PREVENTIVE MAINTENANCE AND CONDITION MONITORING

Maintenance
Machines fail; hence, maintenance is required to

1. Prevent unexpected breakdown

2. Increased equipment life
3. Ensure stable operations
Types
1. Breakdown maintenance
2. Preventive/proactive maintenance
3. Precision maintenance
4. Condition based maintenance
5. Proactive condition based maintenance
Breakdown Maintenance

• Cons of reactive maintenance

• Costly
• Secondary damage
• High production downtime
• Cost of keeping spares
• Overtime labour cost
Precision Operation & Proactive Maintenance

• Performing action that reduce the likelihood of failure i.e

• operating equipment properly
• carrying out the proactive maintenance tasks i.e cleaning and lubrication.
• Should be performed no matter what.
• Concerns with the elimination of root cause of failure
 
Precision Maintenance

• Reducing the likelihood of infant mortality by incorporating practices that ensure

proper installation of new equipment in the plant
Condition Based Maintenance

• Test the condition of the equipment to determine if failure will occur in the
foreseeable future
Proactive Condition Monitoring

• Test the condition of the equipment to determine if there is problem which may
cause the machine to fail.
Reliability Centered Maintenance
• Process to determine which maintenance strategy is most effective
and cost efficient for an equipment.
Examples
Breakdown maintenance: Filter bags
Preventive maintenance: Lubricants for smaller sumps as per OEM
Condition based maintenance: Bearings, Gears, Raw mill main drive
Preventive Maintenance
• OEM prescribed routine inspections
• E.g. Fastening of pulley bearing housing of belt conveyors &
Temperature(allowable 60⁰) on monthly basis
• Check rubber lining(lagging) of the pulley of belts conveyors
• Machine to be operated as per the set standards
• OEM prescribed replacement of equipment after specific/fixed
interval e.g. lubricants
Condition Monitoring
• Why condition monitoring?
Condition Monitoring
Machines indicates signs of failures before failing.
CM METHODS
1. Data collection for Vibration
• Fault condition detectable with vibration
• Bearing problems: both journal and rolling element bearings
• Unbalance
• Misalignment
• Looseness
• Soft foot
• Electric faults
• Eccentric motors
• Belt and coupling problems
• Gear mesh
• Broken rotor bar
Ultrasound Testing
• Rotating equipment and other plant assets emit high frequency
sounds that provide clues to potential problems
Ultrasound Testing
Thermography
• Study of radiated energy using thermal infrared imaging system
• Study of change of temperature due to leaks, wear, electrical arcing, etc.
• Suitable for the inspection of piping and steam traps
Thermography
Thermography Limitations And Rectification
• Infrared camera detects
• Reflected heat
• Transmitted heat
• Emitted heat
• To generate reliable results
• Emissivity must be greater than 0.6
• Background must be known or controlled
• No/controlled wind
Oil Analysis

Note: Oil analysis only determines

the oil condition whereas “WEAR
PARTICLE ANALYSIS” helps to relate
the oil condition with machine
health.
Wear Particle analysis
• Different wear particle size indicates the cause
Maintenance Inventory Management
• Maintenance inventory refers to all the inventories of spare parts,
components that support the manufacturing process, but are not
included in the final product.
Maintenance Inventory Management
Aim is to ensure the stock availability when required.
Lower inventory levels
Lesser or no production loss
Holding Inventory Costs
• Carrying cost
• Storage cost
• Risk cost
Maintenance Inventory Management
Maintenance Inventory Management
1. Deciding Min & Max
i. Criticality
ii. Installed quantity
iii. Consumption trend
iv. Procurement trend
v. Related equipment health
Consumption Trend
Q&A
THANK YOU