3/30/2017 Engr.

Muhammad Sajid, UOG 1

MAINTENANCE
ENGINEERING

Engr. Muhammad Sajid

Lecturer
Department of Chemical Engineering
MAINTENANCE

Why to do maintenance

Purpose/Objectives

Benefits?

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PURPOSE OF MAINTENANCE
To keep equipment/system operative.
Attempt to maximize performance of
production equipment efficiently and regularly
Prevent breakdown or failures
Minimize production loss from failures
Increase reliability of the operating systems
To keep operation safe
To prevent leakages/losses

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TYPES OF MAINTENANCE
Generally maintenance is classified into four categories:

Preventive maintenance
Corrective or Breakdown maintenance
Scheduled maintenance
Predictive (Condition-based) maintenance

(some authors prefer three categories- scheduled and preventive

maintenances are merged)

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TYPES OF MAINTENANCE (Cont.)

There are also some other types of

maintenance; i.e.
Operational Maintenance
Reliability Centered Maintenance
Improvement Maintenance (IM)

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 Types of Maintenance (Cont.)
MAINTENANCE

PLANNED UNPLANNED
MAINTENANC MAINTENANC
E (PROACTIVE) E (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANC MAINTENANC MAINTENANCE MAINTENANC
E E E

STATISTICAL CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN -
- BASED BASED
SERVICES OUT

Shutdown Maintenance

WINDO RUNNIN ROUTINE OPPORTU SHUTDOWN SHUTDOWN SHUTDOWN

W G -NITY PREVENTIVE IMPROVEMENT CORRECTIVE

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 MAINTENANCE
3/30/2017
PREVENTIVE
Engr. Muhammad Sajid, UOG 8
PREVENTIVE MAINTENANCE
Principle Prevention is better than cure
Procedure - Stitch-in-time
Preventive maintenance is maintenance performed in an attempt to
avoid failures, unnecessary production loss and safety violations. where
equipment is maintained before break down occurs. This type of
maintenance has many different variations and is subject of various
researches to determine best and most efficient way to maintain
equipment. Recent studies have shown that Preventive maintenance is
effective in preventing age related failures of the equipment. For
random failure patterns which amount to 80% of the failure patterns,
condition monitoring proves to be effective.
It
Locates weak spots of machinery and equipments
Provides them periodic/scheduled inspections and minor
repairs to reduce the danger of unanticipated breakdowns

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PREVENTIVE MAINTENANCE

Primary goal- Preserve and enhance

equipment reliability

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Reasons for the need of a PM
system
Increased Automation

Business loss due to production delays

Production of a higher quality product

Just-in-time manufacturing

Need for a more organized, planned

environment

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 Preventive Maintenance
PREVENTIVE
MAINTENANCE

INDIRECT DIRECT

Condition Based Fixed time

Maintenance (CBM) Maintenance(FTM)

Detection of failures Cleaning, Lubrication

Before break down Fixed time replacement

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Indirect Maintenance

INDIRECT PM

Subjective Objective
Using human
senses Using off line
Look , feel , listen , instrument
smell , taste

Continuous, on-
line monitoring

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Examples of PM

Oil changes
Greasing
Changing filters
Belt tightening

Anything that increases life of equipment,

and helps it runs more efficiently

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 ADVANTAGES OF PM
Reduces break down and thereby down time
Less odd-time repair and reduces over time of crews
Greater safety of workers
Lower maintenance and repair costs
Less stand-by equipments and spare parts
Better product quality and fewer reworks and scraps
Increases plant life
Increases chances to get production incentive bonus

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Who Does PM?
Only trained, qualified maintenance
personnel should perform PMs

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 SCHEDULED MAINTENANCE
Scheduled maintenance is a stitch-in-time
procedure and incorporates
inspection
lubrication
repair and overhaul of equipments
If neglected can result in breakdown
Generally followed for:
overhauling of machines
changing of heavy equipment oils
cleaning of water and other tanks etc.

