NOTES - 11
EQUIPMENT
MANAGEMENT TIPS FOR THE CONSTRUCTION ENGINEERS
AND
PLANT & MACHINERY ENGINEERS
AN
INTRODUCTION TO CONSTRUCTION PLANT AND EQUIPMENT
SITE
PLANT AND MACHINERY WORKSHOP LAYOUT AND ORGANIZATION OF DEPARTMENT
I. Introduction
Workshop facilities
for inspection, maintenance and repair of equipment are provided by all
construction companies these workshops are designed to meet the requirement of
Inspection/Maintenance/Repair of equipments.
The workshops are
designed in 3-Tier system (i.e.)Light repairs (Type A), Field repairs (Type B)
and Base repairs (Type C)
II.
Light Repair workshop
The light repair
workshops (Type A) are located in temporary accommodation or on wheels at the
Project Site. These workshops carry out inspection, servicing and light repairs
to equipments. Fast moving spares for light repairs and few minor assemblies
are stocked in these workshops. The technical manpower is normally trained in
multi-trades so that they can handle two or three repair systems/trades. The
type of plant and machinery for the workshop will depend upon the number/type
of equipment in use at the project site and duration of the project. The light
repair workshop normally consist of the following Trailer mounted
Equipments/Tools.
i. Generating Set 5-10
KVA for Power Supply
ii. Workshop Machinery
- Lathe, Drilling Machine and Grinder
iii. Electric Welding
Generator/ Transformer
iv. Gas Welding Sets
v. Servicing Trailer -
Diesel/Electric driven compressor, pneumatic hose, H.P., L.P., Pumps for
grease, oil and water pump for washing vehicles.
vi. Tradesmen Tools -
Blacksmith, welder,Tinsmith,Electrician, Electrician, Vehicle Mechanic (Auto /
Diesel), Turner, Carpenter, Maintenance Tools, Special Tools.
vii. Jib Crane - Tools
and Tackles
viii.Store Bins
ix. Recovery Vehicle
Light repair workshop
back loads vehicle/equipment requiring heavier repairs to field repair
workshops.
III.
Field repair workshop
The field repair
workshops (Type B) are normally located in zonal areas of the company giving
repair/maintenance cover to 3 or 4 projects. These workshops are normally
semi-state with full range of repair/maintenance equipments. The workshop
stocks adequate spares/assemblies for replenishing the light repair workshops.
The workshop undertakes t he following:
i. takes over the
overload of light repair workshops
ii. carry out heavier
repairs - such as overhauling engines, gear boxes, transmission, hydraulic
systems etc.
iii. Restricted
repairs to accident vehicles
iv. Local purchase of
spares and local contract repairs to vehicles/equipment.
v. Recovery covers to
project vehicles
vi. Sends special
teams with major assemblies to project site to carry out major repairs in situ.
vii.
Reclamation/Repair of minor assemblies received from light repair workshops.
viii. Inspection/Down
gradation of vehicles
ix. Carry out specific
fuel consumption tests and target Km. per litre tests on vehicles.
x. Carry out any
modifications to vehicles/equipment as directed by Base workshop.
xi. Evacuation of
vehicles/equipment to base repair workshops.
IV. Field repair
workshop can also be established at a major project site under the following
conditions:
i. Duration of Project
exceeds 3 to 5 years
ii. Project has
several types/number of equipments
iii. Local repair
facilities from nearby town are not adequate
iv. Spare parts are
not readily available from local market
v. In-accessible areas
or lengthy lines of communication- Mountainous snow, desert areas.
vi. Heavy
repair/maintenance commitments due to three shift working.
V. The general layout
of a field repair workshop is shown in Appendix A attached. The layout can be
modified to suit the ground conditions. A list of few machinery/equipments used
in the workshop is shown in Appendix B. The organization of the workshop is
shown in Appendix C. The outline functions of various departments/officers of
the workshop are mentioned below:
Workshop officer is
responsible for the following functions:
i.
Administrative/Technical control of all departments in the workshop.
ii. Preparation of
Annual Inspection/ Maintenance program for Equipment.
iii. Provision of
spares/assemblies for repair.
iv. Timely repairs to
the equipment in workshop.
v. Maintenance of
records for equipments
vi. Budgetary contract
repairs and local purchase of spares.
vii. Local contract
repairs and local purchase of spares.
viii. Carry out any
major design modification to equipments.
ix. Audit on the
quality of repairs, inspection done by workshop personnel.
x. Stock checks on
stores.
xi. Security and fire
precaution.
