IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
ISSN: 2278-1684 Volume 3, Issue 1 (Sep-Oct. 2012), PP 20-27
www.iosrjournals.org
Reliability-centered maintenance methodology for goliath crane
of transmission tower
Mrs.R.M. Barai1, Mrs. A.D.Kadam2, Mr.A.V.Harde3, Mr. P.S.Barve4
1,2,3
(Asst.Prof.,Mech Engg. Dept.,J.L. Chaturvedi college of Engg.,Nagpur)
4
(Asst.Prof.,Mech Engg. Dept.,Raisoni college of Engg.,Nagpur)
Abstract: Reliability centered maintenance (RCM) methodology was originally developed by the U.S.
commercial airlines industry in the year of 1960 for identifying applicable and effective preventive maintenance
tasks. Safety systems are usually stand by systems and they are periodically to reveal and repair failures that
may have occurred since the previous activation or inspection.RCM approach has been applied to the goliath
crane system of transmission tower industry for research work reported in this paper.RCM methodology can be
applied to Indian industry for reduction of breakdowns as well as optimization of preventive maintenance cost.
In the present study preventive maintenance task suggested for power transmission subsystem, guiding and
transportation subsystem, hydraulic subsystem and supply current subsystem in goliath train.
Keywords-Goliath crane system, optimization ,rcm, transmission tower
I. Introduction
RCM starts with a comprehensive, zero-based review of the maintenance requirement of each asset in
its operating context. Reliability-centered maintenance, often known as RCM, is an industrial improvement
approach focused on identifying and establishing the operational, maintenance, and capital improvement
policies that will manage the risks of equipment failure most effectively, which specifies that RCM address, at a
minimum, the seven questions:
What is the item supposed to do and its associated performance standards? In what ways can it fail to provide
the required functions?
What are the events that cause each failure?
What happens when each failure occurs?
In what way does each failure matter?
What systematic task can be performed proactively to prevent, or to diminish to a satisfactory degree, the
consequences of the failure?
What must be done if a suitable preventive task cannot be found?
The answers to the first four questions are recorded on RCM information worksheet and answers to the
remaining three questions are recorded on decision worksheet. These are used to record the functions of the
asset under review and to list all the associated functional failures, failure modes and failure effects. Functional
failures, Failure modes, Failure effects Listing of what actually happens when each failure mode occurs is
known as failure effect. Specifically when describing the effects of failure the following should be recorded.
What evidence (if any) that the failure has occurred? What physical damages (if any) is caused by the failure?
What must be done to repair the failure?
1.Failure consequences Failure prevention has much more to do with avoiding or reducing the consequences of
failure than it has do with preventing the failures themselves .A preventive task is worth doing if it deal s
successfully with the consequences of failure, which it is meant to prevent. The next stage is to classify evident
failure into three further categories in descending order of importance as follows.Safety and environmental
consequences, Operational consequences, Non-operational consequences
2. Hidden failure consequences The only consequence of a hidden failure is increased risk of multiple
failures. The performance standard for a hidden function is the availability needed to reduce the risk of the
associated multiple failure to an acceptable level.
3. Safety and environmental consequences A failure mode has safety consequences if it causes a loss of
function or other damage, which could hurt or kill someone.
4. Operational consequences- A failure has operational consequences if it has a direct adverse effect on
operational capability. In general, failures affect operations in four ways namely, output, product quality,
customer service, increased operating cost in addition to the direct cost of repair.
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Reliability-centered maintenance methodology for goliath crane of transmission tower
5. The non-operational consequences-For failure modes with non-operational consequences, a preventive task
is worth doing if over a period of time; it costs less than the cost of repairing the failures, which it is meant
prevent.preventive tasksThe actions which can be taken to deal with failures can be divided into two groups
preventive tasks and defaults tasks which must be undertaken if suitable preventive tasks cannot be found. The
three principal categories of preventive tasks are scheduled on-condition tasks, scheduled restoration tasks and
scheduled discard tasks.Scheduled on condition tasks. On-condition maintenance is based on the facts that
many failure develop over a period of time. Schedule restoration tasks. Scheduled restoration entails
remanufacturing a single component or before overhauling an entire assembly at or before specified age limit,
regardless of its condition at the time. Scheduled discard tasks .Scheduled discard means replacing an item or
component with a new one at preset intervals. [1]
6. Default actionsIf a preventive task cannot be found which is both technically feasible and worth doing for
any failure mode, then the default action, which must be taken, is governed by consequences of the failure. The
default actions are scheduled failure finding tasks and no scheduled maintenance redesign.No scheduled