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Potential errors or damage
of a PM system
Damage to an adjacent
equipment during a PM task.

Reintroducing infant mortality by

installing new parts or materials.

Damage due to an error in

reinstalling equipment into its
original location.

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The key for a successful PM system
Scheduling Should be automated to the
maximum extent possible

Execution Should be done before the

actual break down occurs.

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PM focus on

Cleaning Found through testing

Lubrication and inspection
And correcting deficiencies

Predetermined parts replacement should be minimal and done only where

statistical evidence clearly indicates wear-out characteristics

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Engr. Muhammad Sajid, UOG
PREDICTIVE
MAINTENANCE
(CONDITION-BASED)
22
Predictive Maintenance (PdM)
Definition Techniques that help
determine the condition of in-service
equipment in order to predict when
maintenance should be performed

Primary goal Minimize disruption of

normal system operations, while allowing
for budgeted, scheduled repairs

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PREDICTIVE (CONDITION-BASED)
MAINTENANCE
In predictive maintenance, machinery conditions
are periodically monitored and this enables the
maintenance crews to take timely actions,
such as machine adjustment, repair or overhaul

It makes use of human sense and other sensitive

instruments, such as
audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain gauges
etc.

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PREDICTIVE MAINTENANCE (CONTD.)

Unusual sounds coming out of a rotating

equipment predicts a trouble
An excessively hot electric cable predicts
a trouble
Simple hand touch can point out many
unusual equipment conditions and thus
predicts a trouble

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Examples of Predictive
Maintenance
Vibration Analysis
Infrared Thermography
Oil Analysis
Visual Inspections

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Benefits of PdM
Provides increased operational life
Results in decrease of downtime
Allows for scheduled downtime
Allows for money to be budgeted for
repairs
Lowers need for extensive parts
inventory
DOE reports an estimated 8-12% cost
savings by having a PdM program

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Cont.
DOE also estimates:

Reduction in maintenance costs 25-30%

Elimination of breakdowns 70-75%
Reduction of downtime- 35-45%
Increase in production 20-25%
Who does PdM?
Often done by a contracted, specialized
technician

Reasons:
1)Qualified and trained on latest technology
2)Possess the proper equipment
3)Provide trending and historical data in report
form

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PdM Activities
Oil Analysis
Thermography
Vibration Analysis
Visual inspection
Concrete Deteriorating

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Oil Analysis
Long term program that may take years
before its benefits are seen
Oil analysis determines:
Condition of oil
Quality of the lubricant
Suitability for continued use

Wear particle analysis determines:

Mechanical condition of machine components
Identifies particle size, type, etc.

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Oil Analysis Report
Oil Analysis results may:

Detail the types of metal fragments in the

sample
Show a continued increase in particle size
Recommend increasing sampling intervals
Recommend shutting down machine

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Thermography
Used for Electrical Infrared Inspections
Detects hot spots, load imbalances and
corrosion at a safe distance
Detect failures due to excessive heat

Indoor equipment such as MCCs,

disconnect switches and transformers
Outdoor equipment such as substations,
transformers and outdoor circuit breakers

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Vibration Analysis
Usually done on large equipment, such as
blowers, pumps, etc.
Determines if bearings or components
are loose, moving or wearing
Allows for scheduled repair of equipment
Can provide trending that enables
shutdown of equipment BEFORE failure
and major damage

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 Equipment Inspections
Visual inspection of equipment such as:

Clarifiers and associated

equipment
Mechanical bar screens
Allows for equipment to be coated,
such as bar screens

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 Concrete Deteriorating
Concrete-Deteriorating concrete can
indicate several things

Corrosion Attack on Rebar Presence of H2S

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 Remember

Chemical Tanks
Roofs
Portable equipment
(generators, diesel pumps)
Safety equipment

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 CORRECTIVE or

MAINTENANCE
BREAKDOWN
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Corrective Maintenance

Definition Repair of equipment/machinery in

order to bring it back to original operating
condition.