XIV. Regular
inspection of construction equipment is an important factor to keep the
equipment in serviceable condition at all times. Such inspection enables timely
detection on faults which can be rectified in time and costly breakdowns are
avoided. The inspection should be done at regular intervals by qualified
personnel. The Annual Inspection Program for equipment are prepared in
consultation with users and Workshop Officer. The inspection team should work
independently so that unbiased check can be exercised. The inspection staff
should be technically qualified and competent for the job. The inspection
department decides the classification of equipment based on usage and major
repairs carried out on the equipment. A specimen inspection form for
earthmoving machines is given at Appendix G. Similar inspection forms can be
developed for different types of equipment.
XV. Base Repair
Workshop
Base repair workshop
(Type-C) is a static workshop and normally located near the Head Office of the
Company. The Chief Mechanical Engineer at H. O. controls the policy on
overhauling of equipments and procurement of new equipments in consultation
with the management. These workshops are fully equipped with plant and
machinery.
Base repair workshops
undertake major repairs beyond the scope of field repair workshops and also
complete overhauling of vehicle/equipment. These workshops also carry out the
following:
i. Train mechanics and
operators
ii. Trade testing and
up-gradation of mechanics/operators.
iii. Major
modifications to equipments
iv. Manufacture of
special attachments to equipments.
v. Trail assembly of
production plants such as batching plants, cable ways, crushing plants,
refrigeration and ice plants, heavy earthmoving machinery, tunnel boring
machine, piling equipment etc.
vi. Send specialists
to site to erect the equipments mentioned at Para (e) above.
vii. Maintain records
of all equipments held by the company and update them based on data recorded by
Field Workshops/Users.
viii. Maintain
adequate stocks of spare parts.
ix. Prepare scale of
spares required for stocking in light, field repair workshops.
x. Advise Light, Field
Repairs Workshops on Preservation of Stores.
xi. Testing of new
equipments procured by the company for projects.
xii. Procurement of
new equipments for workshops.
xiii. Decides overall
policy for inspection/maintenance of equipments.
xiv. Transfer of
equipments between projects and arranging rolling stock/road transport.
xv. Arrange imported
spares.
xvi. Disposal/auction
of old unserviceable equipments spares and workshop scrap
XVI. The base repair
workshop carry out the condemnation and disposal of equipment based on the
following factors:
i. Exceed the life
fixed by norms and is not in a good working condition.
ii. The general
condition of the equipment is not satisfactory and further repairs may not be
economical or feasible.
iii. Accident vehicles
which are beyond economical repairs.
iv. Operation of the
equipment is not economical due to high operating costs.
v. Obsolescence
equipment for which spares are not available.
vi. Technological
reasons.
XVII.A well equipped
site workshop with well trained technical manpower will develop confidence in
the project team to complete the project in time.
Appendix A
WORK SHOP – LAYOUT - SAMPLE
Will generally consist
of spaces for work as below depending on the type of work to be done.
Appendix A
I N D E X
Dimension Mtrs.
