MAIN T EN A N C E

ENG I NE E R IN G
INTRODUCTION
SYLLABUS OF MAINTENANCE ENGINEERING
MAIN T EN A N C E
ENG I NE E R IN G
MODULE 1
 MAINTENANCE ENGINEERING

•MAINTENANCE IS THE ROUTINE AND RECURRING PROCESS

OF KEEPING A PARTICULAR MACHINE OR ASSET IN ITS
NORMAL OPERATING CONDITION SO THAT IT CAN DELIVER
THE EXPECTED PERFORMANCE OR SERVICE WITHOUT ANY
LOSS OR DAMAGE
 IMPORTANCE AND BENEFITS OF SOUND
MAINTENANCE SYSTEM
1. MINIMIZATION OF DOWNTIME
2. IMPROVEMENT IN AVAILABILITY OF SYSTEM
3. EXTENDED LIFE OF EQUIPMENT
4. SAFETY AND SMOOTH OPERATION OF THE PROCESS
5. MINIMIZATION OF NORMAL EXPECTED WEAR AND TEAR OF EQUIPMENT
6. SAFETY OF THE PERSONAL INVOLVED IN THE ORGANIZATION
7. INCREASING THE RELIABILITY OF THE SYSTEM
 TYPES OF MAINTENANCE SYSTEM
• THERE ARE TWO TYPES OF MAINTENANCE SYSTEMS
1. BREAK DOWN MAINTENANCE
2. PLANNED MAINTENANCE
1. PREVENTIVE MAINTENANCE
2. PREDICTIVE MAINTENANCE
3. CORRECTIVE MAINTENANCE
4. CONDITION BASED MAINTENANCE ( CBM )
5. RELIABILITY CENTRED MAINTENANCE ( RCM )
 BREAKDOWN MAINTENANCE

• IN THIS TYPE , LESS IMPORTANCE GIVEN TO THE OPERATING CONDITION OF CRITICAL MACHINERY OR
PARTS

• NO MAITENANCE WORK IS CARRIED OUT IN ADVANCE TO PREVANT THE FAILURE

• REPAIR IS TAKEN UP AFTER BREADOWN
 ADVANTAGES DISADVANTAGES

1. DIFFICULT TO CONTROL BUDGETS

1. LOWER THE INITIAL COST

2. SAFETY ISSUES
2. IT REQUIRES FEW STAFF

3. SHORTER LIFE EXPECTANCY OF ASSETS

3. THERE IS NO PLANNING NEEDED

4. TIME CONSUMING
 TYPES OF MAINTENANCE SYSTEM
• THERE ARE TWO TYPES OF MAINTENANCE SYSTEMS
1. BREAK DOWN MAINTENANCE
2. PLANNED MAINTENANCE
1. PREVENTIVE MAINTENANCE
2. PREDICTIVE MAINTENANCE
3. CORRECTIVE MAINTENANCE
4. CONDITION BASED MAINTENANCE ( CBM )
5. RELIABILITY CENTRED MAINTENANCE ( RCM )
 OBJECTIVES OF PLANNED MAINTENANCE

• TO SIMPLIFY COMPLEX MAINTENANCE TASKS

• TO FACILITATE THE SCHEDULING AND CONTROLLING OF MAINTENANCE ACTIONS
• TO FACILITATE AN EFFECTIVE QUALITY ASSURANCE PROCESS
• TO FORECAST AND PLAN MANPOWER AND MATERIAL REQUIREMENTS
• TO PROVIDE A READILY MANAGEABLE MAINTENANCE PROGRAMS
 COMPARISON BETWEEN BREAKDOWN AND PLANNED
MAINTENANCE
Breakdown maintenance Planned maintenance
1.Maintenace is carried out after the machine fails 1.Maintenance is carried out before the machine fails

2.Less manpower required 2.More manpower is required

3.It reduces the equipment life 3.It increases the equipment life

4.Start –up cost is less 4.Start –up cost is more

 PREVENTIVE MAINTENANCE
• IT IS A MAINTENANCE PROGRAM WHICH IS COMMITTED TO THE ELIMINATION OR PREVENTION OF CORRECTIVE AND BREAKDOWN MAINTENANCE

