Maintenance Safety Jim Seay, ICAE Chairman, IAAPA Global Safety Committee President, Premier Rides Immediate Past Chair, ASTM F24 August 30, 2016
Welcome Back!
Overview Industry Growth in Asia Challenges for Vietnam Maintenance Requirements Sample Maintenance Inspection Process Maintenance Case Studies Questions
Shares of Global Attendance by Region
Vietnam, for example, is a growth market as labor costs are low, making it attractive to investors. For these countries, family attractions are the principal venues and growth is being fueled by an expanding middle class. Vietnam will be the second fastest-growing country with a projected 12.9 percent compound annual increase as that country attracts investment. --IAAPA Global Theme and Amusement Park Outlook 2015-2019
Challenges of Industry Growth in Vietnam Lack of training opportunities Insufficient number of highly experienced technicians Language barriers Limited resources for exchanging information No database of equipment Lower capital investment restricting ride options Spare part costs as a percentage of maintenance budget Labor cost differences restricts ability to hire industry consultants
From where do Maintenance Requirements Come?
Development of Maintenance Requirements
What Rides Need Maintenance?
All Rides and Attractions
Key Maintenance Requirements Training Documentation Proper Facilities Lighting Tools/Safety Equipment Cleaning Supplies
Maintenance Daily, Weekly, Monthly and Yearly The Importance of Regular Maintenance Daily, Weekly, Monthly and Yearly Key Areas on which to focus when performing inspections 13
Pa ge Maintenance Daily, Weekly, Monthly and Yearly Daily, Weekly, and Monthly Maintenance is reactive where you respond to indications or issues. Daily maintenance is the best way to prevent problems. Through daily inspections, problems can be noticed before they become dangerous. 14
Pa ge Maintenance Daily, Weekly, Monthly and Yearly Yearly Maintenance is proactive since a partial or complete disassembly of the ride is required. Keep a signed log with a record of findings and repairs so a proper history is maintained. This way, initial stages of a situation will be documented. 15
Maintenance Example of Important Activities Maintain records for history Communicate abnormal issues to coworkers Communicate abnormal issues to manufacturer Repair prior to opening ride to guests Red Tag!
Maintenance Example of Key Areas of Focus Vehicles Drive Systems Braking Systems Track & Columns 18
Pa ge Maintenance Key Area of Focus: Vehicles Wheels & Bogies Axle & Chassis Rider Restraints 19
Pa ge Maintenance Key Area of Focus: Vehicles Perform an overall visual inspection of the entire train. Note and investigate any problems. As part of the normal daily maintenance, the train should be kept clean of grease and dirt to promote effective inspections. 20
Pa ge Maintenance Key Area of Focus: Vehicles Wheels & Bogies 21
Pa ge Maintenance Key Area of Focus: Vehicles Bogie Daily Detailed inspection of all welds for indications of cracks. Check the torque on all fasteners, usually using the torque stripe as a guide. Check for looseness in the bogie assembly. This is accomplished by pulling the bogie. Check condition of wheel liners Spin the wheels to check for frozen bearings or unusual noise. 22
Maintenance Key Area of Focus: Vehicles Bogie Yearly Disassemble the entire bogie assembly. Non-destructive testing (NDT) inspection should be performed on the bogies. A compiled NDT report should be submitted to the manufacturer for review. Remove dust covers and bearings from the road wheels. Bearings should be repacked with grease and replaced if necessary. 23
Pa ge Maintenance Key Area of Focus: Vehicles Axle & Chassis 24
Pa ge Maintenance Key Area of Focus: Vehicles Axle & Chassis 25
Maintenance Key Area of Focus: Vehicles Axle & Chassis Daily Visually inspect the condition of each axle, chassis and bogie yoke. Visually inspect each chain dog. They should move and rotate freely. Detailed inspection of all welds for indications of cracks. Indications should be noted and reported to the manufacturer. Check for missing or broken hardware. Check the torque on all fasteners, usually using the torque stripe as a guide. 26
Maintenance Key Area of Focus: Vehicles Axle & Chassis Yearly Remove axles and yokes from the main chassis If axle bearings or bushings are worn past acceptable wear limits, replace. NDT inspection should be performed on the axles, yokes and chassis. A compiled NDT report should be submitted to the manufacturer. Upon reassembly, ensure all grease cavities are fully packed with appropriate lubrication. Inspect the floor pans and fiberglass components for cracking. 27
Maintenance Key Area of Focus: Vehicles Rider Restraints 28