---------------
1. Sentry Post 3 x 2
1/2
2. Inspection Staff 4
x 5
3. Receipt and
Inspection 2 1/2 x 4
4. Workshop Officer 5
x 5
5. Workshop Office 5 x
10
6. Toilet 2 1/2 x 7
1/2
7. Toilet 2 1/2 x 7
1/2
8. Planning and
Procurement Section 5 x 5
9. Stores office
Section etc. 5 x 5
10. Costing &
Records Section 5 x 5
11. Telecom. repair
shop 5 x 7 1/2
12. Instrument Repair
shop 5 x 7 1/2
13. F .I .E. Repair
shop 5 x 7 1/2
14. Fire Point 2 1/2 x
5
15. Paint store 2 1/2
x 5
16. Painter 2 1/2 x 5
17. Carpenter 7 1/2 x
5
18. Upholater 5 x 5
19. Minor assy. repair
shop 5 x 5
20. Machine shop 15 x
5
21. Elec. repair 6 x 5
22. Battery charging 4
x 5
23. Air compressor
room 5 x 3
24. Fire point 2 x 2
25. Welder 7 1/2 x 5
26. Tinsmith 5 x 5
27. Blacksmith 7 1/2 x
5
28. Sentry post 3 x 2
1/2
29. Elec. sub station
5 x 5
30. Open scrap yard 15
x5
31. Open structural
fabrication yard 15 x 10
32. Open washing and
servicing yard 21 x 15
33. Ramp for vehicles
10 x 5
34. Hard standing for
vehicles servicing 7 1/2 x15
35. Servicing station
7 1/2 x 5
36. Static water tank
5 x 5
37. P.O.L. pump 5 x 4
38. Fire tender 8 x 4
39. Fire fighting
Stores 5 x 4
40. Security guard
room 3 x 4
41. Toilets 7 1/2 x 2
1/2
42. Cycle stand 20 x 2
1/2
43. Time office 4 x 4
44. Tool store 7 1/2 x
7 1/2
45. Expendable Store 7
1/2 x 7 1/2
46. Instrument &
Electronic spares 5 x 7 1/2
47. Vehicle spares 9 x
7 1/2
48. Heavy Equipment
spares 7 1/2 x 7 1/2
49. Tyre store 5 x 7
1/2
50. Engine Over
hauling shop 10 x 7 1/2
51. Servicing Tlr.
52. Recovery Vehicle
Gate 7 1/2 Mtrs
Road 7 1/2 wide
Earthmoving Machine
yard 17 1/2 x 33
Vehicle repair yard 30
x 33
Appendix B
LIST
OF MACHINERY AND EQUIPMENT IN P & M workshop - sample
IN FIELD REPAIR
WORKSHOP (TYPE B)
1. Black Smith Shop:
Blowers, Hearth, Tools and Tackles
2. Tinsmith: Tools for
Radiator Repairs, Soldering Irons, Sheet metal
Working Tools, etc.
3. Welder Shop:
Electric and gas welding
equipment, Gas cutting
torches, Electrode
heating
ovens, Welding
generators,
Submerged ARC welding
Machines
etc.
4. Air Compressor: Air
Compressor of adequate
capacity to supply air
at
desired pressure for
operation
of Pneumatic tools.
5. Battery Charging:
Battery charger for trickle
Shop charges,
re-charge and initial
charging of batteries.
Battery tester,
Hydrometer,
sealing compounds,
Distilled
water plant.
6. Electrical repair:
Cryption tester, Meggar,
Shop Voltmeter,
Ammeter, Armature
rewinders, Baking Ovens,
Neon
tester, Spark plug
cleaner,
tester, etc.
7. Machine Shop:
Lathe, Drilling Machine,
Shaping Machine,
Shears, Bend
Rolls, Tool Post
grinder,
Bench grinder,
Hydraulic Press
Power hack saw, bar
bending/
cutting machine etc.
8. Minor Assembly
Shop: Special Maintenance tools,
pullers, Bench Press
etc.
9. Upholstery shop:
Heavy sewing machine, Puncher,
Scissors etc.
10. Carpenter Shop:
Wood Cutting Machines,
circular saws
11. Painter Shop:
Spray painting machine, Paint
mixer, Dryers, Exhaust
fans.
12. Fuel Injection:
Nozzle grinder/tester, test
Equipment repair shop
bench
for field calibration
and
phasing of F.I.E.
tachometer
etc.
13. Instrument repair:
Precision lathe, Hand press,
shop Lapping machine
for spindles.
14. Telecom Repair
Shop: Electronic test equipments.
15. Engineer
Overhauling: Test stands for engine Shop
assembly, Valve seat
cutter,
Valve grinder,
Portable
cylinder boring
machine,
Honing Machine,
Crankshaft
grinder.
16. General Purpose:
Tool Boxes for all tradesmen
Machinery and Jibcrane
- 5 Tone Tyre rim
Equipment remover,
Wheel alignment
gauge, Gantry crane -
10 tone
Car lift - 3 Tone
Hoists,
Pulley Blocks.
Special Maintenance
Tools,
Tyre inflation unit,
Servicing
trailer, Recovery
Vehicle.
Appendix C
ORGANISATION OF FIELD REPAIR
WORKSHOP - sample just for an idea
Table:-
Workshop
In-Charge
+
Workshop
Supervisors
+
Mechanics
- Mechanical / Electrical
+
Tyre
Man
+
Welder
/ Fitter
+
Helper
NOTE : MANPOWER IN
EACH SECTION DEPENDS ON SIZE/COMPLEXITY OF THE PROJECT.
REPAIR
CARD - sample
1.
Project........................Location....................
2. Name of
Equipment..............Name of Operator............
3. Registration
No................No. of hours used...........
Years in
service............
4. Present
Classification.........Date out from workshop......
5. Date in
Workshop...............
