MAINTENANCE

ENGINEERING

HASEEB ULLAH KHAN JATOI

DEPARTMENT OF CHEMICAL
ENGINEERING
UNIVERSITY OF ENGINERING AND
TECHNOLOGY LAHORE

COURSE DETAILS
COURSE TITLE

MAINTENANCE ENGINEERING

COURSE CODE

CHE-404

SEMESTER

7TH

WEEKLY CONTACT HOURS

CREDIT HOURS

PRACTICAL

NIL

APPROXIMATE NUMBER OF WEEKS

18

APPROXIMATE NUMBER OF
STUDENTS

90

COURSE OUTLINE
Types of maintenance and their applications
Maintenance management
Maintenance of pumps, machines and piping, lubrication programs
Forms of corrosion, prevention and inhibition, design considerations
Layout and construction
Overall safety of plant and personnel
Fire and explosion
Health hazards
Accident prevention
Government Regulations for industrial safety.

Text Books

Reference Books

1. B.S.
Dhillon;
Engineering 1. Gaither Norman & Frazier Greg, Operations
Maintenance-A modern Approach;
Management, 9th Edition, South western/
CRC Press
Thomson Learning (2002)
2. Niebel, Benjamin W. Engineering 2. Sinnott R.K., Chemical Engineering Design;
Maintenance Management Industrial
Coulson & Richardson Series, 4th Edition,
Engineering ; V. 18; CRC Press
volume 6th, Butterworth-Heinemann (2005)
3. R.
Keith
Mobley;
Maintenance 3. Griffin Ricky, Management, 8th Edition,
Fundamentals; 2nd Edition; Elsevier
Houghton Mifflin company (2005)
ButterworthHeinemann

Week
1

Lecture by Lecture Breakdown

Part I (Theory)
Brain Storming, Course Outline
Maintenance and its types

Types of Maintenance

Maintenance Management

Organization

Availability and Reliability

Product and Service Design, Product
Life Cycle

6
7

Types of Designs, House of Quality

Heat Exchanger and Pump

Maintenance

9
10
11

Book / Reference Material

William J. Stevenson,
Production / Operations
Management,
Irwin McGraw-Hill, Boston, Ed 5th
(1996)
Norman Gaither and Greg Frazier,
Operations Management,
SouthWestern/Thomson Learning,
Ed 9th
(2002)
Ricky Griffin,
Management,
Houghton Mifflin Company, Ed 8th
(2005)
William J. Stevenson,
Production / Operations
Management,
Irwin McGraw-Hill, Boston, Ed 5th
(1996)
AMPCO and FFC Manuals

Mid Term
Examinations
Total Productive Maintenance Pillars
URL:
Total Productive Maintenance Pillars
www.managementsupport.com

13

14

15

16

17

18

Industrial Disaster: Union

Carbide The Bhopal
Disaster, BP Texas City
Explosion and Meltdown In
Chernobyl
Health & Safety: Background,
Law and Regulations
Health & Safety: Health,
Accident Prevention, Slip, Trips &
Fall, Electricity, Fire Safety / Fire
Prevention
Health & Safety: Welfare, Risk
Assessment
Health & Safety: Workplace,
Equipment, Ergonomics, Manual
Handling, Hazadous Substances,
Working at Height, Transport,
Noise and Vibration

Seconds From Disaster,

National Geographic Society

Valerie Leeson,
Health and Safety First
Principles,
Chartered Institute of
Environmental Health, UK,
Ed 2nd (2006)

End Term
Examinations

COURSE LEARNING
OBJECTIVES

To understand the importance of mechanical integrity of a plant in

relation to its operations and economics (OB1)
To acquaint the students with the importance of maintenance, its various
types, scheduling and management systems for a sustainable and
reliable running plant (OB2)
To discern in depth the equipment safety (rotary plus stationary), routine
maintenance, lubrication procedures, corrosion and prevention
procedures (OB3)
To understand the equipment vs personnel safety nexus in relation to
health hazards, accidents (major and minor), ergonomics, industrial
safety and regulations (OB4)
To explore the concepts of Corrosion, MI, Plant Turnaround,
Debottlenecking, and MOC as integral parts of equipment maintenance
and safety (OB5)

COURSE LEARNING OUTCOMES

From OB1 students should be able to:
Define and express the concept of mechanical integrity and its
significance (CLO1)
Make a relationship between MI and plant operating costs (CLO2)
Develop a relationship between MI and equipment plus personnel safety
(CLO3)
Draw a comparison between different approaches towards maintenance
philosophies employed in various types of industries (CLO4)

COURSE LEARNING OUTCOMES

From OB2 students should be able to:
Explain various forms of maintenance, their comparison, efficacy,
implementation, prerequisites and pros and cons (CLO5)
Describe and highlight with examples the role of scheduling, planning,
budgeting and execution of maintenance jobs (CLO6)
Express and compare different styles and systems of management
employed for maintenance and their pros and cons (CLO7)

COURSE LEARNING OUTCOMES

From OB3 students should be able to:
Define different types of stationary and rotary equipment, their areas of
deterioration (operational) , weathering (environmental), and operational
practices with examples (CLO8)
Explain vividly routine maintenance, cyclic maintenance, lubricating
cycles, corrosion elimination, and inspection of equipment with examples
(CLO9)

