MEng 5231: Maintenance and installation

of Machinery

2018/2019 Semester I

Chapter One
Introduction
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 The course is intended to enable the
student to
 Understand theoretical and practical aspects of maintenance
practice in industrial setup;
 Understand basics of damages of typical components of
machinery and thereby help the student realize the state of damage of
machinery;
 Realize the use of the concepts of reliability, maintainability and
availability in maintenance technology which are helpful in the
prediction of plant performance;
 Understand the organization of a maintenance department,
maintenance planning and decision making processes;
 Develop practical skill by providing some practical work of
maintenance;
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 Content:

❖Introduction

✓Definition

✓History (Generation) of Maintenance

✓Maintenance Objectives

✓Types of Maintenance

✓Challenge of Maintenance
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Definition:

❖Maintain is defined as
✓ cause to continue (Oxford Dictionary), or

✓ keep in an existing state (Webster Dictionary).

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 Maintenance Definition

British Standard Glossary of terms (3811:1993)

defined maintenance as:

the combination of all technical and administrative

actions, including supervision actions, intended to
retain an item in, or restore it to, a state in which it can
perform a required function.
Maintenance Definition

maintenance is a set of organised activities that are

carried out in order to keep an item in its best
operational condition with minimum cost acquired.
Maintenance Activities

Activities of maintenance function could be either

repair or replacement activities, which are
necessary for an item to reach its acceptable
productivity condition and these activities, should
be carried out with a minimum possible cost.
❖Maintenance activity is the systematic and scientific
upkeep of equipment for:

✓ prolonging life of the equipment,

✓ assuring instant operational readiness,

✓ optimal availability for production at all times, and

✓ making sure that safety of man and machine is at

no time jeopardized

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 Maintenance History

1. In the period of pre-World War II, people thought of

maintenance as an added cost to the plant which did
not increase the value of finished product.

Therefore, the maintenance at that era was

restricted to fixing the unit when it breaks because
it was the cheapest alternative
 Maintenance History

2. During and after World War II at the time when the

advances of engineering and scientific technology
developed, people developed other types of
maintenance, which were much cheaper such as
preventive maintenance.

In addition, people in this era classified

maintenance as a function of the production system.
 Maintenance History

3. Nowadays, increased awareness of such issues as

environment safety, quality of product and services
makes maintenance one of the most important
functions that contribute to the success of the
industry.

World-class companies are in

continuous need of a very well organised
maintenance programme to compete world-wide.
 Maintenance History

✓ According to John Moubray (Reliability-Centered

Maintenance), the evolution of maintenance since the
1930's can be traced through three generations based
on three technical factors:

I. growing expectations of maintenance,

II. changing views on equipment failures, and
III. changing maintenance techniques.
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First Generation

This covers the period up to the World War II.

During this period:

✓ industry was not highly mechanized,

✓ equipment was simple and over designed,

✓ downtime did not matter much,

✓ prevention of equipment failure did not have high priority,

✓ failures were corrected as they occur.

➢ As a result, there was no need for systematic maintenance

beyond cleaning, servicing and lubrication.
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Second Generation
✓ During the war, demand for good increased and supply of industrial outputs was low. This
led to increase in mechanization.

During this period:

✓ machines became numerous and more complex,

✓ industry started to depend heavily on these machines,

✓ downtime started to matter,

✓ the idea that equipment failures could and should be maintained came up.

➢ As a result, the concept of preventive maintenance and

maintenance planning and control systems grew up.
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Third Generation:

✓ Since the mid-seventies, new expectations, new research and new

techniques have revolutionized maintenance.

During this period:

✓ maximizing life of equipment has become important,

✓ higher plant availability and reliability have become very important,

✓ greater automation has been effected,

✓ quality standards, safety and environmental consequences matter quite a lot,

✓ cost of maintenance is becoming central,

➢ As a result: greater expectations and leading to new research which

in turn lead to new techniques.

