COLLEGE OF ENGINEERING

DEPARTEMENT OF MECHANICAL ENGINEERING

Course tittle:-maintenance of machinery and installation

Course code:-Meng 5231

Assignment title:- detecting and protecting failures

NAME: ID NO
1.BELETE GETACHEW ----------------------------------1357/06
2.HAYELOM TEWELDE----------------------------------1382/06
3.ASRAT AGEGNEHU --------------------------------------347/06
4.MEARG GIRMAY------------------------------------------553/05
5.SHISHAY GIRMAY ---------------------------------------486/06
6.BRUK MEZGEBE-------------------------------------------152/03
Submitted to:-inst. Sintayehu
Submission date: 10 / 01 / 2018
PART 1: ESSENTIALS OF LEAK DETECTION AND REPAIR

Detecting and repairing leaks is one of the main components of maintenance

FIG 1: LEAKAGE
On the surface, fluid leakage is a nuisance because the machines that leak need constant
monitoring and top-ups to maintain the ideal level of lubricant to operate properly.
Unfortunately, as we investigate leakage further, we realize that leakage can be a significant
problem on many levels.
Safety is a major concern when oil leakage is a factor. Slips and falls due to oil leakage, which
are preventable, take place and there is also a significant danger of fire or explosion.
Oil consumption is a major motivator for reducing external oil leakage. Lubricant purchases can
usually be tracked, and when these purchases are referenced against the cost of the oil leaking
from the machine and the cost to dispose of the wasted oil as well as items used to collect this
oil, the value on paper can be staggering.
Cleanliness and reliability go hand-in-hand. The cleaner and better kept a machine, the easier it
is to detect oil leaks (among other conditions) as they occur. The longer a leak goes without
repair, the more difficult it is to locate the original source.
So what can be done about leakage that is costing all of this capital? The key is to repair
whatever is leaking and replace old mechanical connectors with new, more efficient fittings.
The problem is often locating the source of the leaks. At any given moment, leakage could be
developing from seals, fittings and covers. And as mentioned before, the longer a leak has to
develop and persist, the harder it is to locate and repair.
Therefore, it is should be assumed that there will always be some amount of leakage at any
given point in time, and that steps need to be followed to identify and correct the problem.

Identify the Source

The first priority is to identify the leaks. This involves discovering which systems are leaking and
precisely where the leaks are coming from. A formal investigation and interview of the
maintenance teams in each area is the best way to identify the obvious and most serious leaks.
A system for identifying and recording the location of each leak must be made available to
maintenance and operations personnel. Leak detection tags should be provided so that leaks
can be marked and cataloged as they are identified in the plant. This strategy will cover a large
portion of the obvious or noticeable leaks.

Inspect and Quantify

As leaks are identified and recorded in a database, those responsible for managing leak
detection are required to inspect the leak to gain further information as to why the leak exists.
The leak should be evaluated for causes and possible redesign for prevention.

It is important to use the information gathered about leakage in the plant as a benchmarking
metric. The easiest way to understand the surface cost of leaks is to quantify the amount of oil
at each leak. For both small and large leaks, use a graduated flask, jar or bottle and capture the
leak for a timed interval and record the amount. Use this information to extrapolate the volume
of leakage over the course of a day, week, month and year. Compare this to the cost of the
lubricant per gallon and determine a dollar value for each system. Compare this data to the
fluid consumption costs on a daily, weekly, monthly and annualized basis.
Available Information
A copy of each tag that is placed on plant equipment must be returned to the planning group.
The tag's information should include the volume of the leak on a per-minute basis, machine
name, the component and the location. The perceived cause of the leak is also essential for
continuous improvement. This information must get entered into a database for planning,
tracking, benchmarking and metrics.
Plan
Based on selected criteria, each recorded leak should be prioritized for repair based on the
volume of the leak, ease or difficulty of repair, system criticality and environmental
considerations. At this stage it is also important to consider alternative designs that can be
incorporated into the repair of the leak to prevent it from recurring.
Repair
A planned and consistent approach to leakage repair is necessary to ensure leaks are identified,
quantified, recorded, planned and ultimately repaired. Repairs should include appropriate
advancements to help reduce the possibility of a recurring leak.

Don't Stop!
When the process has gone from identification of the leak to repair, it should begin again. It is a
beneficial strategy to maintain the process of leak identification and continue to record and
repair leaks throughout the process.

For leaks that may not have an obvious source, a leak detection dye must be used and
performed on a system-by-system basis. When leaks are detected, use a tag to identify the
precise location. Ensure the tag has the location information, volume per minute and suspected
repairs required.