COURSE LEARNING OUTCOMES

From OB4 students should be able to:
Define and explain the relationship of equipment and personnel safety
with maintenance practices (CLO10)
Define different types of hazards, and accidents with examples and case
studies (CLO11)
Explain the concept of safety and safety regulations employed as best
engineering practices with examples (CLO12)

COURSE LEARNING OUTCOMES

From OB5 students should be able to:
Explain the concept of corrosion, its various types and the role of
maintenance in checking it with examples (CLO13)
Explain the concepts of Mechanical Integrity, Plant Turnaround,
Debottlenecking, Management of Change with case studies (CLO14)

MAINTENANCE
BRAINSTORMING
Maintenance activity in industrial history
Challenges of size, cost, complexity and competition
Maintenance is market driven activity
Maintenance Main Objective: Maintenance is a function that
must be performed under normally adverse circumstances
and stress, and its main objective is to rapidly restore the
equipment to its operational readiness state using available
resources.
Maintenance in 21st century

SOME CONCEPTS
Maintenance
Maintenance Engineering
Preventive Maintenance
Corrective Maintenance
Predictive Maintenance
Maintenance Concept
Maintainability
Maintenance plan
Reliability

Active Repair Time

Mean Time to Repair (MTTP)
Overhaul
Quality
Maintenance Person
Inspection
Downtime
Uptime

COST MATTERS
Direct Cost
Standby Cost
Lost Production Cost
Degradation Cost

MAINTENANCE
PHILOSOPHIES
Run-to-Failure Approach
Preventive Maintenance Approach
Predictive Maintenance Approach

MAINTENANCE IN
RETROSPECTIVE
Development of
Maintenance

-Term terotechnology
introduced.
-Recognition of need to
present equipment
failures.
-Models for preventive
maintenance developed.

-Increased awareness of:

-Environment
-Safety
-Quality
-Need for reliable equipment.
-Reduction in costs.

Fix the equipment

when it breaks

Pre-World War II

Post-World War II

1980 Onwards

Time

Figure: Maintenance History

(Adapted From Shenoy, Bhadury 1998)
24

MAINTENANCE OBJECTIVES
PLANT

Maximising Production
Minimising Energy Usage
Optimising Useful Life of
Equipment
Providing Budgetary
Control
Optimising Resources
Utilisation

M
A
I
N
T
E
N
A
N
C
E

Reduce Breakdowns
Reduce Downtime
Improving Equipment
Efficiency
Improving Inventory
Control
Implementing Cost
Reduction

Figure: Maintenance Objectives

25

DEFINING MAINTENANCE

DEFINING MAINTENANCE
Art-Science-Philosophy?

DEFINING MAINTENANCE
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.

28

DEFINING MAINTENANCE
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.
It is the routine and recurring process of keeping
particular machine or asset in its normal operating
condition so that it can deliver its expected performance
or service without causing any loss of time on account
of accidental damage or breakdown.
29

DEFINING MAINTENANCE
It is the work that is to be done to keep the
equipment or system in a running condition such
that it can be utilized to its full designed capacity
and efficiency for maximum amount of time.
Maintenance function also involves looking after
the safety aspects of certain equipment where the
failure of component may cause a major accident.
For example a poorly maintained steam boiler ay
cause a serious accident.
30

DEFINING MAINTENANCE
Maintenance
work
raises
the
equipment
performance level and availability but adds to its
running cost.
It is the combination of repair, service or replace
the components of equipment in a plant or system.
The function of maintenance is to maximize the
availability of the equipment/ facility of production
or operational use.
31

RE-DEFINING
MAINTENANCE
Delivering Reliability

SOME HEURISTICS
The availability of a machine or service over a specified
time can be represented as

Where A is availability of the machine over a specified

time.
UT is the machine uptime over a specified time.
DT is the machine downtime over a specified time.
33

SOME HEURISTICS
The uptime of the machine is the time for which
it is actually available to complete the desired
function.
The downtime or outage of the machine is the
period of time during which it is not in an
acceptable working condition.
Practically, idle(ready) time and time for
operational and administration delays include.
34

SOME HEURISTICS
Availability of the equipment in
effectiveness called operational
expressed as:

terms of working
availability (OA)

OT= operating time

IT = idle time
AD= administrative and operational delays
RT= repair time.
35

SCOPE OF MAINTENANCE RESPONSIBILITIES

Primary Functions:
Maintenance of Existing Plant Equipment
Maintenance of Existing Plant Buildings and Grounds
Equipment Inspection and Lubrication
Utilities Generation and Distribution
Alterations and New Installations

Secondary Functions:
Storeskeeping
Plant Protection
Waste Disposal
Salvage
Insurance Administration
Other Services
(Maintenance Engg. Handbook; 7th Edition)

TYPES OF MAINTENANCE

ACTIVITY
Name three examples (Jobs/Tasks) of each
type of Maintenance

ASSIGNMENT
Identify the three types of maintenance
activities on:
1. Steam Turbine
2. Clarifier Desludging Pump
Deadline:
12 pm , Friday, 9th of September, 2016.