6. Nature of Repairs
to be carried
-----------------------------------------------------------------
Sr. Defect Name of Man
Hours Date Initials
No. Mechanic Booked
for Recti- of
& Grade Rectification
field Foreman
-----------------------------------------------------------------
1.
-----------------------------------------------------------------
2.
-----------------------------------------------------------------
3.
-----------------------------------------------------------------
4.
-----------------------------------------------------------------
5.
-----------------------------------------------------------------
6.
-----------------------------------------------------------------
7.
-----------------------------------------------------------------
8.
-----------------------------------------------------------------
9.
-----------------------------------------------------------------
Date : Signature of
Workshop Officer
7. Inspected by shop
Foreman : Name.............Initials......
Date.............
8. Inspected by
R&I Section : Name of Inspector..............
Date of
Inspection.............
Fit/Unfit for
Service..........
Classification.................
Signature of
Inspector.........
9. Approved/Not
Approved : Workshop Officer signature.....
DAte...........................
10. Signature of user
Representative.................Date.......
LOG
BOOK FOR EQUIPMENTS/VEHICLES - sample
(Note : Separate pages
will be allocated as required for items
mentioned below)
1. Name of
equipment....................Project................
2. Registration
No......................Make & Type............
3. Date of
purpose......................Transfers..............
From...................
To.....................
Date...................
4. Insurance Policy
No...................
5. Road Taxes Paid for
year..............
6.
Classification........................
7. Carried
out/Date......................
8. Engine
Details........................No. of Changes........
9. Battery
Record........................No. of Charges........
10. Tyre
Nos..............................
11. Repairs carried
out/spare fitted
(Details will
completed by workshops)
12. Consumables used
13. Inspection carried
out..............
Type..............
Date..............
14. Maintenance
Schedules
Type..............
Date..............
15. Lubricating Oil
Charge Record
Engine
............................
Transmission
......................
Hydraulic System
..................
Under Carriage ....................
Misc. Items
.......................
16. Hours of Operation
Year.................Month.........
Total Hours Done
Upto..............
Specific Fuel
Consumption..........
17. List of
Modifications Carried out
18. Pre-mature Failure
of Major Assemblies
a.
b.
c.
d.
19. List of Fitment
Items
20. List of Tools
Issued with Equipment
.................
.........................
.................
.........................
.................
.........................
.................
.........................
Date Tools Inspected
.........................
.........................
.........................
.........................
21. Any other details
as
required by management
.........................
.........................
.........................
CARE AND PRESERVATION
OF P & M STORES IS VERY IMPORTANT
1. Care and
preservation of stores forms one of the important functions of stores keepers
as the type of stores largely depends upon maintenance carried out by the stock
holder . Correct treatment to stores at regular intervals will prevent
deterioration while in stock. Proper maintenance of stocks therefore has two
important aspects :
a. Keeping the morale
of the user by issuing stores in good condition.
b. Saving treatment
losses to the company due to storage/ deterioration.
2. Deterioration of
stores that could occur while in stock can be classified into two two broad
categories :
a. Biological damage
caused by living organism i.e. Termite, borer, moth , rates ,fungus and
bacteria.
b. Non-biological
damage caused by agencies other than living organism i.e. Heat, light,
moisture, weathering, rust,corrosion,chemical, deterioration, aging or expiry
of shelf life.
3. The stores
preservation in workshop/store-house should aim at enforcing inspection and
preservation of stores at the following stages :
a. On receipt of
stores
b. During storage
c. Before issue
4. The company should
prepare an annual stores preservation programme and the responsibility for its
execution will be with the stores officer. A periodical examination of
susceptible and non-susceptible stores requiring treatment will be prepared.
Stores officers will
be responsible to maintain separate registers for susceptible and
non-susceptible stores. The date of turnover of stores and the type of
preservation in these registers showing quantities turned over/overhand.
5. Stores at times
have to be stocked in open area at project sites. A preliminary survey of the
storage site should be carried out and the ground selected for stores should
preferably be sandy or gravel with little or no woody vegetation having low
termite activity. the ground chosen for stacking be dug to a depth of and
filled with any of the following :
a. Railway ash
b. Sand
c. Mixture of ash and
dry lime
d. Spray with engine
oil mixed with creosote
6. The following
preservatives are commonly used for different types of stores :
a. Timber - Creosote,
Copper , Naphthenate Borax
(50% creosote with 50%
used engine oil )
b. Wool, felt } - DDT
, Naphthalene Balls
raw hides }
c. Damage to textiles
i. Dunnage (18" above group)
paper , optical for
ease evaporation
instruments, of
moisture from a wet
leather due to damp/
ground.
