crew leader equipment tracking and maintenance

1 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2012 eere.energy.gov

CREW LEADER

Equipment Tracking and Maintenance

2 | WEATHERIZATION ASSISTANCE PROGRAM STANDARDIZED CURRICULUM – August 2012 eere.energy.gov

Learning Objectives

By attending this session, participants will be able to:

• Recognize the importance of keeping track of tools and equipment.

• Explain the importance of equipment maintenance and its effect on production.

• List specific equipment maintenance needs.

• Demonstrate how to involve crew members in tool maintenance and accountability.

EQUIPMENT TRACKING AND MAINTENANCE

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Tracking Tools #1

Why is it important?

• Public funds are heavily scrutinized.

• Production suffers when tools are missing.

• Tracking prevents theft.

• Tracking reduces replacement costs.

EQUIPMENT TRACKING AND MAINTENANCE

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Tracking Tools #2

Categories:

• Major equipment

• Hand power tools

• Hand tools

• Personal protective equipment

• Expendables

Photo courtesy of The Energy Conservatory

EQUIPMENT TRACKING AND MAINTENANCE

Image courtesy of cordless-drills.net

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Tracking Tools #3

• Maintain a tool inventory checklist.

• Note model and serial numbers where applicable.

• Identify all agency tools with indelible etching.

• Empower crew members to be responsible for contents of their assigned tool kits.

• Maintain a disposal record of obsolete and non-serviceable tools.

EQUIPMENT TRACKING AND MAINTENANCE

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Tool Inventory Checklist

Be sure to include:

• Truck number

• Person issued to

• Tool description

• Quantity

• Model and serial numbers

• Status, comments, and date

A brand new $35,000 tool box

Photo courtesy of the US Department of Energy

EQUIPMENT TRACKING AND MAINTENANCE

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Assigning Tools

1-Slotted screwdriver 1-Phillips screwdriver1-Chisel 1-Awl1-Utility knife 1-Leather tool belt1-Hacksaw 1-Handsaw1-Respirator 1-Chalkline1-Tin snip 1-16oz. hammer1-Combination square 1-Keyhole saw1-Wonder bar 1-Scriber1-Coping saw 1-Pair gloves1-pr. Safety glasses 1-Drywall rasp1-Drywall screw setter 1-25’ tape rule

Standard Weatherization Tool Kit Checklist

Issued to: ______________________Date: __________________________

EQUIPMENT TRACKING AND MAINTENANCE

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Missing Tools Exercise

Missing Tools Exercise(20 minutes)

EQUIPMENT TRACKING AND MAINTENANCE

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Tool and Equipment Maintenance

Why is it important?

• Production suffers when equipment falls into disrepair.

• Regular maintenance assures that equipment is safe and reliable.

• Maintenance reduces need for premature replacements.

EQUIPMENT TRACKING AND MAINTENANCE

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Vehicles

Photo courtesy of NRCERT

Your Weatherization Vehicle

Treat it like you would your own!

EQUIPMENT TRACKING AND MAINTENANCE

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Generator

• Change oil every 25 hours.

• Change air pre-cleaner every 25 hours.

• Change oil filter every 100 hours.

• Change air filter every 100 hours.

• Replace spark plugs yearly.

• Replace fuel filter yearly.

• Check valve clearance yearly. Photo courtesy of New River Center for Energy Research and Training

EQUIPMENT TRACKING AND MAINTENANCE

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Blowing Machine

Routine Maintenance:

• Clean blower air filteras needed.

• Clear hopper and blower hose daily.

• Clean every two weeks.

• Check oil every two weeks.

• Check pressure at the end of the hose every two weeks.

Krendl Insulation Blowing Machine Photo courtesy of the US Department of Energy

EQUIPMENT TRACKING AND MAINTENANCE

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Pressure Testing Blowing Machines & Hoses

• Blowing machines and hoses should test at 3-4 pounds per square inch (psi) to be at full capacity.

Dwyer Blowing Machine Pressure Test Gauge Kit

Photo courtesy of the US Department of Energy

EQUIPMENT TRACKING AND MAINTENANCE

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Pressure Testing Blowing Machines and Hoses

Pressure Testing Blowing Machines and Hoses Exercise

(30 minutes)

EQUIPMENT TRACKING AND MAINTENANCE

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Equipment Calibration Schedule

• Calibrate diagnostic instruments on a regular basis.

• Maintain a record of calibrations and repairs for:

o Digital manometer.

o Combustion analysis equipment.

o Gas leak detectors.

o Carbon monoxide detectors.

EQUIPMENT TRACKING AND MAINTENANCE

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Digital Manometer

Calibrate every six months.

• Return to the manufacturer.

• Or calibrate with another digital manometer of the same type.

DG 700 Manometer, Energy Conservatory

EQUIPMENT TRACKING AND MAINTENANCE

Image courtesy of The Energy Conservatory

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Combustion Equipment

• Combustion analyzers: calibrate every 6 months.

o Replace oxygen sensors every 1 to 2 years.

• Carbon monoxide detectors:calibrate to outside air.

o Replace CO sensors every 3 to 5 years.

• Gas leak detectors: test with the gas from a cigarette lighter.

Fyrite Tech, Bacharach

Gas Leak Detector, Bacharach

EQUIPMENT TRACKING AND MAINTENANCE

Images courtesy of Bacharach

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Blower Door

Fan housings that are cracked or misaligned will likely cause false test results.

Minneapolis Model 3 Blower Door

EQUIPMENT TRACKING AND MAINTENANCE

Photo courtesy of The Energy Conservatory

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Safety Upgrades Exercise

Safety Upgrades Lab Exercise

(30 minutes)

EQUIPMENT TRACKING AND MAINTENANCE

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Safety Upgrades Summary

Replace:

• Aluminum ladders. Use industrial-rated, non-conductive fiberglass ladders.

• Frayed or undersized extension cords.

• Ungrounded power tools.

• Hammers with mushroomed heads.

• Dull drill bits, saw blades, utility knife blades.

• Worn out respirators and safety glasses.

EQUIPMENT TRACKING AND MAINTENANCE

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Summary

• Maintaining accurate records of tools and equipment is important for assuring program transparency.

• Scheduled tool and equipment maintenance avoids downtime and lost production.

• Delegating responsibility for equipment tracking and maintenance empowers crew members to be part of the process.

EQUIPMENT TRACKING AND MAINTENANCE