maintenance. No scheduled maintenance is valid if
7. Redesign. Redesign refers to any change to the specification of any item of equipment.
II. Rcm Decision Worksheet
The answers to the last three questions are recorded on RCM decision worksheet is shown in tables. It
is used to record the answers to the questions in the decision diagram covering the aspects of failure
consequences, preventive tasks and default actions.The decision worksheet is divided into columns. The
columns headed F, FF and FM identifies failure modes under consideration. They are used to cross-refer the
information and decision worksheets. The headings on the next columns refer to questions on the RCM decision
diagram as follows; The column headed H, S, E, O and N are used to record the answers to the questions
concerning the consequences of each failure mode.The next three columns (headed H1, H2 ,H3) record whether
a preventive task has been selected and if so what type of task?If it becomes necessary to answer any of the
default questions the columns headed H4 and H5 or S4 are used to record the answers.The last three columns is
also used to record the cases where redesign is required or it has been decided that the failure mode does not
need scheduled maintenance.
1. Failure consequences. The questions for failure consequences H, S, E and O are asked for each failure mode
and answers are recorded on the basis shown in fig. Shows how these answers are recorded on decision
worksheet.
2. Preventive tasks. The eighth to tenth columns on decision worksheet are used to record whether a preventive
task has been selected as follows: The column headed H1/S1/O1/N1 is used to record whether a suitable on-
condition task could be found to anticipate failure mode in time to avoid the consequences. The column headed
H2/S2/O2/N2 is used to record whether a scheduled restoration task could be found to prevent failures. The
column headed H3/S3/O3/N3 is used to record whether a suitable discard task could be found to prevent the
failures. The default questions. The columns headed H4, H5 and S4 on the decision worksheet are used to
record to the answers to the three defaults question are only asked if the answers to the previous questions are all
`no. a. Defaults action (H4) Is a failure finding task technically feasible and worth doing? Record yes if it is
possible to do the task and it is practical to do it at required frequency and it reduces the risk of multiple failures
to an acceptable levels .Default action (H5) could the multiple failures affect the safety or environment? This
question is only asked if answer to question H4 is no. If answer to the question is yes then redesign is
compulsory if the answer is no the default action is no scheduled maintenance but redesign may be desirables.
Default action (S4) is a combination task technically feasible and worth doing? Yes if the combination of any
two or more preventive task will reduce the risk of failure to the acceptable level. If the answer is no redesign is
compulsory. [2]
III. Scope Of This Article
Application of methodology of RCM for selection of proper maintenance strategy is still a new concept
in Indian industry. Although this concept has been applied widely in various countries, its relevance to the
Indian industry has not been realized so far. Indian industry is lab our oriented and information system
specifically in context of maintenance is not fully computerized In the present study RCM methodology has
been applied to goliath crane of a transmission tower company.
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Reliability-centered maintenance methodology for goliath crane of transmission tower
IV. Transmission Tower Company Application
The methodology of RCM has been applied to the transmission tower company. In transmission tower
manufacturing company, Goliath crane are used to transfer raw material from raw yard to different machines in
fabrication shop. The capacity of goliath crane is 5MT. Layout of transmission tower company (ATSL) is
shown in fig. Transmission Tower Company consists of the following sections.
1. Raw Material Section Goliath crane are used for shifting raw materials from raw yard to different machine
in fabrication shops.
2. Fabrication section Power Press Punching Machine,Universal Punching & Cutting Machine Plate Shearing
Machine,Bending Machine, CNC Machine, Notching & stamping Machine
3. Galvanizing Section Protherm furnace is used to convert semi-finish product to finish product.
4. Dispatch section Goliath crane used for shifting finished materials from dispatch section to different
transportation vehicles like container, trailer etc.
Lay-out of transmission Tower Company (Associated transrail structure limited company)
Layout of transmission tower company (ATSL) is shown in fig. Transmission Tower
Company consists of the following sections.
1. Raw Material Section
Goliath crane are used for shifting raw materials from raw yard to different machine in fabrication shops.
2. Fabrication section
Power Press Punching Machine
Universal Punching & Cutting Machine
Plate Shearing Machine
Bending Machine, CNC Machine, Notching & stamping Machine
3. Galvanizing Section
Protherm furnace is used to convert semi-finish product to finish product.
