Tribology & TERO

Technology
Prof. (Dr.) Rajesh R. Jaware
Professor
Datta Meghe College of
Engineering,
Airoli, Navi Mumbai
Course Content
 TERO Technology-Latest concept
 Training (HRD) of Maintenance personnel
 Safety Assessment
 Work Environment
 Fire Prevention and control
 Management of emergencies
Keywords
 Tribology practice, tero technology
particles, indigenous substitute,
reconditioning, advance strategic,
maintenance management information
system, training of maintenance
personnel, Development of problem
solving group, life assessment of sum
assembly, reduction of maintenance
workforce.
Challenges in Maintenance
 Rapid growth of technology resulting in current technology
becoming obsolete. Information and Communications
Technology (ICT) industry where computers and computers
based system (hardware and Software) is the main
component.
 Advent of new advanced diagnostic tools, rapid repair
systems, etc.
 Advance store management techniques to incorporate
modular technologies.
 Requirements of keeping both outdated and modern
machines in service. For example, many industrial
organizations have a combination of the old machines
working on obsolete technology and new systems utilizing the
latest technology and equipment.
 Effective utilization of the maintenance workforce
 Setting up of in house R&D activities for effecting
improvements in maintenance practices.
Continued…
To overcome these challenges, besides the rectification of
the faults in the equipment, the activities of the
maintenance department include:
 Up gradation of the existing plants and equipment's
and training maintenance personnel to attend the
required technical skills.
 Effective maintenance of the old equipment for higher
availability
 Cost optimization of all maintenance functions
 Improvement of maintenance activities in the areas of
tribology and terotechnology
 Reconditioning of used /unserviceable spare parts.
 Development of indigenous sources for parts for import
substitution
 Setting up of an effective maintenance information
management systems (MIMS).
Tribology
• Tribology is derived from the Greek word “Tribos”.
Meaning of Tribos is Rubbing.

• Tribology is a science that deals with friction,

lubrication and wear in all contacting pairs.

• Tribological knowledge helps to improve service

life, safety and reliability of interacting machine
components; and yields substantial economic
benefits.
History
September 1964 -- Conference on Lubrication in Iron and Steel
Works in Cardiff (UK). Realization of considerable losses due to
lack of knowledge related friction and wear of machine
components.

After this realization UK Minister of State for science formed a

committee to investigate the education, research and the need of
industry related to lubrication

Committee after deliberations concluded that only lubrication

engineering could not provide complete solution to deal with
friction and wear of machine components.

An interdisciplinary approach embracing Solid and Fluid

Mechanics, Chemistry, and Material Science. Since there was no
word for such new concept, a new name “Tribology” was coined
in 1966.
Continued…
 Tribilogy is derived from the Greek word ‘tribos’
meaning rubbing.
 Tribology is the ‘ology’ or science of ‘tribein’
coming from Greek roots ‘tribulation’.
 Tribology is defined as the science and practice of
interacting surfaces in relative motion and the
practices related there to.
 It encompasses three classical subject disciplines,
friction, wear and lubrication.
 Friction-Physics – Mechanical Engg.
 Wear- Metallurgy – Mechanical Engg.
 Lubrication and surface interaction – Chemistry
or Chemical Engg
Continued…
 Major breakthrough in tribological science came in 1981 with
development of “Scanning tunneling microscope”(STM) and
systematic theory based on “Contact mechanics”. Such
developments provided tools to predict and estimate the
behaviour of a single asperity contact

 Subsequent development of Atomic Force Microscope(AFM)

in 1985 allowed measurement (surface topography, friction
force) of all engineering surfaces. Atomic Force Microscope
can be used for studies of adhesion, scratching, wear,
lubrication, surface temperatures and measurements of
elastic/plastic mechanical properties

 The developments of tip-based microscopes (STM & AFM) and

computational techniques for simulating tip-surface
interactions and interfacial properties, have allowed
systematic investigations for interfacial problems. Modifying
and manipulating surface microstructure provide a bridge
between science and engineering.
Need of Tribology as subject
 Friction, wear and lubrication have been taught in
many science and engineering classes at a
rudimentary level. It means empirically derived trends
(friction force is proportional to loading force, static
friction is greater than kinetic friction, viscous friction in
a fluid is proportional to the normal contact force, etc.)
are often used as the only predictive tools available.
 These approaches have the drawbacks of being
predictive only over a limited range of parameters.
Since the under-laying physical mechanisms are not
well understood, often one does not even know which
are the important parameters or over what range the
observed trends are valid. This poor predictive power
has led the field of tribology being perceived in many
scientific quarters
Continued…
 It is estimated that about 70% of failures in mechanical
components are due to tribological causes and according a
rough estimate one third of the world’s energy resources
appears as friction in one or the other form which results in
waste

 Most tribological phenomenon are inherently complicated and

interconnected, making it necessary to understand the
concepts of TRIBOLOGY in details

 Integration of knowledge from multifaceted disciplines (solid

mechanics, fluid mechanics, material science, chemistry etc.)
is essential and therefore a separate subject is required.

