Maintenance Engineering

NIGERIAN SOCIETY OF ENGINEERS
MANDATORY CONTINUING
PROFESSIONAL EDUCATION
COURSE MATERIAL ON
MAINTENANCE ENGINEERING
AUTHOR : Engr. Prof. L. O. Adekoya : 2017 REVIEWER : Engr. Mrs. N. S. E. EZIOKWU Page 1
TABLE OF CONTENT
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 SOME TERMS USED IN DISCUSSING MAINTENANCE . . . . . . . . . . . . . . . . . . . 2
3.0 TYPES OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Improvement Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0 IMPLICATIONS OF POOR OR NO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .6
5.0 RESOURCES NEEDED FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Human Resources (Personnel) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Financial Resources (Money) . . . . . .. . . . . . . . . . . . . . . . . . . . . . 7
5.3 Material Resources (Equipment) . . . . . . . . . . . . . . . .. . . . . . . . . 7
5.4 Time Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5 Storage of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.0 CONTROL OF MAINTENANCE COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.1 Costs of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2 Labour Cost . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Delays, Administrative Bottle-necks, Etc . . . . . . . . . . . . . . . . . . . .8
6.4 Improper Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.5 Maintainability of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7.0 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.0 MAINTENANCE ENGINEERING BREAKOUT SESSIONS . . . . . . . . . . . . . . . . . . . . 9
8.1 ELECTRICAL ENGG. : ELECTRICAL TRANSFORMER . . . . . . . 9
8.2 CIVIL ENGINEERING : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
8.2.1 MAINTENANCE OF HIGHWAYS . . . . . . . . . . . . . . . . . . . . . . . .11
8.2.2 MAINTENANCE OF CONCRETE MIXER . . . . . . . . . . . . . . . 11
MAINTENANCE ENGINEERING
Engr. Mrs. N. S. E. EZIOKWU
NSE Hq., NEC, Abuja
1.0 INTRODUCTION
Maintenance is the art of keeping of facilities and equipment in a specified
operating condition.
The major objectives of maintenance include the following:
(i) To extend the useful life of the system. This is particularly important in
developing countries where there is a scarcity of capital funds for
replacement.
(ii) To assure the optimum availability of the system for service or production
and obtain maximum possible return on investment.
(iii) To ensure the safety of personnel using the facility or equipment.
2.0 SOME TERMS USED IN DISCUSSING MAINTENANCE
Breakdown: A collapse or shutdown in duty that puts the system, plants and
machinery in a state of non functional status
Consumables: Materials usedup during the equipments operation, for example,

fuel and engine oil in a car.
Failure: Inability to perform the basic function, or to perform it within specified

duration.
Installation: That period of initial setup, adjustment and checkout of equipment in

the customers environment.
Mean Time Between Failures (MTBF): The average time/distance/events an

equipment delivers between breakdowns.
Spares: Components, assemblies, and equipment that are completely

interchangeable with like items and can be used to replace items removed
during maintenance.
Troubleshooting: Locating or isolating and identifying discrepancies or

malfunctions of equipment and determining the corrective action required.
3.0 TYPES OF MAINTENANCE
Maintenance can be broadly divided into three major types: Corrective Maintenance
Improvement Maintenance, and Preventive Maintenance. See Figure 1 below.
MAINTENANCE
PREVENTIVE CORRECTIVE IMPROVEMENT
PERIODIC PREDICTIVE
ROUTINE SCHEDULED Condition Monitoring OnCondition Monitor

(Condition Monitor)
Figure1: Types of Maintenance
3.1 Preventive Maintenance
These are actions performed in an attempt to keep a machine in a specified

operating condition, by means of systematic inspection, detection and prevention of
incipient failures.
Preventive maintenance is advantageous because it prevents failure at very
inopportune times, injury to personnel, and costs less than repair. On the other
hand, many organizations do far too much scheduled maintenance and thereby
induce problems and incur excessively high costs.
Preventive maintenance could be subdivided into:
Periodic Maintenance and
Predictive Maintenance
These subgroups can be further respectively subdivided into :
Routine Maintenance
Periodic Preventive
Maintenance Scheduled Maintenance
Condition Monitoring (or Condition Monitor)

Predictive Preventive
Maintenance OnCondition Maintenance
3.1.1 Periodic Preventive Maintenance
i. Routine Preventive Maintenance

These are maintenance operations, not involving disassembly or replacement of
components and comprising mainly of cleaning and adjustments, that are
carried out regularly such as every hour or everyday or every week.
ii. Scheduled Maintenance

