspection according to recommendation

and documents.
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4 Maintenance Manual

The manufacturers equipment maintenance manual contains

complete instructions for maintenance of all systems and
components installed in the equipment

5 Overhaul Manual

The manufacturers overhaul manual contains brief descriptive

information and detailed step by step instructions covering work
normally performed on an equipment.
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Accurate Measurements and Condition Monitoring

Performing these accurate measurements by using different tools
and compare it with documents.
Historical Record
The previous items has been recorded to form a complete
picture for each equipment status and to make our investigation
easier in case of problems detection and it facilitates problems
analyzing and find the specified root cause analysis for
equipment.
Interpretation and Analyzing of Results
The success and reliability of inspection depends upon the
inclusion with which the data has been collected.
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Oil Analysis and Wear

Oil Analysis Tests

A good oil analysis package looks at four main Points to provide
A unique way of indicating what is going on inside the
equipment:
1. Oil condition: development specifications
(oxidation, viscosity, additives, etc.)
2. Equipment condition: type of wear (normal,
abnormal)
3. Contaminants: type and quantity (dirt, water,
debris, other lubricants, etc.)
4. Equipment operating conditions: (load,
temperature, alignment, balance, speed,
ASEC Academy

Oil Analysis and Wear

Oil Analysis Tests

There are a few key tests for industrial lubricants that show
their general condition.
These tests includes the following categories:
I. Viscosity
II. Water content
III. Acid number (AN)
IV. Oxidation
V. Elemental analysis
ASEC Academy

1
1 Viscosity

It is a measure of a fluids resistance to flow.

It is the single most important property of a lubricant.
The most common units for describing kinematic viscosities are
centistokes (cSt), which are reported at 40C (104F) for industrial
gear lubricants.
Where a lubricants viscosity is defined in ISO-VG grades, a change
of approximately 24% from typical levels indicates a need for
corrective action.
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If the lubricants viscosity shows an Increase above the typical

value, it may be due to high soot or insoluble content,
contamination with higher viscosity lubricant and oxidation.
Corrective action should be applied such vacuum dehydration,
and filtration to remove particulate and/ from the oil, thus
extending oil life.
Also the correction action may be adding new oil to refresh the
charge or change the whole charge.
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If the lubricants viscosity shows a Decrease, it may be due to

water contamination, dilution with lighter viscosity oil, or shear
down of a viscosity index improver.
Corrective action should be taken is change the oil, either
partially or completely.
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2
1 Water Content

A lubrication oil is considered absolutely fit for further use only if its
water content is less than 0.2 %.
Water can enter the oil from a cooling system leak, or bad sealing.
The nature of water (fresh or salt) can be determined from the
sodium and magnesium levels detected.
Water reduces film strengths and reacts with aggressive
components in the oil to form acids. These acids degrade the oil and
attack the equipment component.
Corrective action should be taken is first dehydrate the oil and
second is change the oil, either partially or completely.
ASEC Academy

3
1 Acid Number ( AN)

The acid number (AN) is the amount of acidic substances present in

the lubricating oil.
A high value implies that the oil is degraded by high acidity.
If the oil has a high acid number and remains in service, the
equipment elements will be attacked and create corrosion.
Corrective action should be taken is change the oil, either partially
or completely.
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4
1 Oxidation

Oxidation is measured using infra-red (IR) test methods.

This test is run for all samples, with the exception of some synthetic
based oils.
An oxidized oil normally increases its viscosity and turns dark in
color.
The oxidation process can be due to high operating temperatures.
Corrective action should be taken is change the oil, either partially
or completely.
ASEC Academy

5
1 Element Analysis

Elemental analysis measures the presence of elements in the oil, in

parts per million (PPM).
This test is run for the purpose of diagnosing wear.
Limit values for each element depend on the equipment builder and
the application.
If the values are above the attention limits, the test indicates
changes in machinery wear and lubricant contamination.
Corrective action should be taken is fixing any problem, according
to the element(s) shown in the test and change the oil, either
partially or completely.
ASEC Academy

If the values are above the alert limits, the test indicates severe
changes in the machinery regime wear.
Corrective action should be taken is stop the equipment and
inspect it for failures or damages, then fix the problem and change
the oil completely.
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Technical Reports
Writing the technical reports which indicates equipment technical
data, the problem and discussion upon documents, measurement
and actual notes from site.

Lubrication Circuit
Planning for Shutdown
Planning for shutdown according to the jobs required because of
all inspection work and scheduling these jobs with full co-
operation between all departments.