Reliability and Safety Engineering

Course Overview Intro. to Maintenance Management Preventive Maintenance Predictive Maintenance Conditioned Based Maintenance Fault Tree Analysis FMECA Reliability Centered Maintenance

Course Overview Introduction to Reliability Engineering Reliability Measures System Reliability Reliability Allocation Safety Engineering

Course Overview 2 Assignment 2 Tests

Books
Effective Maintenance Management by V.Narayan

maintenance
It is the combination of all technical and administrative actions, including supervision intended to retain an item in or restore it to a state in which it can perform a required function. All actions which keep the system running and ensures that it is maintained at an acceptable standard

objectives
To reduce the consequences of failure To extend the life of a system by keeping the system in a proper condition for a longer time > increase uptime of a system To ensure that the system is fit and safe to use To maintain the value of the system To maintain reliability and achieved a high level of safety. To maintain the system availability, therefore, minimise prod and quality losses To reduce the overall maintenance cost.

Maintenance function
Two function: Basic Composite

Basic function
Replace > to remove an unserviceable part and install a new one. Repair > to correct specific damage or fault or malfunction. overhaul > to restore an item to a completely serviceable or operational condition. Rebuild > recondition, renovate Service/ lubricate > to clean, to drain, to lubricate Inspect > to determine the serviceability of an item by comparing its physical, mechanical characteristic thru examination.

Basic function(cont)
test > to verify serviceability by measuring mechanical characteristic with prescribed standard. adjust > to bring into a proper or exact position. install > to fix into position an item.

Composite function
Protecting building, plants and structures. Reducing downtime and increasing equipment availability. Controlling and directing labour forces. Maximising utilisation of available resources. Utilisation is the proportion of time that the equipment is working out of the total time that the equipment is available. Ensuring safety of installation and reducing environmental pollution. Preparing maintenance budgets. Training of personel.

2 Maintenance Types
Preventive Maintenance to prevent failure Corrective Maintenance - repairs after failure

Preventive Maintenance
2 types: Systematic maintenance specified components are replaced at regular intervals. E.g, gearbox oil, filter, spark plugs .. Conditional based maintenance the decision to replace or not to replace is made according to the outcome of a diagnostic study. Example, analysis of oil, vibration monitoring.

Maintenance costs
Maintenance costs includes all money spent on keeping the system up to an acceptable standard. Preventive maintenance cost total cost of maintenance resources needed to inspect or replace an item before failure takes place. Corrective maintenance the total cost of maintenance resources needed to repair or to replace failed items.

Maintenance Costs
Cost (Rs) Minimum Total Cost of Repairs

Total Costs Cost of preventive maintenance Cost of breakdown/downtime

0 Level of maintenance

What are the Maintenance resources?

Maintenance supply support- these include consumables spare parts. Maintenance tool and support equipment- tools and calibration equipment. Maintenance personnel- eg technicians, engineers Maintenance technical data include manuals Maintenance facilities incl labo, workshop Maintenance computer resources software, databases

Maintenance Strategy
4 types of maintenance strategies: Breakdown maintenance- operate to failure and replace Planned maintenance Preventive or Fixed Time maintenance. Condition Based Maintenance Design out maintenance

Breakdown Maintenance
Operate to failure and replace

Advantages Breakdown Maintenance

Simple planning- work is not scheduled until it is really needed.

Disadvantages Breakdown Maintenance

Failure can occur at any time(full load) May lead to expensive damage A large breakdown personnel may need to be available on standby A large spares stock is necessary Therefore, appropriate when consequences of failure is small

Planned/Preventive/Fixed Time Maintenance

Maintenance is scheduled in advance to prevent failure. It is therefore assumed that component life is predictable.

Advantages
More effective use of time. Spares are only ordered as required. This strategy avoid failures

Disadvantages
Components may not fall according to a fixed time period Failure may still occur. Many components are replaced much before the end of their life. Plant failure data is not always available, so it will be difficult to predict component life. This strategy is effective when the failure mechanism is time dependent.

Condition Based Maintenance

It is a maintenance strategy used to avoid failures by detecting early machine deterioration. It monitors a m/c parameter which is indicative of m/c health and conditions, and uses this parameter to trigger maintenance action

Advantages
Failure rate is reduced > improving plant availability and reliability. Inconvenient breakdowns and expensive consequential damages are avoided. Better planning of repairs is possible. Reduced spares inventory. Unnecessary works are avoided.

Disadvantage
Expensive strategy because of high cost involved in monitoring equipments and cost of monitoring and analysis. This strategy should be used in critical plants. The criticality of plants is decided on: safety, capital value and potential for production loss or service loss.

Design-out Maintenance
The aims is to eliminate the cause of maintenance. It requires engineering action rather than maintenance action. for ex, redesigning This is usually the policy for areas of high maintenance cost which exist either because of poor design or because the equipment is being used outside its design specs.