4. Dispatch section
Goliath crane used for shifting finished materials from dispatch section to different transportation vehicles
like container, trailer etc
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Reliability-centered maintenance methodology for goliath crane of transmission tower
5. Manufacturing process Associate Transrail Structure Ltd. Company is manufacturing of transmission
tower. The raw materials is supplied from raw yard to different machines in fabrication shop through
goliath crane. The various operations are performed on raw materials with the help of different machines
like punching, cutting, notching and stamping etc. & semi-finish materials transfer to galvanizing section
and finally finish product produced. In galvanizing section, semi-finish products are deep in acid tank, flux
tank and galvanizing furnace at temp. of 450C and finally finish product produced. The finish products are
delivered to dispatch section through trolleys. In dispatch section goliath crane also used to supply finish
good to different automobile vehicles like as container, truck and trailor etc. In major breakdown of goliath
crane , raw materials is not transfer to different machines shops results in high production loss.
V. Identification And Formulation Of Proposed Work
In analysis of goliath crane identify the break down list for a span of two years which revealed that
most of the failures occurred due to shot of supply current cable & wear out of wheel collar.RCM concept has
been applied to goliath crane. Goliath crane has been categorized in following four sub systems:1.Power
transmission subsystem 2. Guiding & transportation sub system 3. Hydraulic sub system 4. Supply current sub
system
1. Power transmission subsystem Power transmission sub-system is as shown in fig. The motor is coupled
with the reduction gear box by brake drum. The output shaft of reduction gear box is connected to drive wheel
of goliath crane by gear coupling. Gear box equipped in the system reduces speed of drive wheel. Power
transmission sub-system consists of following components. Motor ,Brake drum, Reduction gear box, Gear
coupling, Key.
2. Guiding and transportation subsystem Slide view of the drive /idle wheel is as shown in fig. The wheels
are fitted with double spherical roller bearing. The Roller bearing is enclosed with the Plummer block. It is
covered by mild steel plate, 10-12 mm thick. The mild steel plate is fixed at both sides of the Plummer block.
Guiding and transportation subsystem consists of the following components. Drive or Idle wheel, Double
spherical roller bearing, Plummer block, Foundation bolt.
3. Hydraulic subsystem Hydraulic subsystem is used to control the speed of goliath crane. The electro
hydraulic thrustor is used in hydraulic subsystem normally it is in close position when crane starts running in
vertical, longitudinal & cross movement. When the current is given to thrustor coil through control panel the
impeller start rotating and pressure develop inside of the thrustor assembly. These pressure acts in upward
movement of the arm at this stage brake liner is free from drum and smooth crane movement occur. Major
components of hydraulic subsystem are Electro hydraulic thrustor, Tie rod mechanism, Brake drum, Brake liner.
4. Main control panel (MSEB) Supply current subsystem is used to supply current to motors and thrustors in
all movements like lateral travel, cross travel and hoist (up-down). The current supply from main control panel
(MSEB) to crane panel through trolley cable of size 10 sq-mm 4 core & 60m length. Trolley cable rotates
continuously in forward and reverse direction due to cable damages or shot.
VI. Rcm Information Worksheets
RCM information worksheets were prepared for power transmission subsystem, guiding and
transportation subsystem, hydraulic subsystem and supply current subsystem to indicate the functions,
functional failures, failure modes, i.e. causes of failure..
Table-1 (RCM information worksheet for power transmission subsystem)
Function Functional Failure Mode Failure Effect
Failure
(1)The function of (A)Reduction (1) Oil Frictional power loss increase.
reduction gear box is to gear box not contamination
supply the reduced speed working properly (2)Low oil level Tooth wear & transmitted speed
to the drive wheel. The variation will increase
gear coupling connects the (3)Teeth damage For excessively worn out teeth
two shafts. The proper of transmitted speed variation level will
coupling is to connect the increase which will induce noise in
shaft & transmit the gear box.
torque.
(B)Gear coupling (1) Teeth wear Impact will increase, due to this
fails induced stress in coupling increase,
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Reliability-centered maintenance methodology for goliath crane of transmission tower
hence coupling fails then it is not
(2) Hub damage. transmit motion to drive wheel.
(3)Coupling bolts Transmitted speed will be very low
broken may lead to breakage of damage hub.