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Maintenance History

-Term terotechnology
introduced.
-Recognition of need
to present equipment
Development of
Maintenance

failures.
-Models for
preventive
maintenance -Increased awareness
developed. of:
-Environment
Fix the equipment -Safety
when it breaks -Quality
-Need for reliable
equipment.
-Reduction in costs.
Time
Pre-World War II Post-World War II 1980 Onwards

Figure 1.1 Maintenance History

(Adapted From Shenoy, Bhadury 1998)
 GROWING EXPECTATIONS OF
MAINTENANCE

Second Generation:
First Generation: ▪ Higher plant availability
▪ Fix it when it ▪ Longer equipment life
broke ▪ Lower costs
Third Generation:
▪ Higher plant availability
▪ Greater safety
▪ Better product quality
▪ No damage to the
environment
▪ Longer equipment life
▪ Greater cost effectiveness

1940 1950 1960 1970 1980 1990 2000

Figure 1.2 Maintenance History
 CHANGING MAINTENANCE
TECHNIQUES

Third Generation:
▪ Condition monitoring
▪ Design for reliability and
maintainability
▪ Hazard studies
▪ Small, fast computers
Second Generation: ▪ Failure modes and effects
▪ Scheduled overhauls analyses
First Generation: ▪ Systems for planning and ▪ Expert systems
▪ Fix it when it controlling work ▪ Multiskilling and teamwork
broke ▪ Big, slow computers

1940 1950 1960 1970 1980 1990 2000

Figure 1.3 Maintenance History
 Maintenance Objectives

Maintenance objectives should be consistent with and

subordinate to production goals.

The relation between maintenance objectives and

production goals is reflected in the action of keeping
production machines and facilities in the best possible
condition.
 Maintenance Objectives
 Maximising production or increasing facilities
availability at the lowest cost and at the highest
quality and safety standards.
 Reducing breakdowns and emergency shutdowns.
 Optimising resources utilisation.
 Reducing downtime.
 Improving spares stock control.
 Maintenance Objectives

 Improving equipment efficiency and reducing scrap

rate.
 Minimising energy usage.
 Optimising the useful life of equipment.
 Providing reliable cost and budgetary control.
 Identifying and implementing cost reductions.
Maintenance Objectives

PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy I Reduce Downtime
Usage N
T
Optimising Useful Life Improving Equipment
of Equipment
E Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources E Implementing Cost
Utilisation Reduction

Figure 1.4 Maintenance

Objectives
 Objectives of Maintenance:

✓ Maintenance purposes, functions and objectives are inter-related and are

overlapping to some extent. From the various aspects and paragraphs

mentioned earlier in this chapter, maintenance objectives for an industry can
be the followings:

➢ To maintain plants and equipment's at its maximum operating

efficiency, reducing down times and ensuring operational safety;

ensure maximum availability of plant, equipment and

machinery for productive utilization through planned

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maintenance
➢ To safeguard investments by minimizing rate of
deterioration and achieving this at optimum cost through
budgeting and controls; maintain plant equipment, and
facilities at an economic level of repairs at all times, to
conserve these and increase their life-span

➢ To help management in taking decisions on replacements

or new investments and actively participate in specification

preparation, equipment selection, its erection and
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commissioning etc,
 ➢ Help in implementation of suitable procedures for procurement,

storage and consumption of spares, tools and consumables etc

(inventory control etc)

➢ Standardization of spares and consumables, in conformity with

plant, national and international standards and help in adoption

of these standards by all users in the plant

➢ Running of centralized services like steam generation and

distribution, water supply, air supply and fuel etc.

➢ Running of captive workshops for repairs and conditioning and

also for making some new spares; etc.

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 Types of Maintenance

A. Run to Failure Maintenance (RTF)

B. Preventive Maintenance (PM)

C. Corrective Maintenance (CM)

D. Improvement Maintenance (IM)

E. Predictive Maintenance (PDM)

 A.Run to Failure Maintenance (RTF)

 The required repair, replacement, or restore action

performed on a machine or a facility after the
occurrence of a failure in order to bring this
machine or facility to at least its minimum
acceptable condition.