Continuous Improvement
Vibration, shock loading and water hammer in pipes all contribute to failed seals, seams and
fittings. During the process, it is important to identify situations where advanced methods for
sealing and connecting can replace those locations prone to leakage.
Ensuring that the process is repeated will highlight those systems and components that are
prone to leakage. The leakage volume can also be used as a metric for success. Keeping track of
the leakage will allow the total volume of leakage to be compared over a given time after each
round of detection and repair.

Again, the goal is to manage the machine, not the leakage. Once an estimate of the leakage is
established, the machine can be a point of focus
Benefits of Leak Detection and Repair
• Improved operational efficiency.
• Lowered water system operational costs.
• Reduced potential for contamination.
• Extended life of facilities.
• Reduced potential property damage and water system liability.
• Reduced water outage events.
• Improved public relations.

PART 1: ESSENTIALS PROTECTION AND REPAIR OF MACHINE COMPONENTS

Wear

FIG 2 : WEAR
Wear is related to interactions between surfaces and specifically the removal and deformation of
material on a surface as a result of mechanical action of the opposite surface.

In materials science, wear is erosion or sideways displacement of material from its "derivative" and
original position on a solid surface performed by the action of another surface.

Wear of metals occurs by the plastic displacement of surface and near-surface material and by the
detachment of particles that form wear debris. The size of the generated particles may vary from
millimeter range down to an ion range.[2] This process may occur by contact with other metals,
nonmetallic solids, flowing liquids, or solid particles or liquid droplets entrained in flowing gasses.[3]

Wear can also be defined as a process where interaction between two surfaces or bounding faces of
solids within the working environment results in dimensional loss of one solid, with or without any
actual decoupling and loss of material. Aspects of the working environment which affect wear
include loads and features such as unidirectional sliding, reciprocating, rolling, and impact loads,
speed, temperature, but also different types of counter-bodies such as solid, liquid or gas and type of
contact ranging between single phase or multiphase, in which the last multiphase may combine
liquid with solid particles and gas bubbles.
Adhesive wear (Wear by adhesion)
Adhesion
When surfaces slide relative to one another, there is a tendency for one material to transfer onto
the counterface. In its most severe form, adhesive wear results in galling and possibly machinery
seizure through cold welding. Adhesion can be combated with coatings that provide dissimilar
materials and harder surfaces. We offer a variety of surface solutions using coating and diffusion
techniques that match specific applications. For highly loaded components such as gears, plasma
nitriding is the best solution.

Engineering surface is never perfectly flat. The surface of a most highly polished engineering
component show irregularities or asperities. When two such surfaces are brought into contact,
the real contact actually occurs only at some high asperities which is a small fraction, e.g. 1/100
of the apparent contacting area. As a result, plastic deformation and intermetallic adhesion will
occur, forming cold weld junctions between the contacting asperities. The strength of junction
is determined by the surface structure and by the mutual solubility of two contact metals. The
tendency of adhesion is the lowest for a pair of metals with almost zero mutual solubility, but
this is limited to very few metals. Most metallic materials show appreciable tendency of
adhesion.
Fig 3: adhesive wear( Adhesive wear occurs by material transfer)

When two contact surfaces undergo relative movement, tearing must take place either at the
(cold weld) junction or inside the original materials depending on which is weaker. If the
strength of the adhesion junction is relatively low, as in the case of a contact pairs with low
mutual solubility, or metallic surfaces separated by oxide film, tearing will take place at the
junction and material loss during wear will be minimal. However, when tearing occurs inside
the softer material, a fragment of the softer material will be dragged away and adhering to the
harder body, as a schematic shown in Fig. 3. This process is known as material transfer.
The transferred fragment is plastically deformed during continued action of sliding so that the
transferred materials frequently has a plate-like morphology. Multi-material transfer and plastic
deformation of the transferred material result in a layered surface morphology on the counter
face as shown in Fig. 4. The next stage is detachment of the transferred layer, probably when
the bond between the layer and the underlying material has been locally weakened by cyclic
loading.
How to improve adhesive wear resistance?

– Improving mechanical properties (hardness and strength) of the contacting material because
tearing is more likely to happen in adhesion junction.
– Material selection or changing the chemical nature of the surfaces, e.g. by surface engineering,
will fundamentally reduces the possibilities of adhesion and reduce adhesive wear rate.
A tailored surface engineering process will increase the surface hardness of a contacting surface,
and reduce the possibility of adhesion between contacting surfaces, therefore, surface
engineering is the most effect way to improve the adhesive wear resistance.

Conclusion

We conclude that we should take responsible for any machine component. We have to maintain
and repair regularly if the components needs so and fix constant period of time for maintenance.