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 CORRECTIVE or BREAKDOWN
MAINTENANCE
Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and can
not perform its normal function anymore

Corrective maintenance can be defined as the

maintenance which is required when an item has
failed or worn out, to bring it back to working order.
Corrective maintenance is carried out on all items
where the consequences of failure or wearing out are
not significant and the cost of this maintenance is
much greater than PREVENTIVE MAINTENANCE.

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CORRECTIVE or BREAKDOWN
MAINTENANCE (Cont.)
Quite justified in small factories where:
Down times are non-critical and repair costs are
less than other type of maintenance
Financial justification for scheduling are not felt

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Planned & unplanned corrective maintenance
Corrective maintenance is divided in

CORRECTIVE
MAINTERANCE

UNPLANNED PLANNED

Break Down
Planned Maintenance
Emergency Repairs
Prepared Properly
Urgent
Possible to Control
Not possible to Control
You control the
You are controlled by
Equipment
the equipment

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 Important Facts
Use original OEM parts
Install per manufacturers
specs
Dont take shortcuts
Do it right

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 DISADVANTAGES OF CORRECTIVE MAINTENANCE

Breakdown generally occurs inappropriate times

leading to poor and hurried maintenance
Excessive delay in production & reduces output
Faster plant deterioration
Increases chances of accidents and less safety for
both workers and machines
More spoilt materials
Direct loss of profit
Can not be employed for equipments regulated
by statutory provisions e.g. cranes, lift and hoists
etc

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 OPERATIONAL MAINTENANCE
Where equipment is maintained in OPERATING CONDITION.

Operational maintenance is the program focused on the regular

task that will maintain all the critical machinery and the system in
optimum operating conditions. The major objectives of the
program are to

1.Eliminating breakdown

2.Eliminating deviation

3.Eliminating unnecessary repairs

4.Optimize all the critical planned system

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 RELIABILITY CENTERED MAINTENANCE

It is a process to ensure that assets continue to do what their users

require in their present operating context.

It is generally used to achieve improvements in fields such as the

establishment of safe minimum levels of maintenance, changes to

operating procedures and strategies and the establishment of capital

maintenance regimes and plans. Successful implementation of RCM

will lead to increase in cost effectiveness, machine uptime, and a

greater understanding of the level of risk that the organization is

managing.

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RELIABILITY CENTERED
MAINTENANCE (Cont.)
It regards maintenance as the means to maintain the
functions a user may require of machinery in a defined
operating context. As a discipline it enables machinery
stakeholders to monitor, assess, predict and generally
understand the working of their physical assets. This is
embodied in the initial part of the RCM process which
is to identify the operating context of the machinery,
and write a Failure Mode Effects and Criticality Analysis
(FMECA). The second part of the analysis is to apply the
"RCM logic", which helps determine the appropriate
maintenance tasks for the identified failure modes in the
FMECA.

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DETERMINING THE SIZE OF
REPAIR CREWS
Problem:
A factory has 200 machines and the
maintenance engineer supervises the repair
crews who repair malfunctioning machines.
The maintenance policy is to repair the
broken down machine and bring back in
production within 2 hours on the average. If
average breakdown rate is 3.5
machines/hour and each repair crew can
repair 0.25 machine per hour on the
average. How many repair crews are
required ?

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Summary

Proper maintenance programs have huge

returns
Keeps equipment running longer
Allows for scheduled, budgeted repairs
Reduces unscheduled down time
Makes life less stressful

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SOLUTION
The formula for average repair rate () is
1
ts = ---------- or = + 1/ ts
-
Where = repair rate
= arrival rate of malfunctioning machines
ts = average time arrivals in the system

Required average repair rate

= 3.5 + 1 / 2 = 4 machines / hour
No. of Crews = machines/hour a crew can repair
= 4 0.25 = 16 repair crews required

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 ?
Thanks
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