 It is the oldest type of maintenance.

 Run to Failure Maintenance (RTF)
❖It is subdivided into two types:
 Emergency maintenance: it is carried out as fast as
possible in order to bring a failed machine or facility to a
safe and operationally efficient condition.
 Breakdown maintenance: it is performed after the
occurrence of an advanced considered failure for which
advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.
 Run to Failure Maintenance (RTF)
❖ Disadvantages:

1. Its activities are expensive in terms of both direct and

indirect cost.

2. Using this type of maintenance, the occurrence of a failure

in a component can cause failures in other components in
the same equipment, which leads to low production
availability.

3. Its activities are very difficult to plan and schedule in

advance.
 Run to Failure Maintenance (RTF)
❖ This type of maintenance is useful in the following situations:

1. The failure of a component in a system is unpredictable.

2. The cost of performing run to failure maintenance activities

is lower than performing other activities of other types of
maintenance.

3. The equipment failure priority is too low in order to include

the activities of preventing it within the planned
maintenance budget.
 B. Preventive Maintenance (PM)

➢ It is a set of activities that are performed on plant

equipment, machinery, and systems before the
occurrence of a failure in order to protect them and to
prevent or eliminate any degradation in their operating
conditions.
Preventive Maintenance (PM)
British Standard 3811:1993 Glossary of terms
defined preventive maintenance as:

the maintenance carried out at predetermined

intervals or according to prescribed criteria and
intended to reduce the probability of failure or the
degradation of the functioning and the effects
limited.
 Preventive Maintenance (PM)

 The advantage of applying preventive maintenance

activities is to satisfy most of maintenance
objectives.
 Preventive Maintenance (PM)
❖ The factors that affect the efficiency of this type of maintenance:

1. The need for an adequate number of staff in the maintenance

department in order to perform this type of maintenance.
2. The right choice of production equipment and machinery that is
suitable for the working environment and that can tolerate the
workload of this environment.
3. The required staff qualifications and skills, which can be gained
through training.
4. The support and commitment from executive management to the
PM programme.
5. The proper planning and scheduling of PM programme.
6. The ability to properly apply the PM programme.
 Preventive Maintenance (PM)
 It is good for those machines and facilities which
their failure would cause serious production losses.

 Its aim is to maintain machines and facilities in

such a condition that breakdowns and emergency
repairs are minimised.

 Its activities include replacements, adjustments,

major overhauls, inspections and lubrications.
 Preventive Maintenance (PM)
❖ Researchers subdivided preventive maintenance into different
kinds according to the nature of its activities:

 Routine maintenance which includes those maintenance

activities that are repetitive and periodic in nature such as
lubrication, cleaning, and small adjustment.

 Running maintenance which includes those maintenance

activities that are carried out while the machine or
equipment is running and they represent those activities that
are performed before the actual preventive maintenance
activities take place.
 Preventive Maintenance (PM)
 Opportunity maintenance which is a set of maintenance
activities that are performed on a machine or a facility when
an unplanned opportunity exists during the period of
performing planned maintenance activities to other machines
or facilities.

 Window maintenance which is a set of activities that are

carried out when a machine or equipment is not required for
a definite period of time.

 Shutdown preventive maintenance, which is a set of

preventive maintenance activities that are carried out when
the production line is in total stoppage situation.
 C. Corrective Maintenance (CM)
 In this type, actions such as repair, replacement, or
restore will be carried out after the occurrence of a
failure in order to eliminate the source of this
failure or reduce the frequency of its occurrence.

In the British Standard 3811:1993 Glossary of terms,

corrective maintenance is defined as:

the maintenance carried out after recognition and intended to

put an item into a state in which it can perform a required
function.
 Corrective Maintenance (CM)
❖This type of maintenance is subdivided into three
types:

 Remedial maintenance, which is a set of activities

that are performed to eliminate the source of failure
without interrupting the continuity of the
production process.

