Traditional Definition of Maintenance

 Keeping equipment in repair

(Oxford)
 The act of causing to continue
(Websters)
 Maintenance Strategies
On Failure Condition Based
Fix it when it fails Maintain Based Upon
known Condition

Maintenance Plan

Fixed Time Design Out

Identify & design
Maintain Based upon
Out root cause of
Calendar
failure
 Run to Failure - Corrective

Consciously allowing equipment to run to

failure. No intervention is planned prior to
failure. (this means there that every failure is
planned - there are no unplanned failures.
Every corrective task has a pre-planned
action)
 Breakdown - Reactive

This is an unplanned, disruptive, interruption,

which is the most costly ineffective response
option. Allowing this to prevail as an existing
response increases the overall cost and
complexity of managing the system. (highly
undesirable)
 Advantages and Disadvantages
Advantages
• it requires no pre-care of the plant
• it requires little management apart from organizing labor and stores
• if applied correctly, it can be very cost effective
Disadvantages
• there is a need to provide standby plant if higher levels of availability are required - this can lead
to higher build costs
• it requires a large standby maintenance team - as you have no indication of what will fail, you
need a standby team ready to repair any of your equipment
• secondary or consequential damage may occur - a bearing failure may lead to the failure of the
shaft, followed by the pump, etc, which will lead to higher costs of spares and longer repair
times
• there is a requirement for a large spares stock to cater for any kind of failure that may occur
 Preventative Maintenance

Preventative maintenance is defined as regularly

scheduled repair of components and equipment. It
may consist of scheduled inspection, cleaning,
lubrication, parts replacement, and repair of
components. Preventative maintenance is time
based intervention according to a prescribed
schedule.
 Advantages And Disadvatages
Advantages
• it reduces failures (compared to the on-failure strategy)
• it uses the workforce cost-effectively with planned work schedules
• it allows work to be planned well in advance
• it can only be applied effectively on fixed time intervals where the
deterioration is age related
Disadvantages
• the maintenance activity and associated costs will increase
• the actual maintenance activity can sometimes cause failures itself
• may be replacing a component that still has useful life
 Predictive Maintenance

A process which requires technologies and people

skills which combines and uses all available
diagnostic and performance data, maintenance
histories, operations data and design data to make
timely decisions about maintenance requirements of
major / critical equipment.
 Advantages
• The advantages of utilizing the Predictive Maintenance strategy are many, some of
which are not so tangible - such as increased motivation of the workforce through
increased competency. The main advantage to Predictive Maintenance is that
impending equipment failure can be detected, which in turn provides the
following benefits:
• equipment can be shut-down before severe damage occurs
• alternatively, equipment can be run to failure if desired
• production can be modified to extend the unit life, for example, decrease the load
on equipment so that it can continue to run until the next planned plant shutdown
• the required maintenance work can be planned, with labor organized, spares
assembled, etc.
 Disadvantages
• following identification of the real root cause for failure, it is
possible to plan in design modifications if required
• Different organizations will present differing reasons for not
implementing Predictive Maintenance, but the only
disadvantage to the strategy is that:
• it is costly if implemented incorrectly
• That is, if condition monitoring is undertaken without an
understanding of the equipment, and not as a part of an
overall maintenance plan, then it is likely that it will fail, result
in expenditure, and lose credibility within the organization. To
succeed, Predictive Maintenance must be implemented
correctly within the improvement context and against a
complete understanding of the equipment, its failure modes,
and root causes.
 Proactive Maintenance

Elimination of conditional failures through the

identification of the root cause condition that
initiates the failure cycle.
 Advantages And Disadvantages
Advantages
• it is a one-off maintenance activity
• it reduces failures
• it will lead to increased production
• it will remove or reduce the need for maintenance
Disadvantages
• large design changes can be costly
• plant outages may be required to effect design changes
• unless root causes of failure are fully understood, changes may be ineffectual, or
potentially detrimental
• there are sometimes unknown ‘knock-on’ effects of design changes that can cause
further difficulties later on
 Opportunity Maintenance
Opportunity Maintenance is considered by many
to be an additional maintenance strategy. This is
where maintenance actions, whatever they may
be, are performed on a piece of equipment only
when the opportunity arises (i.e. when that piece
of equipment is non-operational for one reason or
another).
 Relative Costs of Maintenance ($/HP)

60

50

40

US $ 30

20

10

0
Breakdown Planned Predictive Proactive
Realtive Cost 51 30 12 7

ASME: Hudachek & Dodd

 Survey Results: Respondents Spending
Where Companies Focus Over 50% Man-hours on
Each Maintenance Type
Their Maintenance Efforts
All Industry Now

60
%
50

40

30

20

10

0
Reactive Preventive Predictive Proactive
 Survey Results: Respondents Spending
Where Companies Focus Over 50% Man-hours on
Each Maintenance Type
Their Maintenance Efforts
All Industry Now
All Industry in 5 years
60
%
50

40

30

20

10

0
Reactive Preventive Predictive Proactive

Source: Deloitte & Touche , CSI Survey

Bathtub Curve
Failure Patterns
 Maintenance Requirements First build the
Maintenance Requirements foundations

Determines the maintenance requirements of each

physical asset in its operating context

Reliability Centered Maintenance

19
 Systems

Skills Tools
Spares

Maintenance Requirements
Maintenance Requirements

20
 1930-1950 1951-1990 1991-2000

2nd Generation 3rd Generation

1st Generation
• Schedule Overhauls • Condition
• Fix it when Broke monitoring
• System for planning
and controlling • Design for reliability
work and maintainability
• Low-tech • Hazard studies
computerization • High-tech computers
• Failure modes and
effects analysis
• Expert systems
• Multiskilling and
team work
 TECHNOLOGIES

• Plant condition monitoring.