 Solid Mechanics: Focus is on expressions of contact

stresses/deformations and surface temperatures due to
rolling/sliding
Continued…
A complete Tribologist should have knowledge
of:
 Plasticity and elasticity
 Visco elasticity
 Contact mechanics and dynamics
 Mechanical and properties
 Surface chemistry, oxidation,
 Surface engineering processes
 Topographical characterization methods
 Lubricants and lubrication
TERO Technology
 The word “tero-technology” stems from the Greek root
‘terein’ means to look after, to guard over, and to take
care of.

 The term “tero-technology” refers to the study of the

costs associated with an asset throughout its life
cycle-from acquisition to disposal.

 It is a combination of management, financial,

engineering, and practices applied to physical assets
in pursuit of economic life cycle costs

 The goals of this approach are to reduce the different

costs incurred at the various stages of the asset’s life &
to develop methods that will help extend the asset’s
life span. It is also known as “life-cycle costing”.
Continued…
 Forexample, an oil company is attempting to map
out the costs of an offshore oil platform. They would
use terotechnology to map out the exact costs
associated with assembly, transportation,
maintenance & dismantling of the platform & finally
a calculation of salvage value.

 Tero–technology uses tools such as net present

value, internal rate of return & discounted cash flow
in an attempt to minimize the costs associated with
the asset in the future.

 Thesecosts can include engineering, maintenance,

wages payable to operate the equipment, operate
costs & even disposal costs.
Continued…
 Practice of tero-technology is a continuous cycle that
beings with the design & selection of the required item,
follows through with its installation, commissioning,
operation and maintenance until the item’s removal &
disposal & then restarts with its replacement.

 This approach helps to obtain maximum benefit from

the physical asset. This involves
i) Systematic application of engineering
ii) Financial & management expertise in the assessment of
the life cycle impact of an acquisition
(plants/equipment/machines etc.) on the revenues &
expenses of the acquiring organization.
Continued…
 Maintenance system combines all the action carried
out to retain an item in, or restore it to, an acceptable
condition.
 Tero-technology envisages application of a
combination of managerial, financial, engineering &
other practices applied to physical assets in pursuit of
economics life-cycle costs.
 This gives rise to huge potential for saving in terms of
costs effectiveness of replacement on consideration of
the whole life-cycle.
 It is approached to incur at the various stages of the
assets life & to develop methods that’s will extend the
asset’s life span. In this way tero-technology fulfills the
objectives of maintenance system.
Continued…
 Tero-Technology is concerned with the application
of managerial, financial, engineering skills to
extend the operational life/increase efficiency of
equipment/machinery.
 Components of Tero Technology:
i) Installation
ii) Commissioning
iii) Planned Maintenance
iv) Replacement
v) Removal of Plant, Machinery, equipment
vi) Related subjects and practices
Training of Maintenance Personnel
Concept of Maintenance organization
i) Establish reasonably clear division of authority with
minimum overlap
ii) Keep vertical line of authority and responsibility as
small as possible
iii) Span of control
iv) Equal Maintenance work distribution
v) Maintenance is subordinate (subsidiary) service
not support (backing) service
Continued…
Factors governing maintenance organization:

 Type of operation
 Continuity of operations
 Geographical location
 Equipment age and condition
 Size of plant/industry
 Scope of plant maintenance engineering department
 Employees level of training and reliability
 Complexity of business and machines and extent of
automation
 Extent of outsourcing
 Local labour laws and prevailing industrial culture and
practices
Continued…
Aims/objectives of Maintenance Organization
The basic objective aim of Maintenance Dept. is to
ensure that, production plant and equipment are
available at minimum cost for production for scheduled
hours and quantity, operating to agreed standards,
safety and with minimum waste.
In order to develop an effective maintenance
organization,
Two important features:
i) Maintenance is basically the teamwork activity, still
the individuals should be able to work, reasonable
freedom for specific/defined job
ii) The jobs/trades/crafts of individuals should be
interlinked and supporting to each other to achieve
common goal
Continued…
 Types of Maintenance organization:
 Formal Organization: Separate, distinctive
department
 Line and staff organization
 Functional organization
 Centralized/decentralized organization
Training of Maintenance Personnel
 Finding it difficult to attract qualified technicians
for manufacturing technology, maintenance,
repair, and service functions.