The way to carry out this type of corrective maintenance is

by taking the item to be corrected out of the production line
and replacing it with reconditioned item or transferring its
workload to its redundancy.
 Corrective Maintenance (CM)
 Deferred maintenance, which is a set of corrective
maintenance activities that are not immediately
initiated after the occurrence of a failure but are
delayed in such a way that will not affect the
production process.

 Shutdown corrective maintenance, which is a set of

corrective maintenance activities that are performed
when the production line is in total stoppage
situation.
 Corrective Maintenance (CM)
 The main objectives of corrective maintenance are the
maximisation of the effectiveness of all critical plant
systems, the elimination of breakdowns, the elimination of
unnecessary repair, and the reduction of the deviations from
optimum operating conditions.

 The difference between corrective maintenance and

preventive maintenance is that for the corrective
maintenance, the failure should occur before any corrective
action is taken.

 Corrective maintenance is different from run to failure

maintenance in that its activities are planned and regularly
taken out to keep plant’s machines and equipment in
optimum operating condition.
 Corrective Maintenance (CM)
❖ The way to perform corrective maintenance activities is by
conducting four important steps:

1. Fault detection.
2. Fault isolation.
3. Fault elimination.
4. Verification of fault elimination.

In the fault elimination step several actions could be taken

such as adjusting, aligning, calibrating, reworking,
removing, replacing or renovation.
 Corrective Maintenance (CM)
❖Corrective maintenance has several prerequisites in
order to be carried out effectively:

1. Accurate identification of incipient problems.

2. Effective planning which depends on the skills of the
planners, the availability of well developed maintenance
database about standard time to repair, a complete repair
procedures, and the required labour skills, specific tools,
parts and equipment.
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
 D. Improvement Maintenance (IM)
 It aims at reducing or eliminating entirely the need for
maintenance.
 This type of maintenance is subdivided into three types as
follows:

1. Design-out maintenance which is a set of activities that

are used to eliminate the cause of maintenance, simplify
maintenance tasks, or raise machine performance from the
maintenance point of view by redesigning those machines
and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very
expensive.
Improvement Maintenance (IM)

2. Engineering services which includes construction and

construction modification, removal and installation, and
rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of

improvement maintenance activities that are performed
while the production line is in a complete stoppage situation.
 E. Predictive Maintenance (PDM)
 Predictive maintenance is a set of activities that detect
changes in the physical condition of equipment (signs of
failure) in order to carry out the appropriate maintenance
work for maximising the service life of equipment without
increasing the risk of failure.

❖ It is classified into two kinds according to the methods of

detecting the signs of failure:
 Condition-based predictive maintenance
 Statistical-based predictive maintenance
 Predictive Maintenance (PDM)

 Condition-based predictive maintenance depends on

continuous or periodic condition monitoring equipment to
detect the signs of failure.

 Statistical-based predictive maintenance depends on

statistical data from the meticulous recording of the
stoppages of the in-plant items and components in order to
develop models for predicting failures.
 Predictive Maintenance (PDM)
 The drawback of predictive maintenance is that it depends
heavily on information and the correct interpretation of the
information.

 Some researchers classified predictive maintenance as a type

of preventive maintenance.

 The main difference between preventive maintenance and

predictive maintenance is that predictive maintenance uses
monitoring the condition of machines or equipment to
determine the actual mean time to failure whereas preventive
maintenance depends on industrial average life statistics.
Types of Maintenance
MAINTENANCE

PLANNED UNPLANNED
MAINTENANCE MAINTENANCE
(PROACTIVE) (REACTIVE)

EMERGENCY BREAKDOWN

PREDECTIVE PREVENTIVE IMPROVEMENT CORRECTIVE

MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE

STATISTICAL CONDITION - DEFERRED REMEDIAL

ENGINEERING DESIGN -
- BASED BASED
SERVICES OUT

Shutdown Maintenance

WINDOW RUNNIN ROUTINE OPPORTU SHUTDOWN SHUTDOWN SHUTDOWN

G -NITY PREVENTIVE IMPROVEMENT CORRECTIVE

Figure 1.5 Maintenance

Types
The Challenges of Maintenance
❖The challenges that modern maintenance managers face

are summarized as follows:

✓ to select the most appropriate maintenance techniques,

✓ to deal with each type of failure process appropriately,

✓ in order to fulfill the expectations of users,

✓ in the most cost-effective and sustainable mode,

✓ with active support of people involved.