Due to loose fitting of bolts or
jerkish motion , induced stress on
coupling bolts & it will broken.
(C) Incorrect key (1) Loose key Impact on driven rotating member,
clearance therefore it can reduce the life of
(2) Tight key driven rotating member. It can cause
key failure.
(3)Shear Rise in initial compressive & shear
deformation stress. It will further increase during
power transmission cause early key
failure & reduces life.
Heavy pressure on edges of key.
Under the effect of slight relative
displacement between edges of key
& shaft at one end & driven wheel at
other, key edges gets worn out
Table-2 (RCM information worksheet for guiding and transportation subsystem)
Function Functional Failure Mode Failure Effect
Failure
The function of the system is (A) Drive wheel (1) Due to failure of key Drive wheel does not get motion , key
to provide smooth not working (2) Due to bearing wear out & power transmission stop
movements of drive wheel, properly seizure. Noise in drive wheel & shaft get
bearing is provided at both (3) Drive or Idle wheel jammed.
the ends of drive wheel. collar wear out Due to improper alignment between
Roller bearing is enclosed wheel & rail (I-beam)wheel collar
with Plummer block wear out.
(B) Roller (1) Due to wear out sieve Interrupted contact between wheel &
bearing fails bearing fails shaft .This causes additional friction
& power loss. Hence sieve bearing
(2) Improper lubrication fail.
Frictional power loss increases &
(3)Roller wear bearing temp. rises so Bearing parts
surface damage takes place.
Due to improper alignment between
wheel & rail (I-Beam) stresses will
increase & bearing fail occurs
(C) Plummer (1) Dynamic load Stresses will increase, vibration will
block damage increase which may lead to initiation
(2) Vibrations of crack & eventual failure.
Additional stress due to vibration will
increase leading to crack initiation.
(D) Foundation (1) Dynamic load Will increase stress & vibration. This
bolts fails (2) Vibration leads to accelerated crack formation.
Due to vibration, it will add to all
(3) Thread wear adverse effects of increase in dynamic
load. It will loosen the foundation
bolts
It will weaken the thread because of
weak thread, it will lead to shear off
& thread failure.
Table - 3 (RCM information worksheet for hydraulic subsystem)
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Reliability-centered maintenance methodology for goliath crane of transmission tower
Function Functional Failure Mode Failure Effect
Failure
Hydraulic system (A) Hydraulic (1)Low oil level Due to minimum oil level pressure
is used to control brake thrustor not develop in cylinder
the speed of fails (2)Thrustor coil shot.
goliath crane like
as cross travel, Due to oil seal damage, oil enters in
lateral travel & coil.
hoist up-down.
(B) Hydraulic (1)Leakages Oil leakages from hydraulic cylinder
cylinder so the pressures not develop.
(2) Corroded Increase in friction between piston &
cylinder will increase power loss.
(3) Damaged Inside surface roughness increases or
distortion along the axis takes place.
(C) Brake liner (1)Wear out Not proper control the speed of crane
if brake liners wear out.
(D) Arm (1) Bush wear Motion will become jerkish. Increase
impacts at the bush which will cause
additional unwanted stresses occur in
bush.
(E) Tie rod (1)Wear out Due to up & down movement of
mechanism thrustor stresses will induce in tie rod
mechanism.
Table- 4 (RCM information worksheet for supply current subsystem)
Function Functional Failure mode Failure effect
failure
.(1) The main (A) Crane not (1) Main MCB trip Due to overloading MCB trip.
important function is to work (2) Main supply Stretching of cable due to revolving in forward and
supply current to all cable shot(10 sq-mm reverse direction, it is shot or damages.
electrical accessories 4core)
like motors, thrustor (3) Main contactor If main contactor fails then it is not supply current
and contactor etc. not work to all electrical accessories.
(4) Fuse shot Due to shot circuiting of cable.
(5) Crane panel Supply current wire break, new dummy wire fitted.
switch not work
(B) L.T.,C.T & (1) Contactor not Due to continuous up & down movement,
Hoist not work works. contactor shot or not works.
(2) Motor not works. Motor slip ring wire break, jointed it.
VII. Rcm Decision Worksheet
RCM decision worksheet were prepared for power transmission subsystem, guiding and transportation
subsystem, hydraulic subsystem and supply current subsystem, to reveal the nature of hidden, safety,
environmental and operational.