• ELEMENTS OF PREVENTIVE MAINTENANCE

1. INSPECTION
2. SERVICING
3. CALIBRATION
4. TESTING
5. ALIGNMENT
6. ADJUSTMENT
7. INSTLLATION
 Advantages Disadvantages

1.It keeps the equipment in good condition 1.Catastrophic failures still likely to occur

2.It detects the problem at earlier stages 2.Performance of maintenance based on schedule is
not required

3.It keeps equipment safer 3.Labour intensive

4.It greatly reduces unplanned downtime 4.It included performance of unneeded maintenance

5.It reduces the equipment or process failure 5.Risk of damage when conducting unneeded
maintenance
 PREDICTIVE MAINTENANCE

• IT IS A METHOD IN WHICH THE SERVICE LIFE OF IMPORTANT PART IS PREDICTED BASED ON

INSPECTION OR DIAGNOSIS IN ORDER TO USE THE PARTS TO LIMIT OF THEIR SERVICE LIFE
• THE AIMS ARE
• 1.PREDICT WHEN EQUIPMENT FAILURE MIGHT OCCUR
• 2. TO PREVENT OCCURRENCE OF THE FAILURE BY PERFORMING MAINTENANCE
 Advantages Disadvantages
1. It reduces breakdown losses 1.The cost of condition monitoring equipment needed
for predictive maintenance is often high

2. It reduces the maintenance cost of the equipment 2.Skill level and experience required to accurately
interpret condition monitoring data are also high

3.It reduces the total maintenance time of equipment 3.Investment on diagnostic equipment for predictive
maintenance is high

4. It improves safety and environment

5.Product quality is better

6.It increases net operating profit

 CORRECTIVE MAINTENANCE

• IT IS DEFINED AS THE MAINTENANCE CARRIED OUT TO RESTORE THE UNSERVICEABLE EQUIPMENT

THAT HAS STOPPED WORKING TO ACCEPTABLE STANDARDS
• MAIN OBJECTIVES ARE
• 1. ELIMINATE BREAKDOWNS
• 2.ELIMINATE DEVIATION FROM OPTIMUM OPERATING CONDITIONS
• 3.ELIMINATE UNNECESSARY REPAIRS
 Advantages Disadvantages

1.It lowers the short – term costs 1.It increases long – term costs due to unplanned
equipment downtime

2. It requires less staff 2.It is prone to neglect of assets

 COMPARISON BETWEEN PREDICTIVE &
CORRECTIVE MAINTENANCE
Predictive maintenance Corrective maintenance

1.Initially equipment is assessed to predict when the 1.Maintenance is carried out to restore the
equipment failure might occur and then maintenance is unserviceable equipment that has stopped working to
performed to prevent occurrence of failure acceptable standards

2.It is done before the problem occur 2. It is done after the problem occur

3.Highly skilled manpower is required 3. Less skilled manpower is sufficient

4.It reduces the breakdown losses 4.It increase the breakdown losses

5.It increase the equipment life 5.It reduces the equipment life
CONDITIO N B A S ED &
R ELI A B I LI T Y C E N T RE D
MAIN T EN A N C E
MODULE 1
 CONDITION BASED MAINTENANCE ( CBM)

• IT IS A MAINTENANCE STRATEGY THAT MONITORS THE ACTUAL CONDITION OF THE

ASSET TO DECIDE WHAT MAINTENANCE NEEDS TO BE DONE
• IN THIS TYPE ,THE MAINTENANCE IS PERFORMED AFTER ONE OR MORE INDICATORS
SHOW THAT EQUIPMENT IS GOING TO FAIL OR THAT EQUIPMENT PERFORMANCE IS
DETERIORATING
 CONDITION BASED MAINTENANCE TECHNIQUES
1. VIBRATION MONITORING
2. THERMOGRAPHY
3. TRIBOLOGY – DYNAMIC CONDITION OF BEARING LUBRICATION ETC...
1. LUBRICATING OIL ANALYSIS
2. SPECTROGRAPHIC ANALYSIS
3. WEAR PARTICLE ANALYSIS
4. ELECTRICAL MOTOR ANALYSIS
5. VISUAL INSPECTION
 Advantages Disadvantages