Maintenance Key Area of Focus: Vehicles Rider Restraints Daily Verify the lap bar locks correctly by closing the restraint click by click if the system is a ratchet system or by slowly closing the restraint if it is a hydraulic system. Check the torque on all fasteners, usually using the torque stripe as a guide. Verify that the return assist is working correctly and that the lap bar comes up smoothly. 29
Maintenance Key Area of Focus: Vehicles Rider Restraints Yearly Completely disassemble the restraint housings. Clean all dust, debris, and lubricant from the housing and components. NDT inspection should be performed on the ratchets and pawls. A compiled NDT report should be submitted to the manufacturer. Inspect the release mechanism components. Replace spacer rings, springs, hardware, dust covers, etc. that show signs of wear. Reassemble and lubricate the entire assembly. 30
Maintenance Key Area of Focus: Chain Lift System Chain Lifts 31
Maintenance Key Area of Focus: Chain Lift System Chain Lifts Daily Remove any accumulated dirt or debris from the chain. Carefully inspect the welds and chain links. Cracked welds or signs of weak material must be repaired. Perform a careful visual inspection of the entire chain guide, checking for any broken, missing or loose bolts, rivets, or wear strips. 32
Maintenance Key Area of Focus: Chain Lift System Chain Lifts Yearly Check shaft and sprocket alignment and check for wear on sprockets. Check length of the chain. A change in length indicates pitch elongation. Links can be removed to correct. Optimal storage during off-season is to remove the chain and store. It is recommended to have a chain specialist inspect annually.. 33
Maintenance Key Area of Focus: Chain Lift System Chain Drive Yearly Visually inspect the sprockets Check tightness of all connections and pillow block mountings Inspect the chain tensioning system for wear and tightness Inspect alignment of the chain on the chain sprockets. Correct any misalignments. Lubricate pillow blocks as necessary 34
Maintenance Key Area of Focus: Braking Systems Braking Systems 35
Maintenance Key Area of Focus: Braking Systems Mechanical & Platen Brakes Daily Visually inspect the condition of the brake and welds. You should cycle the brake. Ensure braking surfaces are in good condition. Inspect any pads or bumpers that limit the range of motion. Braking surfaces should be free of grease. Make sure all connection hardware is tight. Check the torque on all fasteners, using the torque stripe as a guide. Run the attraction listening for unusual braking sounds. 36
Maintenance Key Area of Focus: Braking Systems Mechanical & Platen Brakes Yearly Disassemble the brake. Replace brake pads if worn. NDT inspection should be performed on brakes. A compiled NDT report should be submitted to the manufacturer. Replace the bearings, bushings, and pivot blocks and other moving components. Pneumatic canisters should be replaced yearly. 37
Maintenance Key Area of Focus: Ride Structure Track & Columns 38
Maintenance Key Area of Focus: Ride Structure Track & Columns Daily and Yearly Daily maintenance requires a visual inspection of a different part of the track/structure every day of the week, looking for any visible cracks or abnormalities Visually inspect the grounds for any fallen hardware and determine its original location Yearly maintenance requires a thorough close visual inspection of 100% of the track and columns Perform NDT on a portion of the structure focusing on high-stress areas. A compiled NDT report should be submitted to the manufacturer Touch up the paint as needed. 39
Case Studies
Case Study 1 Parts Replacement Schwarzkopf Wildcat
Case Study 1 Parts Replacement Issue: Worn chain dog No spare chain dog in stock High replacement cost for one chain dog Shipping time approximately 1 week
Case Study 1 Parts Replacement Park Solution: Machine new part in-house using old chain dog as guide
Case Study 1 Parts Replacement Result of Repair
Case Study 1 Parts Replacement Lessons Learned: Certified spare parts Adequate spare parts in stock Purchase spares with new ride to lower cost No modifications without manufacturer involvement
Case Study 2 Industry Communication
Case Study 2 Industry Communication Key points: Inspector Corrosion Correct NDT Access to high areas
Case Study 2 Industry Communication IAAPA Europe, Middle East, Africa Headquarters
Case Study 2 Industry Communication
Case Study 2 Industry Communication
Case Study 2 Industry Communication
Suggestions Maintenance management involved in the design phase. Spare parts, tools, safety equipment and diagnostic equipment included in ride contract. Train the trainer programs in addition to manufacturer training. Participate/ volunteer to create connections. ASTM, IAAPA, AIMS
In Closing It is a very sobering feeling to be up in space and realize that one s safety factor was determined by the lowest bidder on a government contract --Alan Shepard Astronaut/First American in Space
Thank You Again 54
Questions? 55