CHAPTER 1

1. CHAPTER 1

2. MAINTENANCE “Act of causing to continue ” [New Oxford Dictionary]

3. TRADITIONAL DEFINITION : • “The combination of all technical and associated actions intended to retain an item in, or, restore it to a state in which it can perform its required function”. CURRENT DEFINITION : • “All actions that are carried out to safeguard the technical integrity of an asset and to ensure its availability such that maximum cash returns can be realized from the asset thereby enhancing the value of the asset”.

4. ROLE OF MAINTENANCE • Preserve and prolong the working life of plant and equipment. • Upkeep and protection of plant, buildings, machinery and other fixed assets. • Safeguard investment by minimising deterioration. • Keep the assets in efficient working condition. • Ensure reliability of plant and equipment. • Minimise idle time and loss of production. • Maximise efficiency through optimum use of facilities. • Generate a safe and healthy, working environment and maintain safety consciousness. • Minimise maintenance cost. • Improve performance of plant and machinery. • Keep abreast of latest maintenance techniques and achieve excellence to meet the new challenges.

5. NEED FOR MAINTENANCE • To keep assets in top condition. • To avoid failures. • To minimize hazardous situations. • To correct deterioration. • To modify plants. • To generate safe working conditions. • To obtain on grade products. • To increase productivity. • To reduce wastage of material & parts. • To reduce manufacturing cost. • To add in high quality & economical operation.

6. INCREASES CASH MARGIN INCREASES SALES AND REVENUE BUSINESS OBJECTIVES REDUCES OPERATING COSTS INCREASES PRODUCTION INCREASE RESERVES HIGH FACILITY AVAILABILITY COST EFFECTIVE MAINTENANCE Maintenance is a key element in the organisation’s value chain

7. TYPES OF MAINTENANCE BREAKDOWN MAINTENANCE • This is a PANIC or CRISIS maintenance • It is not desired at all in today's environment

8. TYPES OF MAINTENANCE BREAKDOWN MAINTENANCE • BATH TUB CURVE • Infantile Deaths • Wear-out Stage • Abnormal Operations • DISADVANTAGES • Uncertain - Occurrence & Repairs • Uncertain Production • Costly Repairs • Unsafe Situation

9. TYPES OF MAINTENANCE PREVENTIVE MAINTENANCE This is a systematic and planned attention, monitoring and analysis. It is most effective if there is strong age related failure mode. The guiding principle is “Prevention is better than cure” Objectives of Preventive Maintenance are • Retard process of deterioration and wear • Asses extent of deterioration • Action to restore original capacity • Improve reliability and maintainability of equipment thus eliminating breakdown

10. TYPES OF MAINTENANCE PREVENTIVE MAINTENANCE EXAMPLES • Visual External Inspection • Lubrication Replenishments • Strainer Cleaning • Painting • Adjusting Belt Tension Preventive Maintenance Programme

11. TYPES OF MAINTENANCE ADVANTAGE OF PREVENTIVE MAINTENANCE • Less down time • Fewer repetitive repairs • Lower repair cost than breakdown repair cost • Superior quality control • Increased life of plant and equipment • Need of standby equipment reduced • Reduction in maintenance cost • Leveled workload and workforce • Better spares control • Enhanced safe working conditions • Increase in production

12. TYPES OF MAINTENANCE PREDICTIVE MAINTENANCE By predictive maintenance equipment condition can be known during normal operation through : • Online monitoring, measurements, ND testing, etc. • Health of equipment can be predicted with certainty and necessary corrective actions generated • The result of predictive maintenance can be extrapolated to determine useful residual life • Leading to prediction of approximate date of failure

13. TYPES OF MAINTENANCE PREDICTIVE MAINTENANCE EXAMPLES • Ultrasonic thickness measurements • On-line vibration measurements • Measurement program • Testing lubricating oil / hydraulic oil

14. TYPES OF MAINTENANCE POPULAR PREDICTIVE MAINTEANCE TECHNOLOGY TECHNOLOGY APPLICATIONS • All rotary equipment • All rotary equipment • Critical rotary equipment • Critical & low speed equipment • Electrical components,insulation • Motor stator and insulation • Break down • Motor rotor bars, eccentricity • Steam traps, vacuum leaks • Pipe and vessel thickness • Process or mechanical • Degradation • Iodic vibration analysis • Vibration analysis • On-line vibration analysis • Oil sample analysis • Thermography • Motor stator analysis & elect. • - Surge testing • Motor current signature analysis • Air borne ultrasonics • Pulse-echo ultrasonics • Process parameters

15. TYPES OF MAINTENANCE PROACTIVE MAINTENANCE Proactive Maintenance emphasizes on • Root Cause Failure Analysis • Precision repairs and installation • Training of maintenance and operational personnel • Review and correct purchase specification Proactive maintenance is easily integrated with predictive maintenance and completes the platform needed for Reliability Centered Maintenance program

16. TYPES OF MAINTENANCE ADVANTAGES OF PROACTIVE MAINTENANCE • Repetitive problems that shorten component life are identified and designed out • This can include standards placed on suppliers for performance acceptability of their products/services, and verification that these are met • Assuring that equipment installation is done to precision standards (Balancing, Aligning) leading to extended life • Factors limiting component life are identified and eliminated • Reliability centered maintenance program

17. TYPES OF MAINTENANCE ROOT CAUSE FAILURE ANALYSIS PROACTIVE MAINTENANCE PREDICTIVE MAINTENANCE BREAKDOWN MAINTENANCE PREVENTIVE MAINTENANCE RELIABILITY CENTERED MAINTENANCE