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Involvement of Maintenance activities
➢ Maintenance is related to profitability through:

▪ equipment output and equipment running cost.

▪ time taken for maintenance purposes.

➢ The importance of maintenance increases with

industrialization.

➢ The level of maintenance required at the equipment

operation stage is affected by factors at other stages

through which the equipment passes.
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➢ Design stage:
✓ Reliability and maintainability are the important factors which should be

considered properly in relation to performance of equipment, capital and

running costs.
➢ Installation stage:
✓ Maintainability is an important factor to be considered during the installation,

for it is here that maintenance problems become clear.

➢ Commissioning stage:
✓ This is a stage of technical performance testing and also a stage of where
primary design faults are located and designed out.
➢ Operational stage:
✓ The operational stage is a stage of learning where maintenance plays an

important role.
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 Equipment Life – Cycle

OPERATIONAL INVOLVEMENT

MANUFACTURE COMMISSIONING OPERATION

SPECIFICATION DESIGN REPLACEMENT
INSTALLATION
- Conceptualization - Performance - Primary design - Design fault - Wear-out
- Reliabilty - Quality control fault control detection - Obsolescence
- Maintainability - Design fault - Technical - Maintenance
- Support system detection performance test optimization
- Maintainability - Maloperation
avoidance

LEARNING PERIOD

CONTINUAL FEEDBACK

Figure
Fig. 1.2 Equipment life-cycle 1.6 Equipment Life – Cycle
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Maintenance Management
✓ is the direction and organization of resources in order to control the

availability and performance of an industrial plant to a specified

level.

✓ In maintenance management the problem is two-dimensional:

▪ Determination of size and nature of the maintenance work load,

▪ Organization and control of labour, spares and equipment to

meet the workload.

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Function of maintenance work

➢ Earlier the objective of maintenance function was

considered to optimize plant availability at minimum cost.

➢ Today it is being considered as "Maintenance affects all

aspects of business effectiveness and risk-safety,

environmental integrity, energy efficiency, product quality
and customer service, not just plant availability and cost."

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➢ The maintenance department influences plant availability directly

through preventive and corrective maintenance.

The most basic definition of availability is

Top
Availability 
Top  Tdown
where Top = cumulative time of operation

Tdown = cumulative outage time

Tdown = Down time = repair time + delays

Repair time = f(maintainability, management method, engineering techniques)

Delays = f(organization of maintenance resources and information)

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 Equipment Time EQUIPMENT TIME

ACTIVE TIME INACTIVE TIME

UPTIME DOWNTIME

MAINTENANCE MODIFICATION DELAY

PM TIME CM TIME

PROCUREMENT FAULT
PREPARATION CLEANUP
TIME CORRECTION
TIME TIME
TIME

ISOLATION ADJUSTMENT CHECKING LOGGING AND

TIME CALIBERATION TIME RESTORATION
TIME TIME

REPAIR IN REMOVE REMOVE AND REPAIR

PLACE REPLACE-REPAIR WITH A LIKE ITEM

INSPECTION SERVICING REPLACING MINOR OVERHAUL MAJOR OVERHAUL

TIME TIME TIME TIME TIME
57 (aging units)

Figure 1.7 Equipment Time

 Equipment Down Time

DOWNTIME

CM PM DELAYS
(Repair Time) (Off-line Time) (Waiting for M)

RESOURCES INFORMATION

MAINTAINABILITY MANAGEMENT ENGINEERING TECHNIQUES

(Logical fault-finding: Diagnostics)

Figure 1.8 Equipment Down Time

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 The End!!

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