Module 25 – Maintenance Coordination & Equipment Care

Objective:
By the end of this module, a trainee will be able to:

1. Understand the operator’s role in preventive and corrective maintenance.

2. Perform routine equipment inspections and basic care.

3. Coordinate effectively with the maintenance team for repairs and preventive tasks.

4. Maintain accurate logs and records of equipment condition.

5. Promote equipment reliability and safety.

25.1 – Introduction to Maintenance & Equipment Care

Definition:

• Preventive Maintenance = planned activities to keep equipment in optimal condition and prevent failures.

• Corrective Maintenance = reactive repair after equipment malfunctions or breakdown.

• Operator Care = daily attention to equipment for smooth operation, including lubrication, monitoring, and minor adjustments.

Importance:

• Reduces unexpected downtime and process interruptions.

• Extends equipment life and reliability.

• Enhances safety by preventing equipment-related hazards.

Operator Role:

• Conduct routine inspections and rounds.

• Detect early signs of wear, leaks, vibration, or abnormal noise.

• Coordinate with maintenance for repairs and preventive activities.

Analogy:

• Maintenance = “regular health checkup and exercise for the plant’s equipment.”

25.2 – Operator Responsibilities in Maintenance

Daily Inspections

Check pumps, compressors, motors, valves, heat exchangers, and safety devices

Monitoring

Observe vibration, temperature, pressure, flow, and level trends

Lubrication

Apply lubricants to rotating equipment as per schedule

Minor Adjustments

Tighten loose fittings, adjust alignment, clean strainers

Reporting

Notify maintenance team of abnormal conditions, leaks, or wear

Documentation

Record inspections, maintenance performed, and observed anomalies

Operator Tips:

• Always follow SOPs and safety guidelines during inspections.

• Use PPE and lockout/tagout when handling equipment.

• Be proactive—early detection prevents major failures.

25.3 – Preventive Maintenance Concepts

Key Points:

1. Scheduled Checks – pumps, compressors, valves, motors.

2. Calibration & Testing – instruments and sensors checked periodically.

3. Cleaning – strainers, filters, heat exchanger tubes.

4. Lubrication & Oil Change – for rotating equipment.

5. Alignment & Adjustment – check belts, shafts, couplings, and seals.

Operator Role:

• Ensure maintenance schedules are visible and followed.

• Perform routine cleaning, lubrication, and minor adjustments.

• Communicate any potential issues detected during operation.

Analogy:

• Preventive maintenance = “changing oil and checking tires regularly to prevent car breakdown.”

25.4 – Coordinating with Maintenance Team

Best Practices:

1. Clear Communication: report issues promptly and clearly.

2. Documentation: provide observations, readings, and trends.

3. Scheduling: coordinate shutdowns or minor repairs to minimize production impact.

4. Follow-up: confirm that corrective actions were performed correctly.

5. Safety First: ensure lockout/tagout and isolation procedures are applied.

Operator Tips:

• Use standardized forms or digital logs for reporting.

• Participate in pre-maintenance briefings for critical equipment.

• Track equipment history to anticipate future maintenance needs.

25.5 – Basic Equipment Care Practices

Pumps

Check seals, vibration, lubrication, suction

Schedule: Daily/weekly

Compressors

Oil level, cooling, vibration, pressure

Schedule: Daily/weekly

Heat Exchangers

Check for fouling, leaks

Schedule: Weekly/monthly

Valves

Operate to prevent sticking, check packing

Schedule: Weekly/monthly

Motors

Temperature, vibration, noise

Schedule: Daily/weekly

Strainers & Filters

Clean or replace

Schedule: Weekly/monthly

Operator Tips:

• Visual and sensory checks are important: listen, feel, smell for abnormalities.

• Always follow plant SOPs and OEM recommendations.

• Document each inspection for reference.

25.6 – Common Issues Detected by Operators

Pump vibration

Misalignment, cavitation

Notify maintenance, check suction, reduce load if needed

Excessive heat

Bearing or motor overheating

Stop equipment if unsafe, notify maintenance

Leak

Seal, gasket, flange failure

Isolate equipment, report immediately

Flow drop

Blocked strainer or valve

Inspect strainer, check valve position, notify maintenance

Noise

Mechanical wear, loose bolts

Investigate safely, report to maintenance

Operator Tips:

• Early detection prevents unplanned shutdowns.

• Compare readings to baseline normal operation.

• Document all abnormalities clearly.

25.7 – Quiz / Knowledge Check

1. What are the main responsibilities of an operator in maintenance coordination?

2. Name three preventive maintenance activities operators can perform.

3. How should operators report equipment abnormalities?

4. Why is lubrication and equipment inspection important?

5. Give an analogy for operator involvement in maintenance.

6. What should an operator do if a pump shows abnormal vibration?

25.8 – Media Sites Integration

• Videos:

  • Daily inspection rounds demonstration

  • Lubrication and minor adjustments for pumps and compressors

  • Coordination with maintenance team on equipment issues

• Diagrams / Infographics:

  • Equipment care checklist

  • Lubrication points on pumps and compressors

  • Maintenance workflow diagram

• PDF Downloads:

  • Daily/weekly inspection checklist template

  • Maintenance request form

  • Equipment condition logbook template

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect equipment abnormalities and take proper operator action

25.9 – Summary & Key Takeaways

1. Operators play a critical role in preventive maintenance and equipment care.

2. Routine inspections, lubrication, and minor adjustments prevent breakdowns and improve reliability.

3. Clear communication and documentation ensure maintenance efficiency and accountability.

4. Early detection of abnormal conditions reduces unplanned downtime and enhances safety.

5. Collaboration between operations and maintenance teams is essential for sustained plant performance.