Maintenance Engineering(ChE-405)

Dr Sikander Rafiq
Assoc. Professor
 Course Outline
 Introduction to maintenance engineering; maintenance concept,
objectives, challenges and benefits, MTTR, MTBF. Types of maintenance;
breakdown, planned, preventive, predictive, scheduled, corrective and
reliability-centred. Organization of maintenance. Scheduling of
maintenance. Internal maintenance and external maintenance. Inspection
techniques; non-destructive testing techniques. Total productive
maintenance (TPM); concept, objectives, implementation, eliminating
process losses, benefits and problems related to total productive
maintenance. Overall safety of plant and personnel. Impact of safety on
productivity. Safety equipment, fire fighting equipment and their uses.
Types of accidents in chemical industry. Govt. regulations for industrial
safety. Accident and loss statistical methods. Accident rate calculations.
Accident investigation and case history. Accident analysis and prevention.
Economics of accident prevention. Source models. Safety management
system; policy & planning, organization & communication, hazard
management and monitoring & review. Hazard and risk assessment.
Exposure to volatile toxicants, dust and noises. Fires and explosions; fire
triangles, flammability characteristics, preventions of fires and explosions.
TEXT BOOKS:
 Mobley, R.K. et al. Maintenance Engineering Handbook. 7th ed. McGraw Hill, 2008.
 Ben-Deya,M, Duffuaa.S.O, Abdul Rouf, Handbook of Maintenance Management and
Engineering
 Mishra R.C. and Pathak K. Maintenance Engineering and Management. Prentice-Hall of
India, 2002.
 Crowl, D.A. and Louver, J.F. Chemical Process Safety Fundamentals with Application. 3rd
ed. Prentice Hall, 2011.

REFERENCES:
 Bhattacharya S.N., “Installation, Servicing and Maintenance”, S. Chand and Co., 1995
 Higgins L.R., “Maintenance Engineering Hand book”, 5th Edition, McGraw Hill, 1988.
 Armstrong, “Condition Monitoring”, BSIRSA, 1988.
 Davies, “Handbook of Condition Monitoring”, Chapman & Hall, 1996. 6. “Advances in
Plant Engineering and Management”, Seminar Proceedings - IIPE, 1996.
 Duffua, S. O. et al. Planning and Control of Maintenance Systems: Modelling and
Analysis. 2nd ed. Springer, 2015
 Mobley, R.K. An Introduction to Predictive Maintenance. 2nd ed. Butterworth-Heinemann,
2002.
 Mobley, R.K. Maintenance Fundamentals. 2nd ed. Butterworth-Heinemann, 2004.
 Davis M.L. and Cornwell D.A. Introduction to Environmental Engineering. 5th ed. McGraw
Hill Inc., 2012.
 Masters, G.M. and Ela, W.P. Introduction to Environmental Engineering and Science. 3rd
ed. Prentice Hall, 2007.
 Maintenance Engineering
▪ It is the art that is intended to retain a machine or an
equipment or restore it to, a state in which it can perform a
required function or an operation.

▪ It is the discipline and profession of applying engineering

concepts to the optimization of equipments, procedures to
achieve better reliability and availability of equipments.

▪ It is the art, science and philosophy that aides in increased

productivity and has become the most important component
of plant maintenance.
 It’s purpose
▪ The main purpose of maintenance in an industrial perspective is
to reduce the business risks.
▪ Production capacity, productivity and business profit mainly
depends on maintenance operations.
▪ Its main purpose is to support ,configure, diagnose , repair,
update and mange a equipment throughout it’s life cycle.
▪ In general maintaining all equipments at its full functionality and
helping productivity is the main function of maintenance
engineering.
1. Attempt to maximize performance of production equipment
efficiently and regularly.
2. Prevent breakdown or failures.
3. Minimize production loss from failures.
4. Increase reliability of the operating systems.
▪ With the increased complexity, Sophistication and automation
of the equipments and systems , a heavy burden falls on
maintenance engineers regarding the quality and quantity of
maintenance , maintenance aids, documentation etc.,

▪ The current scenario is that today’s jobs and problems cannot

be solved with yesterday’s tools and techniques. So continuous
development is needed in maintenance areas to tackle today’s
need and also anticipated need of tomorrow.
 Principle Objectives in Maintenance
1. To achieve product quality and customer satisfaction through
adjusted and serviced equipment.
2. Maximize useful life of equipments.
3. Keep equipments safe and prevent from hazards.
4. Minimize frequency and severity of interruptions/shutdowns.
5. Maximize production capacity – through high utilization of
facility.
6. Minimising energy usage.
7. Identifying and implementing cost reductions.
8. Providing reliable cost and budgetary control
 Sound maintenance system-importance
▪ Profit depends mainly on return on the investments.