This is maintenance in which preventive activities are scheduled for fixed
intervals that are much longer than routine intervals. Moreover these activities
include oiling, greasing, adjustments, replacement of parts, etc. This type of
maintenance may be due to government regulations, scheduling of downtime
around production operations, availability of special personnel or simply the
need for a finite standard that can be understood by everyone involved e.g. oil
changes.
There are advantages in scheduling a fixed time for preventive maintenance. All
the necessary personnel, parts, tools, and information may be scheduled and
made available so that there are no delays. Coordination with production and
other organizations may be accomplished. A typical scheduled maintenance is
turnaround maintenance of refineries.
3.1.1 Predictive Preventive Maintenance

i. Condition Monitoring (or Condition Monitor) Maintenance
This is a selfscheduled, machinecued predictive maintenance that is based on
the periodic, and sometimes continuous, measurement of one or several
parameters of condition in an equipment such that a significant change is
indicative of a developing failure.
Examples are:
Measurement of the viscosity of engine oil in a working machine and
The amplitude of vibration of rotating machinery.
The evolutions o f t h e se p a r a me t e rs a r e considered to be representative of
the actual condition of the machine. Nevertheless, a deviation from a reference
value (e.g. temperature, viscosity, or vibration amplitude) must occur to
identify impending damages. In failure detection, the emphasis is on inspection
and test, since that is the best way to determine if warning signs of impending
failure are occurring.
In order for condition monitoring to be effective, the failure must not be

catastrophic. The pay-off from inspection is best with a slow wear-out situation.
ii. OnCondition Maintenance

Oncondition maintenance is a type of maintenance based on previous database of
failures of the system to predict when increasing failures of certain types may be
alleviated by preventive maintenance. It is necessary to establish targets and run
frequency ratios on failure rates and parts usage that may indicate problem
areas.
The Weibull distribution is particularly useful for projecting the point at which
maintenance should be done in order to head off future failures. With
sophisticated data processing systems, it is possible to evaluate a specific
machines performance and potential failures based on the machines use,
environment, operator skill, and other influencing conditions.
3.2 CORRECTIVE MAINTENANCE

These are operations carried out to restore a machine to operative condition
after a breakdown, accident, wear, etc. Since these activities are generally not
known in advance, and therefore cannot be scheduled, they are often referred to
as Unscheduled, Emergency or Repair maintenance.
3.3 IMPROVEMENT MAINTENANCE

These are modifications, retrofits or redesigns in order to achieve better
maintenance. The objective is the same as that of reliability, that is, to reduce, or
even eliminate the need for maintenance. For example, air flow can be diverted so
that components are more adequately cooled and (therefore) subjected to less
environmental contamination or overheating. This results in less frequent
maintenance.
4.0 IMPLICATIONS OF POOR OR NO MAINTENANCE

Poor maintenance or non-maintenance could lead from minor to serious
injuries to the operator or user of equipment. It could also lead to expensive
repairs. As shown in Table 1 below, preventive maintenance is definitely better
than corrective maintenance.
Table 1: Implications of poor or no maintenance of a car :
S/N Maintenance task Cost of Probable Cost of
preventive consequences consequence
Maintenance of not carrying
N out task N
1 Checking of engine oil 500.00 Knocking of 25 000.00 +
level engine
2 Changing of engine oil 1 500.00 Knocking of 25 000.00 +
engine
3 Checking of coolant 500.00 Knocking of 25 000.00 +
level engine
4 Checking of braking 500.00 Brake failure Writing-off
system Injuries/Death
5 Checking of brake 500.00 Brake failure Writing-off
fluid level Injuries/Death
5.0 RESOURCES NEEDED FOR MAINTENANCE

The resources needed for equipment maintenance are H u m a n ; F inancial;
M aterial and Time. To obtain effective plant maintenance the resources have to
be provided in the right mix.
5.1 Human Resources (Personnel)

Personnel include E ngineers; Technicians; Craftsmen and Artisans. They need
regular capacitybuilding through selfstudy; Onthejob training; External
Training and retraining on some relevant technical/engineering p r o c e d u r e s .
5.2 Financial Resources (Money)

Effective equipment maintenance is more costeffective than nonmaintenance.
Funds are needed to set up a workshop; recruit and maintain the personnel;
purchase the necessary maintenance tools; buy the needed spare parts and
maintenance consumables such as solvents and lubricants.
5.3 Material Resources (Equipment)

For a typical business organization with a production plant, where much
equipment has to be maintained, a Maintenance Department (with a standard
Workshop) is the ideal. Such a workshop needs a full complement of test (or
diagnostic) and repair tools. The maintenance Department may also need
supportive equipment such as vehicles to reach locations and/or to move
personnel and maintenance tools around.
5.4 Time Resources