1.it reduces the cost of asset failures 1.Condition monitoring test equipment is expensive to
install and databases cost money to analyse

2. It improves the equipment reliability 2.There is a need of knowledge professional to

analyse the data and perform the work

3.It maintenance the time spent on maintenance 3.Uniform wear failures are not easily detected with
CBM measurements

4.It minimizes the requirement for emergency spare 4.Condition sensors may not survive in the operating
parts environment

5.It improves worker safety 5.Maintenance periods are unpredictable

RELIABILITY CENTERED MAINTENANCE (RCM)

• IT IS ONE OF WELL –ESTABLISHED SYSTEMATIC AND A STEP - BY –STEP INSTRUCTIONAL TOOL

FOR SELECTING APPLICABLE AND APPROPRIATE MAINTENANCE OPERATION TYPES
• THE FOUR PRINCIPLES THAT ARE CRITICAL FOR A RCM PROGRAM AS FOLLOWS
1. IT PRESERVES SYSTEM FUNCTION
2. IT IDENTIFIES FAILURE MODES THAT CAN AFFECT THE SYSTEM FUNCTION
3. IT PRIORITIZES THE FAILURE MODES
4. IT SELECTS APPLICABLE AND EFFECTIVE TASKS TO CONTROL THE FAILURE MODES
 Advantages Disadvantages

1.It increases equipment availability 1.It can have significant start –up cost ,training ,equipment

2.It increases component reliability 2.Savings potential is not readily seen by management

3.It lowers the cost by eliminating unnecessary

maintenance

4. It incorporates root cause analysis

LUBRIC A T IO N &
CLASS IF I C A T IO N
MODULE 1
 LUBRICATION

•TO REDUCE THE POWER LOSS AND ALSO WEAR AND TEAR
OF MOVING PARTS , A FOREIGN SUBSTANCE CALLED
LUBRICANT IS INTRODUCED IN BETWEEN RUBBING
SURFACES .THE LUBRICANT KEEPS THE MATING SURFACES
APART
 OBJECTIVES OF LUBRICATION
1. COEFFICIENT OF FRICTION COULD BE REDUCED
2. HEAT WILL BE REDUCED
3. WEAR OF THE SURFACES COULD BE REDUCED
4. REDUCE OXIDATION AND RUST FORMATION
5. PROVIDE INSULATION IN TRANSFORMER APPLICATION
6. TRANSMIT MECHANICAL POWER IN HYDRO FLUID POWER SYSTEMS
7. SEAL AGAINST DUST ,DIRT AND WATER
 FUNCTIONS OF LUBRICATION

1. IT REDUCES FRICTION BETWEEN MOVING PARTS

2. IT REDUCES WEAR AND TEAR OF THE MOVING PARTS
3. IT MINIMIZES THE POWER LOSS DUE TO FRICTION
4. IT PROVIDES THE COOLING EFFECT
5. IT REDUCES NOISE
 LUBRICANTS

• ANY MATERIAL USED TO REDUCE FRICTION BETWEEN WEARING SURFACES WITH HIGH COEFFICIENT
OF FRICTION BY ESTABLISHING LOW-VISCOUS ( SHEAR STRENGTH ) FILM ARE CALLED LUBRICANTS

• TYPES OF LUBRICANTS
• SOLID LUBRICANTS – SOAP ,MICA ,ETC…
• HEAVY LOAD – GRAPHITE
• LIQUID LUBRICANTS – OIL
• GAS LUBRICANTS – AIR ,NITROGEN AND HELIUM
 METHODS OF LUBRICANTS

1. HYDROSTATIC LUBRICATION
2. HYDRODYNAMIC OR FLUID FILM LUBRICATION
3. BOUNDARY LUBRICATION
4. ELASTO HYDRODYNAMIC LUBRICATION ( EHD )
5. EXTREME PRESSURE ( EP ) LUBRICATION