▪ Higher investments- possible –machineries and equipments in proper

working condition.

Some benefits of sound maintenance are,

➢ Minimization of downtime

➢ Provide Adequate back up supply

➢ Extended life of equipments

➢ Increased reliability of the system

➢ Safety of the personal involved.

Machine Failures
 Maintenance Objectives
PLANT
Maximising
Maximising Reduce
Production
Production M Breakdowns
A
Minimising Energy I Reduce
Usage N Downtime
T
Optimising Useful Improving
Life of Equipment
E Equipment Efficiency
N
Providing Budgetary A Improving Inventory
Control N Control
C
Optimising Resources Implementing Cost
E
Utilisation Reduction
 Types of Maintenance

• Run to Failure Maintenance (RTF)

• Preventive Maintenance (PM)

• Corrective Maintenance (CM)

• Improvement Maintenance (IM)

• Predictive Maintenance (PDM)

 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) .. (contd.)

• 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. This
approach of maintenance is extremely expensive. The
following factors contribute to high cost.
• poor planning
• Incomplete repair
 Run to Failure Maintenance (RTF) .. (contd.)
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.
Benefits
This type of maintenance is useful in the following situations:
1. The failure of a component in a system is unpredictable.
2. The equipment failure priority is too low in order to include
the activities of preventing it within the planned
maintenance budget.
• 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. It is intended to
reduce the probability of failure.
• It is designed for day to day maintenance like cleaning
inspection, lubricating etc. to retain healthy condition.
Benefits
The advantage of applying preventive maintenance activities is to
– Prevent the equipment from bigger problems
– Prolong the effective life of the equipment
– Detect the problem at the earlier stages
 Preventive Maintenance (PM) .. (contd.)
• 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.
The activities include replacements, adjustments, major overhauls, inspections
and lubrications.
 Preventive Maintenance (PM) .. (contd.)
Preventive maintenance are further divided into different kinds
according to the nature of its activities:
• Routine/Scheduled maintenance which includes those
maintenance activities that are repetitive and periodic in
nature.

• Good example of PM program is car maintenance. After so

many kilometers or miles oil should be changed, parts
renewed.

• Running maintenance which includes those maintenance

activities that are carried out while the machine or
equipment is running mode. e.g greasing, tightening of
loose nut and bolts, cleaning, and small adjustment.
 Preventive Maintenance (PM) .. (contd.)
• 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. E.g standby unit.

• Shutdown preventive maintenance, which is a set of

preventive maintenance activities that are carried out when
the production line is in total stoppage situation.
• These are performed generally after three or six months.
• These involves the inspection of plant items which are
known or suspected to occur.
 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.
• It also include the different types of actions like typical
adjustment of redesign equipment.
It 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.

• 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).. (contd.)

• 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) ..(contd.)
• The way to perform corrective maintenance activities is by
conducting four important steps:
1. Fault detection.
2. Fault isolation.
3. Fault elimination. (adjusting, aligning, calibrating, removing, replacing etc.)
4. Verification of fault elimination.
Corrective maintenance has several prerequisites in order to be
carried out effectively:
1. Accurate identification of incipient problems.
2. Effective planning (depends on the skills, well developed database about
standard time to repair and the required labour skills, specific tools, parts and
equipment.)
3. Proper repair procedures.
4. Adequate time to repair.
5. Verification of repair.
 Improvement Maintenance (IM)
• It aims at reducing or eliminating entirely the need for
maintenance.
Improvement 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.
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.
 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.
Predictive maintenance is classified into two kinds according to
the methods of detecting the signs of failure:
• 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 precise recording of the stoppages of
the in-plant items and components in order to develop
models for predicting failures.
 Predictive Maintenance (PDM) ..(contd.)