Time is needed to inspect equipment, source for spare parts, disassemble,
replace/repair, reassemble, and test equipment.
5.5 Storage of Spare Parts
For ease of identification and retrieval, it is recommended that spare parts be
stored in properly labelled open shelves or bins.
6.0 CONTROL OF MAINTENANCE COSTS

Control of maintenance Costs is geared towards optimizing maintenance costs
rather than holding them to a minimum. The interplay of the following factors
control maintenance costs.
6.1 Costs of Spare Parts

High cost of spare parts will increase maintenance cost while low spare parts
cost will reduce maintenance costs. The cost of spare parts can be controlled by
bulk-purchasing (when feasible), checking pilfering and proper inventory control.
6.2 Labour Cost

The cost of labour depends on whether Work is done by staff members or by
external contractors, the competence of the maintenance crew, etc. The cost of
labour can be controlled by proper personnel training, adequate supervision of
personnel and assigning work to competent personnel.
6.3 Delays, Administrative Bottle-necks, Etc

Delays and administrative bottle-necks result in increased downtime. These could
be due to waiting for funds to be released or waiting for spare parts. Delays,
administrative bottle-necks, etc. can be controlled by proper inventory control to
reduce downtime due to waiting for repair, and proper planning of maintenance.
6.4 Improper Use of the Equipment

Improper use of the equipment will lead to frequent malfunctions and
breakdowns. It is therefore necessary to properly train equipment operators in
order to control maintenance costs.
6.5 Maintainability of the Equipment

The maintainability of equipment is the inherent characteristic of a design or
installation that determines the ease, economy, safety, and accuracy with which
maintenance actions can be performed. It determines the ability to restore a
product to service or to perform preventive maintenance within required limits.
Maintainability is not within the control of the end-user of the equipment.
However, the effects of maintainability could be controlled by proper equipment
selection.
REFERENCES
1. Bruel and Kjaer, Ref. Bulletin No. BO 0094 11 Vibration measurement

in predictive maintenance pages 3 11.
2. John Deere, 1973. Fundamentals of Machine Operation:
Preventive Maintenance. John Deere Publications.
3. Patton, J. D. J., 1980. Maintainability and Maintenance Management.
The Instrument Society of America, pages 8 19.
8.0 MAINTENANCE ENGINEERING BREAKOUT SESSIONS
8.1 ELECTRICAL ENGINEERING : ELECTRICAL TRANSFORMER

Preventive maintenance strategies that identify and cure potential problems
before they affect operation or longevity have been developed such as oil
sampling; electrical test; safety maintenance and visual inspection. Together,
these methods provide the information to analyze the condition of transformers
and switchgear and to determine the steps needed to assure reliability and top
performance.
Electrical Testing
Electrical tests accurately measure these important values:
Insulating value of insulation (DC Megger)

Resistive and Capacitive loss (DC Hipot)
Power Factor (tests of transformers & bushings)
Relationship of primary and secondary voltages (TTR)
Trip levels and accuracy of relays and low, medium and high voltage circuit
breakers
Test results are compared to manufacturers specifications and/or performance
standards set by NETA, IEEE and NEMA, and establish a baseline for
comparison with future tests.
Repairs or calibration needed to bring equipment
into specification can be easily identified, and post
repair testing assures that proper corrective action
has been taken.
In many cases, testing identifies the need for

simple repairs and adjustments that preclude
costly repairs and downtime in the future.
Tests Performed
The suite of tests include the following: Equipment Used
Dielectric Absorption Microprocessor based circuit breaker
Insulation resistance test, winding-to- test sets for high current injection
winding and winding-to-ground. 5KV Insulation Resistance testers
Turn to Turn Ratio Test: to determine actual Automated Insulation Power Factor
vs. calculated voltage Test Set
Power Factor Test: to assess condition of Protective Relay Test Set
electrical insulation in high voltage Digital Low Resistance Ohmmeters
apparatus 10KV automated power factor test
set
Breaker and Relay Maintenance Unit (RMU) tests Turn to Turn Ratio Test Set
of contact resistance, conductivity, insulation
resistance, current and /or voltage trip levels
correct load inbalance and disconnections.
REPAIRS
Breakers and relay test processes compares the performance of the transformer to
manufacturers maintenance specifications. In addition to testing, technicians perform onthe
spot repairs such as:
Cleaning cubicles
Burnishing and adjusting contacts
Lubricating moving parts
Retrofitting trip units
Repairing faulty subassemblies
8.2 CIVIL ENGINEERING :
8.2.1 MAINTENANCE OF HIGHWAYS
Maintenance of Highways is preserving and keeping each type of roadway, roadside,
structures as nearly as possible in its original condition as constructed or as subsequently
improved and the operation of highway facilities and services to provide satisfactory and
safe transportation.
The various maintenance functions include :
1. Surface maintenance
2. Roadside and drainage maintenance
3. Shoulder and approaches maintenance
4. Bridges Maintenance
5. Traffic Maintenance
(i). Highway maintenance is closely related to the quality of construction of original

