MAINTENANCE AND

SAFETY ENGINEERING
B.Tech./ MECHANICAL/IV/VIII SEM

Mr.A.BHOJAN

Achariya College of Engineering Technology

(Approved by AICTE and affiliated to Pondicherry University)

An ISO 9001:2008 Certified Institution

Achariyapuram, Villianur, Puducherry 605 110.
www.acet.edu.in
(For internal circulation only)

MET82 MAINTENANCE AND SAFETY ENGINEERING (3 0 0 3)

Unit I
Objectives of maintenance - types of maintenance Breakdown, preventive and
predictive maintenance - Repair cycle - Repair Complexity, Lubrication and
Lubricants. Maintenance of Mechanical transmission systems and process
plants.(12hours)
Unit II
Predictive Maintenance - vibration and noise as maintenance tool - wear debris
analysis -Condition monitoring concepts applied to industries - Total Productive
Maintenance (TPM) -Economics of Maintenance- Computer aided maintenance.
(12 hours)
Unit III
Reliability: Definition, concept of reliability based design, failure rate, MTTF, MTBF,
failure pattern, system reliability: Series, Parallel and Mixed configurations Availability and Maintainability concepts- Applications.(12 hours)
Unit IV
Safety and productivity - causes of accidents in industries accident reporting and
investigation -measuring safety performance - Safety organizations and functions Factories act and rules.(12 hours)
Unit V
Safety Codes and Standards - General Safety considerations in Material Handling
equipments -Machine Shop machineries-pressure vessels and pressurized pipelines
welding equipments operation and inspection of extinguishers prevention and
spread of fire emergency exit facilities. (12 hours)
Text Books :
1.P.Gopalakrishnan - Maintenance and Spare parts Management, Prentice Hall of
India Pvt. Ltd., New Delhi, 1990.
2.L.S.Srinath - Reliability Engineering, Affiliated East West press, 2003
3. Rolland P.Blake - Industrial Safety, Prentice Hall of India Pvt. Ltd., New Delhi, 1973.
Reference Books :
1. R.C. Mishra and K. Pathak, Maintenance Engineering and Management, Prentice
Hall of India
Pvt. Ltd., New
Delhi, 2002.
2. H.P. Garg, Industrial Maintenance, S Chand & Co Ltd., New Delhi, 1990.
3. E. Balagurusamy, Reliability Engineering, Prentice Hall of India P Ltd., New Delhi,
2003.

CHAPTER NO
UNIT-1
1.1
1.2
1.2.1
1.2.1.1
1.2.1.2

TITLE
MAINTENANCE
MAIINTENANCE
OBJECTIVES
MAINTENANCE TERMS
MAINTENANCE
MAINTENANCE

PAGE NO
2
2
3
3
3

ENGINEERING
1.2.1.3
1.2.1.4
1.2.1.5
1.2.2
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.4
1.5
1.6
1.7

MAINTENANCE CONCEPT
MAINTENANCE PLAN
MAINTENANCE PERSON
MAINTENANCE FUNCTION
TYPES OF MAINTENANCE
CORRECTIVE
MAINTENANCE
PREVENTIVE
MAINTENANCE
PREDICTIVE MAINTENANCE
ZERO HOUR MAINTENANCE
PERIODIC MAINTENANCE
BREAKDOWN
MAINTENANCE
PREVENTIVE
MAINTENANCE
PREDECTIVE
MAINTENANCE
REPAIR CYCLE

3
3
3
3
2
4
4
4
4
5
5
5
6
7

1.8
1.9
1.9.1
1.9.2
1.9.3

LUBRICANTS
LUBRICATIONS
THICK FLIM LUBRICATIONS
THIN FLIM LUBRICATIONS
EXTERME PRESSURE
LUBRICATIONS

7
8
8
8
8

1.10

MAINTENANCE OF
MECHANICAL
TRANSMISSION SYSTEMS
AND PROCESS PLANTS

1.10.1

GOOD MAINTENANCE
PRACTICE OF GEARS
MAINTENANCE PRACTICE
OF GUIDE WAYS
MAINTENANCE PRACTICE
OF BEARINGS

PREDECTIVE
MAINTENANCE

12

1.10.2
1.10.3
UNIT -2
2.1

9
10

2.2
2.3
2.4
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.5.8
2.6
2.7
UNIT-3
3.1
3.2
3.3
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
UNIT-4
4.1
4.2
4.3
4.4

VIBRATION AND NOISE AS

MAINTENANCE TOOL
WEAR DEBRIS ANALYSIS

12

CONDITION MONITORING
CONCEPTS APPLIED TO
INDUSTRIES
TOTAL PRODUCTIVE
MAINTENANCE
5S
JISHU HOZEN
KAIZEN
PLANNED MAINTENANCE
QUALITY MAINTENANCE
TRAINING
OFFICE TPM
SAFETY, HEALTH AND
ENVIRONMENT
ECONOMICS OF
MAINTENANCE
COMPUTER AIDED
MAINTENANCE

16

14

17
18
19
22
24
25
26
27
30
30
31

RELIABILITY
INDICES OF RELIABILITY
FAILURE RATE
CALCULATING SYSTEM
RELIABILITY
AVAILABILITY AND
MAINTAINABILITY
CONCEPTS

34
34
35
37

CONCEPT DEVELOPMENT
IN MAINTAINABILITY
VALIDATION IN
MAINATAINABILITY
PRODUCTION IN
MAINATAINABILITY
OPERATION IN
MAINATAINABILITY

40

SAFETY AND
PRODUCTIVITY
CAUSES OF ACCIDENT IN
INDUSTRIES
ACCIDENT REPORTING AND
INVESTIGATION
MEASURING SAFETY
PERFORMANCE

43

38

40
40
40

43
43
45

4.5
4.6
UNIT-5
5.1
5.2

5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.6.3
5.7

SAFETY ORGANIZATIONS
AND FUNCTIONS
FACTORIES ACT AND
RULES

47

SAFETY CODES AND

STANDARDS

53

GENERAL SAFETY
CONSIDERATIONS IN
MATERIAL HANDLING
EQUIPMENTS
MACHINE SHOP
MACHINERIES
PRESSURE VESSEL AND
PRESSURIZED PIPELINE
WELDING EQUIPMENTS
PREVENTION AND SPREAD
OF FIRE
LIQUEFIED PETROLEUM
GAS
EMPLOYEE TRAINING

56

FIRE EXTINGUISHERS
EMERGENCY EXIT
FACILITIES

47

58
60
63
64
65
66
67
67