• 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 - OUT
BASED BASED
SERVICES

WINDOW RUNNING ROUTINE OPPORTU- SHUTDOWN SHUTDOWN SHUTDOWN

NITY PREVENTIVE IMPROVEMENT CORRECTIVE
 NOTE

STUDENTS ARE REQUIRED

TO APPLY THESE TYPES OF
MAINTENANCE TO CHEMICAL
INDUSTRY
Nature of Maintenance Problems
General Classification Maintenance Problems
Machine Failures
 Maintenance Economics
Life Cycle Cost Analysis
 The factors to be considered in the purchase of equipment for industries
include the cost, quality, performance and maintenance requirements.
 Life cycle costing is the cost analysis for the equipment over a span
of time which includes the capital cost, operating cost and maintenance
costs. It leads to selection of proper and economically viable equipment.
Maintenance cost
-Difficult to measure due to random nature of failures.
-records on maintenance history can be used .
Component of Maintenance Cost :
 Fixed Cost includes the cost of support facilities, including the
maintenance staff.
▪ Variable cost includes the consumption of spare parts, components
replacements etc.
 All buildings & capital assets go through a life cycle process during the
course of their life.
 In the asset life cycle class, there are three different phases identified
based on studies.
 Almost all the equipment, that operates under normal distribution
curve (over 99.0%) goes through the following three phases. As per
Six Sigma & Statistical studies, 95% of the universal processes go
under normal distribution curve (bell curve).
 Phase-1 "Start-Up Cycle": Failures occur on materials,
workmanship, installation, and/or operator mis-handling on new
equipment. Some of the costs are partially covered by equipment
warranty. By the nature of this life cycle, there is a lack of
historical data.
 The failures are very hard to predict or plan for, and it is difficult
to know which parts / components to be kept in stock (for back
filling in case of failure)
 Preventative Maintenance Standards are developed in this cycle.
This period could last from one day to several years on a complex
system. Be vigilant in monitoring the mis-application (the wrong
machine for the right job), inadequate engineering and
manufacturer deficiencies.
 Phase-2 "Wealth Cycle": This cycle is where the organization
makes money on the useful output of the machine, building, or other
asset.This cycle is also called the “usage cycle”.

 Phase-3 "Breakdown Cycle": This is the cycle that organizations

find themselves 'in', when they do not follow a good Preventative
Maintenance (PM) practice.
 Phase-3 is characterized by wear out failures, breakdowns, corrosion
failures, fatigue, downtime, and other general headaches
 Parts usage change as we move more deeply into life cycle 3.
 The parts tend to be more in number, bigger, more expensive, and
harder to get.
 The goal of most maintenance operations is to identify when an asset is
slipping into this Phase-3 and fix the problems.
 Fixing the problem will result in the assets moving back to life cycle 2,
which is getting back to Wealth Cycle mode.
End of unit 1
Determining the Frequency of Performing PM
 First, compute the expected number of breakdowns for each
PM policy.
 Next, compute the expected breakdown cost, preventive
maintenance cost, and total cost for each PM policy.
 Finally, identify the policy that minimizes the total cost per
unit of time (say, per week).
 Expected Number of Breakdowns
n
B n = N( p n ) + B(n −1) p1 + B(n − 2) p 2 + ... + B1p (n −1)
1

where:
Bn = expected number of breakdowns for each of the PM policies
pn = probability that a breakdown will occur between PM inspections when
PM is performed every n periods
N = number of machines in group
Example: PM Frequency
It costs $6,000 to perform PM on a group of four
machines. The cost of down time and repairs, if a machine
malfunctions between PM inspections, is $8,000.
How often should PM be performed to minimize the
expected cost of malfunction and the cost of PM?
 Machine Breakdown History

Weeks Probability That a

Between PM Machine Will Malfunction
1 0.2
2 0.3
3 0.5
 Solution: n n
B n = N( p n ) + B(n −1) p1 + B(n − 2) p 2 + ... + B1p (n −1)
BB1 n==4(0.2) n ) + B (n −1) p1 + B (n1 − 2) p 2 + ... + B1p (n −1)
N( =p0.800
B2 = 4(0.2 1+ 0.3) + 0.8(0.2) = 2.160
B3 = 4(0.2 + 0.3 + 0.5) + 2.16(0.2) + 0.8(0.3) = 4.672
Exp. Weekly
PM Exp. Number Exp. Weekly Total
Every number of BDs Cost of Cost Weekly
nWks. Of BDs per Wk. BDs of PM Cost
1 0.800 0.800 $6,400 $6,000 $12,400
2 2.160 1.080 8,640 3,000 11,640
3 4.672 1.557 12,456 2,000 14,456

The policy that minimizes total weekly cost is: perform PM every 2
weeks.