• Asset optimization.
• Non destructive Testing.
Why use vibration?

"Of all the parameters that can be measured

non-intrusively in industry today,
the one containing the most information
is the vibration signature."

Art Crawford
 Why use vibration – Three Facts
• All machines vibrate
• Developing machinery problem, generate
increase in vibration amplitude
• Each fault generate vibration with unique
characteristics
• Vibration …a technique to diagnose the
problems
 Condition monitoring is the study of conditions in machinery, which
indicate functional problem or developing failure.

 Avoid the consequences of failure, before the failure occurs.

 It is a tool that helps effectively manage site plant assets, logistics and
labor requirements.

 It is use of advanced technologies in order to determine equipment

condition, and potentially predict failure.
 To predict equipment failures

 To reduce the cost of Maintenance

 To improve equipment and component reliability

 To optimize equipment performance

 For a holistic view of equipment condition

 For greater accuracy in failure prediction

  Dye Penetrant Testing
Visual Inspection  Videoscope Inspection

 X-Ray Inspection
Radiographic Inspection  Neutron Imaging

 Magnetic Particle Inspection

Mag./Elec. Inspection  Eddy Current Testing

 Ultrasonic Testing
Ultrasonics  Acoustic Emission Testing

 Chemical Spot Testing

Chemical Inspection  Oil/Lube Analysis

 Infrared Thermography
Thermal Inspection

 Vibration Monitoring
Vibration Analysis  Spectrum Analysis

 Dynamic Field Balancing

Corrective Measurements
 Laser Alignment
The use of noninvasive techniques to determine the
integrity of a material, component or structure
(Inspect/Measure without doing harm)
 Test piece too precious to be destroyed
 Test piece to be re-use after inspection
 Test piece is in service
 For quality control purpose
And many others….

 Flaw/Leak Detection and Evaluation

 Location & Dimensional Measurements
 Structure and Microstructure Characterization
 Estimation of Mechanical and Physical Properties
 Material Sorting and Chemical Composition Determination
 What are Some Uses
of NDE Methods?
• Flaw Detection and Evaluation
• Leak Detection
• Location Determination
• Dimensional Measurements Fluorescent penetrant indication

• Structure and Microstructure Characterization

• Estimation of Mechanical and Physical Properties
• Stress (Strain) and Dynamic Response Measurements
• Material Sorting and Chemical Composition
Determination
 When are NDE Methods Used?
There are NDE application at almost any stage in the production or life
Cycle of a component.

– To assist in product development

– To screen or sort incoming materials
– To monitor, improve or control manufacturing
processes
– To verify proper processing such as heat treating
– To verify proper assembly
– To inspect for in-service damage
 Common Application of NDT
• Inspection of Raw Products
• Inspection Following Secondary
Processing
• In-Services Damage Inspection
Visual Inspection
Most basic and common
inspection method.

Tools include fiberscopes,

borescopes, magnifying
glasses and mirrors.

Portable video inspection unit

with zoom allows inspection
of large tanks and vessels,
railroad tank cars, sewer lines.

Robotic crawlers permit

observation in hazardous or
tight areas, such as air ducts,
reactors, pipelines.
 DPT is one of the most widely used Non Destructive Testing (NDT)
methods.
 DPT can be used to inspect almost any material provided that its surface
is not extremely rough or porous.
Materials that are commonly inspected using LPI include metals , glass,
many ceramic materials, rubber, and plastics.
 Magnetic particle inspection can detect both production discontinuities
and in-service damage in ferromagnetic materials.
 It works on principal of electromagnetism.
 A test specimen is magnetized with a strong magnetic field .
 If the specimen has a discontinuity, it will interrupt the magnetic field
and a leakage field will occur.
 X-Ray Source
 RT is based on the abruptness of
change in ‘γ’ or X-rays while Specimen
transferring from one medium to
X-Rays
another.

 Radiation is directed through a

part .

 The resulting shadowgraph shows X-ray film

the internal features and
soundness of the part.

 Material thickness and density

changes are indicated as lighter or
darker areas on the film.
Top view
Radiographic Images
 Eddy Current Testing

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
 In UT, very short ultrasonic pulse-waves having frequency range of 0.1-
15 MHz are injected into the specimen.
IRT is based on the principle that:
 Radiation can be detected in the infrared range of the electromagnetic
spectrum (9–14 µm) through thermal imaging camera.
 The amount of radiation emitted by an object increases with
temperature.
 Oil analysis (OA) is the laboratory analysis of a
lubricant's properties, suspended
contaminants, and wear debris.

 OA is performed during routine preventive

maintenance to provide meaningful and
accurate information on lubricant and machine
condition.

 By tracking oil analysis sample results over the

life of a particular machine, trends can be
established which can help eliminate costly
repairs and early Oil Change
 Fact – All machines vibrate to greater or lesser extent.
 Developing machinery problem, generate increase in vibration
amplitude.
 Each fault generate vibration with unique characteristics/pattern that
distinguish it from others.
 Examination of vibration spectrum indicates the type of fault.

After Repair

RMS (G’s)
Before Repair

Freq. (CPM)
 Fault – Unique vibration profile – Amplitude spikes after specific
intervals in the spectrum.
 For Example:
 Imbalance – 1 x Ts (Turning Speed)
 Misalignment – 2 x Ts
 Looseness – 3 x Ts

1X 2X 3X
• Force created when the center of mass is not the center of
rotation

Center of Mass = Center of Shaft

Heavy Spot

Center of Shaft
Center of
Mass

Rotation
• Increase machine life by.....
– Reduce cyclic fatigue on machine components
– Reduce heat from preloading and friction
– Lower vibration and noise levels
• Minimize shaft bending
• Life is extended dramatically with a slight alignment improvement!