 Shortagesare due to: not enough young people

pursuing career in manufacturing/maintenance
technology as little dirtier in nature.

 Management consultant Peter Druker defined the

knowledge worker as a person who has formal
education but require manual dexterity skills to
perform job.
Continued…
Need of Training:
• To encounter more uncertainties and unpredictable
situations
• Multidisciplinary function
• Non repetitive in nature
• Technology is changing at faster pace

Advantage:
Increases effectiveness of maintenance personnel in
human behaviour aspects and technical and skill
aspects
Human factor in Maintenance
 Human factor is important in maintenance due to
safety and maintenance performance
 Physical attributes like colour vision, eye sight,
hearing, sufficient strength, power, are important

 Objectives of maintenance training:

 Knowledge objective
 Attitudinal objective
 Job-behaviour objective
 Skill objective
 Advanced technological objective
Types of Maintenance Training
Programs
1) Multi skilled technician program
2) Maintenance management courses
3) Customized maintenance training programs
4) Performance test ratings
5) Accelerated apprenticeship training
6) Continuing training (Refresher courses)
7) Induction and orientation training
8) Safety and environmental training
9) Maintenance troubleshooting training
Training Tools, modes and
methods
 There are mainly three types of training
 1) Auditory (learn by hearing)
 2. Visual (learn by seeing)
 3. Kinesthetic (learn by doing)
A good training session combines all the three learning
styles so as to gain maximum benefit from session.
Types of Training:
1) Formal: Universities, colleges, govt. semi govt. and
private institutions e.g. degrees and diplomas
2) Less Formal: Acquired by individuals from books,
seminars, on job trainings, visits to manufacturers,
radio and TV broadcasts,
Continued…
3) Computer based training (CBT): Technology supported
education/learning where medium of instruction is through
computer technology, particularly involving digital
technologies.
e.g. Maintenance seminars, various maintenance trainings like
lubrication, gas, and air compressor, electrical safe working
practices, AC motor controls, Hazardous area instrumentation
and shutdown..

4) Web based training: It is the modern version of e-learning.

It is innovative approach to distance learning in which
computer based training is transformed by the technologies
and methodologies of the world wide web, internet and intranet.
WBT is media rich training fully capable of evaluation,
adaptation, and remediation, all dependent of computer
platform.
e.g. Belt –chain drive, Preventive and predictive maintenance
Lighting:
Suitable light levels based on Australian Standard AS 1680 –
1990 Interior Lighting:
General background 200 Lux
Routine office work (typing, filing) 400 Lux
Work with poor contrast (proof reading)600Lux
Overhead lighting should be fitted with glare reducing
diffusers and light should fall from the side rather than
from the front to avoid reflection

Windows should be on the side of the user if possible, not

directly behind or in front of the screen

28
Air movement of less than 0.1 meter per
second can lead to stuffy rooms whereas
air movement of more than 0.2 meters
per second causes droughts to be felt.

Australian Standard AS 1668.2 – 1991

Mechanical ventilation for acceptable
indoor-air quality sets the minimum rate
of 10 liters per second per person for
general office space or 10 liters per
second for every 10 square meters of
floor space

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A comfortable temperature range for
sedentary work is between 210 and 240 C
 The optimum range of relative humidity is
40-50%. Relative humidity below 20% can
cause dryness of the eyes, nose, throat
and build up of static charges. Humidity
above 80% can cause fatigues
 Draughts around the neck and the feet
can cause muscle contraction

30
Continued…
 Humidity:
 Sound:
 Light
 Ventilation
Fire Prevention and controls
 An injury prevented is an aid, an injury
compensated- an regret
 Unless it be on combustible origin or of a friendly
and purposeful nature, the occurrence of a fire is
properly termed accidental, and as such, it comes
with in the scope of accident prevention.
 There are three basic principles of accident
prevention.
i) Interest sufficient to induce action
ii) Development and analysis of pertinent facts as
to cause and remedy
iii) Corrective action based on the facts
Continued…
 Method of fire prevention:
 Whether personal or mechanical faults
predominate, the first action invariably is that
making the environment as nearly foolproof as
possible.

 Maintenance supervisors should have clearly in

mind the specific unsafe acts which have already
caused fires as well as those which could do so.
Management of Emergencies
 The goal of emergency management is to provide
protection from all hazards for the citizens, properties,
and governments

 Careful planning in advance of an emergency gives

an organization a far better chance to successfully
survive a major storm or disaster.

 It also provides more and better services while

reducing lost revenue and recovery costs.

 Defining the role and abilities of the maintenance and

engineering department in emergency preparedness
must start in the planning process, which helps avoid a
reactionary, fix-the-problem approach.
Continued…