road.
(ii). Insufficient pavement or base thickness or improper construction of these
elements soon results in expensive patching or surface repair.
(iii). Shoulder care becomes a serious problem where narrow lanes force heavy
vehicle to travel with one set of wheels off the pavement.
(iv). Improperly designed drainage facilities give rise to erosion or deposition of
material and costly cleaning operation or other corrective measures.
(v). Sharp ditches and steep slopes require manual maintenance as compare to cheap
maintenance of flatter ditch and soil by machine
8.2.2 MAINTENANCE OF CONCRETE MIXER

Maintenance of concrete mixer generally includes five (5) points :
1). Check and clean the concrete mixer ;

2). Check the link status between the mixing arm and leaves;
3) Check reducer;
4) Check running condition of the concrete plant ;
5) Lubricate the two ends of main shaft bearing and the discharging door;
The Technical staff should follow the following requirements during the maintenance of the
corresponding mixer:
1) Concretes and other dirt adhering inside and outside the concrete mixer should be cleaned
after each shift working, and then washing with saline water;
2) Weekly check the concrete bonding status inside concrete plant and the cement adhesion
condition on the spray pipe. Cut off the power to eradicate if necessary;
3) Check connecting screws and ensure no loosening and serious wear, otherwise, that will cause
accident;
4) Check temperature rise of the drive motor after each shift working, if the motor is
overheating, trouble shoot and uncover the reason before the mixer malfunctions.
5) When the concrete mixer works, it should be smooth without abnormal sound; the
discharging door should start or close easily, tight closing, no leakage.
6) Ensure you lubricate the machine after each shift working.

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NIGERIAN SOCIETY OF ENGINEERS

2.0 SOME TERMS USED IN DISCUSSING MAINTENANCE . . . . . . . . . . . . . . . . . . . 2

3.0 TYPES OF MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 IMPLICATIONS OF POOR OR NO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .6

5.0 RESOURCES NEEDED FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.0 CONTROL OF MAINTENANCE COSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.0 SOME TERMS USED IN DISCUSSING MAINTENANCE

Consumables: Materials usedup during the equipments operation, for example,

Failure: Inability to perform the basic function, or to perform it within specified

Installation: That period of initial setup, adjustment and checkout of equipment in

Mean Time Between Failures (MTBF): The average time/distance/events an

Spares: Components, assemblies, and equipment that are completely

Troubleshooting: Locating or isolating and identifying discrepancies or

PREVENTIVE CORRECTIVE IMPROVEMENT

ROUTINE SCHEDULED Condition Monitoring OnCondition Monitor

Figure1: Types of Maintenance

3.1 Preventive Maintenance

These are actions performed in an attempt to keep a machine in a specified

Preventive maintenance could be subdivided into:

Periodic Maintenance and

Condition Monitoring (or Condition Monitor)

3.1.1 Periodic Preventive Maintenance

i. Routine Preventive Maintenance

ii. Scheduled Maintenance

3.1.1 Predictive Preventive Maintenance

In order for condition monitoring to be effective, the failure must not be

ii. OnCondition Maintenance

3.2 CORRECTIVE MAINTENANCE

3.3 IMPROVEMENT MAINTENANCE

4.0 IMPLICATIONS OF POOR OR NO MAINTENANCE

5.0 RESOURCES NEEDED FOR MAINTENANCE

5.1 Human Resources (Personnel)

5.2 Financial Resources (Money)

5.3 Material Resources (Equipment)

5.4 Time Resources

6.0 CONTROL OF MAINTENANCE COSTS

6.1 Costs of Spare Parts

6.2 Labour Cost

6.3 Delays, Administrative Bottle-necks, Etc

6.4 Improper Use of the Equipment

6.5 Maintainability of the Equipment

1. Bruel and Kjaer, Ref. Bulletin No. BO 0094 11 Vibration measurement

8.0 MAINTENANCE ENGINEERING BREAKOUT SESSIONS

8.1 ELECTRICAL ENGINEERING : ELECTRICAL TRANSFORMER

Electrical tests accurately measure these important values:

Insulating value of insulation (DC Megger)

In many cases, testing identifies the need for

(i). Highway maintenance is closely related to the quality of construction of original

8.2.2 MAINTENANCE OF CONCRETE MIXER

1). Check and clean the concrete mixer ;

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