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Reliability-centered maintenance methodology for goliath crane of transmission tower
1. RCM decision worksheet for power transmission sub-system
2. RCM decision worksheet for guiding and transportation sub-system
RCM decision worksheet Unit Guiding & transportation
subsystem
Component - (a) Drive wheel (b) Roller bearing (c) Plummer block (d)Foundation
bolts
Information Consequenc H H H Default
reference e evaluation 1 2 3 action
S1 S2 S3 Proposed task
O O O
1 2 3
H H S
F FF FM H S E O N1 N2 N3 4 5 4
1 A 1 Y N N Y N N N No scheduled maintenance
1 A 2 N N Y Greasing of bearing Schedule restoration
No Scheduled maintenance
1 A 3 N N N N N N N
1 B 1 N N N N N N No scheduled maintenance
Check bearing for lubrication. Schedule
1 B 2 N Y on condition
1 B 3 N N N Y Bearing replacement. Schedule discard
Plummer block check. Schedule on
1 C 1 Y N N Y Y condition
1 C 2 Y N N N Y Vibration check. Schedule on condition
Check for foundation bolts. Schedule on
1 D 1 Y N N Y Y condition
1 D 2 Y N N N Y Vibration check, schedule on condition
1 D 3 N N N N N N No scheduled maintenance
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Reliability-centered maintenance methodology for goliath crane of transmission tower
3. RCM decision worksheet for hydraulic subsystem
RCM decision worksheet Unit Hydraulic subsystem
Component- (a) hydraulic cylinder (b) Thrustor coil (c) Piston (d)Impeller (e) Brake liner (f) Spring (g)
Tie rod mechanism
Information Consequence Default action
reference evaluation H1 H2 H3
S1 S2 S3
O1 O2 O3 Proposed task
F FF FM H S E O N1 N2 N3 H4 H5 S4
Check oil level. Schedule on condition
1 A 1 Y N N Y Y
Scheduled restoration task
1 A 2 Y N N N N Y N N N
Scheduled restoration task
1 B 1 Y N N Y N N N
Check cylinder when shut down.
Schedule on condition
1 B 2 N N N N Y
No scheduled maintenance
1 B 3 Y N N Y N N N
1 C 1 N Y N N N N Y Replace brake liner. Schedule discard
1 D 1 Y N N N N N Y Replace bush. Schedule discard
Replace tie rod, schedule discard.
1 E 1 N N N Y N N Y
4. RCM decision worksheet for supply current subsystem
VIII. CONCLUSION
In the present study, preventive maintenance tasks suggested for power transmission subsystem, guiding and
transportation subsystem, hydraulic subsystem and supply current subsystem in goliath crane are 12 scheduled on condition
tasks, 06 scheduled on restoration tasks, 09 scheduled discard tasks. Whereas for 08 failure modes no scheduled maintenance
has been proposed. Existing maintenance schedule for goliath crane indicates the maintenance action as and when required.
Hence RCM based schedule specifies that additional preventive maintenance tasks need to be executed as compared to none
initially. In power transmission subsystem significant aspects are proper lubrication schedule restoration task is required in
gearbox and gear coupling. In supporting system failure of bearing and wheel collar wear out occurs due to scant lubrication
and mis-alignment of wheel and I-beam (rail). Maintenance task such as greasing of bearing proper lubrication are to be
carried out.In hydraulic subsystem, significant aspects are scheduled restoration task is apply on oil leakages from hydraulic
thrustor and scheduled discard task has been suggested in brake liner, arm and tie rod mechanism. No scheduled
maintenance is proposed to hydraulic cylinder.In supply current subsystem, high breakdown occurs in supply current cable
system. Hence no scheduled maintenance is proposed because these are related to damage or shot of cable during revolving
in forward and reverse direction. So to avoid this problem redesign will be required. If bus-bar system used instead of
existing supply current cable trolley system then breakdown is negligible.
References
[1] Deshpande V. S. & Modak J.P. Reliability Engg. & System safety,Elsevier Sci Ltd. 80 (2003) 1-18
[2] Society of automotive engineers (SAE), and Potential Failure Mode and Effects Analysis machinery (Machinery FMEA), June
2000.
[3] Sushil Kumar Shrivastava , Maintenance Engineering and Management, S.chand and co. ltd new Delhi, 1998
[4] Jones Richard B. Risk based management, Mumbai jaico publishing house ,1997
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