wet conditions of
ii.Open stacking and damp
storage or wet stores
should be banned.
iii.Turnover of stores
should
be carried out at
regular intervals
iv. Covers stores with
Tarpaulin
d. Damage by Rats -
Use rat traps or poisoning.
poison used - whit
Arsenic, Zinc phosphide
e. Leather goods -
Dubbin (Castorol 75% + Bees wax 25%) Soap
f. Rubber - French
Chalk
g. MT Stores
(Metallic)
i. Cleaning - Clean by
vapour degreasing,
Solvent degreasing,
Alkaline degreasing
Electric degreasing
ii.
De-rusting by mechanical means-
use emery paper, shot
blasting,
sand blasting,
chemical means-use
phosphoric acid or
rust removing
solution.
Preservation
Brass - Mixing of
sodium bichromate.
sulphuric acid and
water
Aluminium - Acid
phosphoric and chromic acid
Armatures - wrap with
wax paper
Ball & Roller
Bearings - Mineral
Jelly
Carburetors - Wrap
with grease resisting paper
Clutch plates -
Metallic parts - Brushed
Friction plates -
Brushed
Splices - Greases
Crank shafts - Dip in
rust preservation solution
Cylinders Block -
Exterior - pained
Cylinder Bores -
greased
Fuel Pump - Wrap with
grease resisting paper
Petrol Tanks - Flush
internally by preservative,
seal orifice
Piston - Mineral Jelly
Water Pumps - Grease
Radiators - Tubes
thoroughly dried by
flushing all orifices,
sealed
press-relief valve
oiled
Springs - Mineral
Jelly
Rolled steel - Paint -
Red lead
products
Steel water - Paint -
Black
tanks
Steel water -
Bituminous solution
tanks (inside)
SPARES
ISSUED/ RECEIVED SAMPLE FORM
Sr. No.
|
Items
|
Date of
Issue
|
No. Issued
Sr.
|
No. of
items Received Rep.
|
Initials
of U/S
|
Initial
of Mechanic
|
Initial
of Store-Keeper
|
Remarks
|
1
|
||||||||
2
|
||||||||
3
|
||||||||
4
|
||||||||
5
|
||||||||
6
|
||||||||
7
|
||||||||
8
|
||||||||
9
|
||||||||
10
|
||||||||
Total
No. of items issued.....................
Date
Repair card closed.....................
-------------
Signature
Store-in-Charge
Appendix G
INSPECTION
FORM FOR EARTHMOVING MACHINES
1. Nature of
Inspection - Monthly. Quarterly, Annual, Special
2. Date of last
Inspection ................ Project .......
3. Equipment Type
...........................Make.........
4. Registration
No..................Date of Purchase.......
5. Power Unit-make
& type...............No...............
6. Mileage, Hours
worked.........................
7. Power unit
condition
a. Compression
b. Ignition/Injection
system
c. Fuel system
d. Lubrication system
e. Cooling system
f. Induction and
exhaust System
g. Controls &
Linkages
h. Instruments
i. Compression release
Mechanism
8. Starting Mechanism
9. Transmission,
Steering, Brake
a. Main Clutch
b. Gear Box-Main
c. Control &
clutches
d. Gear Box -
Auxiliary
e. Shafts U-Joints
& coupling
f. Belts, Ropes Chains
g. Axles
h. Steering gear and
controls.
i Sprockets and
reduction gear
j. Brakes
k. Ram & hydraulic
Operating gears
10. Tracks, Wheels and
Suspension
a. Trucks/Wheels
b. Roller and
adjusting wheels
c. Bogies
d. Tyres and Tubes
e. Springs
f. Shock absorbers
11. Frames, Super
structure accessories and attachments
a. Chassis frame
b. Body /Guards
c. Blades and cutters
d. Hopper and Bucket
tanks,
e. Reservoir Piping
f. Valves, Control
Valves
g. Dozer fittings
h. PCU, CCUS
i. Jibs, Pulleys Hooks
j. Winches
k. Chains, wire,
ropes, cordage
l. Tool kits
12. Electrical
Equipment
a. Motors
b. Generators
c. Switches
d. Fuses and minor
controls
e. Batteries
f. Lights
13. General condition
of equipment ...................
Recommended for
continuation in service
for No. of
Hours/Mileage/Years.........................
14. Equipment debited
to ..............
Date ............
Station : Signature of
Inspector
Name of Workshop
...........
Project
....................
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