Purpose of maintenance: 08-01 -2019

Plant maintenance is an important service of an efficient production system. It helps in maintaining and
increasing the operational efficiency of plant facilities. It may report the break down or after the break down.
Plant maintenance usually refers the methods, strategies, and practices use to keep an industrial factory
running efficiently. This can include anything from regular checks of equipment to make sure they are running
properly. The general aim of plant maintenance is to create a productive working environment that is also safe
for workers.
MAINTENANCE OBJECTIVES:
 To increase functional reliability of production facilities.
 To maximize the useful life of the equipment.
 To maximize the production capacity from the given equipment.
 To maximize the total production cost.
 To minimize the frequency of interruption in production by reducing the break down.
 To enhance the safety of man power.
IMPORTANCE OF MAINTENANCE:
 It helps in identify the cause of failure whether the failure is due to cause of deign effect or a wear out failure.
 It also helps in deciding the type of maintenance, maintenance decisions, like replace and repair.
 It provides the necessary information regarding the life and reliability of the equipment.
 With the help this tool spear part management got initiated.
TYPES OF MAINTENANCE:
 Planned maintenance
 Un planned maintenance
PLANNED MAINTENANCE.
 Preventive maintenance
 Corrective maintenance
 Predictive maintenance
UN PLANNED MAINTENANCE
EMERGENCY MAINTENANCE
Preventive maintenance
a. Running maintenance b. shutdown c. schedule
Corrective maintenance
a. Breakdown b. shutdown
PLANNED MAINTENANCE.
In planned maintenance the maintenance action is carried out with some fore thoughts, prior planning, record
keeping, and control actions.
PREVENTIVE MAINTENANCE;
It is based upon the principal that prevention is better than cure. It is the set of activities that are perform on
the plant equipment, machinery and system before the occurrence of the failure in order to protect them and
to prevent or eliminate any degradation in their operating conditions or the maintenance carried out at
predetermine intervals or according to prescribe criteria and intended to reduce the probability of the failure
or the degradation of the functioning and the effect limits.
RUNNING MAINTENANCE.
It includes those maintenance activities that are carried out while the machine or equipment is running e.g.
lubrication, adjustment of nuts, and screw, tightening of loose nuts and bolts.
SCHEDULED MAINTENANCE
It is any variety of scheduled maintenance to an object or item of equipment specially planned maintenance is a
scheduled service visit carried out by a competent and suitable person to ensure that an item of the equipment is running
correctly and therefor avoid any unscheduled brake down and down time.
 SHUTDOWN MAINTANENCE. 09-01-2019
It is the set of preventive maintenance activities that are carried out when the production line is in total
stoppage situation. These are perform generally after three, six or twelve months. These involve the inspection
of plant items which are known or suspected to occur.
CORRECTIVE MAINTENANCE
In this type action 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.
The difference b/w corrective and preventive maintenance is that
for corrective maintenance the failure should occur before any corrective action is taken. It is of two types
1. Breakdown maintenance
2. Shutdown maintenance
BREAKDOWN MAINTENANCE
It is an emergency policy in which the plant or equipment is operated until fails and then it is brought back
into running condition by repair. The maintenance staff locate any mechanical, electrical or any other fault to
correct it immediately.
PREDICTIVE MAINTENANCE
As the name shows it involve the prediction of failure before it occurs, identifying the root cause for the failure,
symptoms and eliminating those causes before they result in extensive damage of the equipment. This type of
maintenance perform continuously or at intervals according to the requirement to diagnose and monitor a
condition or a system.
UN PLANNED MAIMTENANCE:
Maintenance action which is carried out without any fore thoughts or a prior planning s called UN planned
maintenance. Emergency maintenance is one of the example of UN planned maintenance. In this type of
maintenance, the maintenance action is executed with the help of all available resources in least possible time
without any major time lag. 29-01-2019
NAYURE OF MAINTENANCE PROBLEMS:
 General classification of maintenance problems
1. Mechanical failure
2. Thermal failure
3. Chemical failure
 Classification of maintenance problems based on time span.
1. Short run maintenance problems
2. Long run maintenance problems
MCHANIAL FAILURE
Worn out bushes and bearings, and other moving parts.
 Fatigue of machine members
 Creep of other material on high temperature
 Excessive vibration or misalignment
THERMAL FAILURE
 Overheating of the components
 Lack of vibrations
 In adequate of cooling
 Electrical insulations
CHEMICAL FAILURE
 Highly corrosive fluid containing abrasive particles
 Failure of protective lining like glass or rubber materials etc.
CLASSIFICATION OF MAINTENANCE PROBLMA BASED ON TIME SPAN.
 Short run maintenance problems
Maintenance problems which are carried out in a short period of time are known as short run
maintenance problems. It may be hourly, daily, weekly, and monthly.
HOURLY
Inspection of correct lubricant, level of coolant, and sharpness of cutting tools
 DAILY
Cleaning of machines, tightening of nuts, correct cooling, inspection of various indicators, and minor
adjustment of parts.
WEEKLY
Major adjustment, lubrication, tightening of parts
MONTHLY
Checking for insulation, safety guards, corrosion, and checking of worn out and distorted parts.
PROCEDURE OF PREVENTIVE MAINTENANCE
 Job identification by preparing of facility engineer
The very first step is to prepare the facility register which
defines that what to be maintain.
 Preparation of maintenance schedule
1. In this step we prepare a maintenance schedule. It is simply a comprehensive list of all incidents and their
time of incidence.
2. It gives the useful information regarding the method, time and place of maintenance work.
3. It also provides information about maintenance and man power requirement.
4. It gives the various detail regarding maintenance like what, when, how, where.
PREPARATION OF HISTORY CARDS
It not only gives the useful information about result of maintenance events but
also furnish the essential detail regarding the usage of machine free of failure and failure mode.

PREPARATION OF JOB SPECIFICATION

 In this step the job specification is prepared. It is simply a document which provide the essential
information regarding the maintenance work to be done.
 In general practice these job details are specifications compiled from maintenance schedule.
 They are means of communicating the engineer requirement to guide the worker
 They are prepare separately for each job
PREPARATION OF MAINTENANCE PROGRAMMNG
1. It is an essential list which allocate specific maintenance work to specific period
2. In order to apply the job specification the maintenance program is generally prepared for long run when
the machine oblique equipment are to be inspected.
3. It is not a good practice because an industry can’t prepare a long run production well in advance since too
many factors arise and they will result into change in production and maintenance requirement.
4. It presents the overall picture o present and future maintenance commitments.
PREPARATION OF WEEKLY, MONTHLY MAINTENANCE PROGRAM
The maintenance program includes the following topics
 Re conditioning or replacing the lubricating oil.
 Repairing and replacing worn out parts and tools
 Checking all electrical connections of the system
 Checking the control system
 Checking the performance of each part
 Cleaning the interior like spark plug, filter, indicator, crank case, and cylinders.
PREPARATION OF INSPECTION REPORT
This step is followed after the maintenance program is over. This is simply a document which furnishes
the useful information about maintenance, inspection which were perform in the past.
PREPAIRING THE MAINTENANCE REQUEST.
1. The next step under plant maintenance procedure is to preparation of maintenance request. It is simply a
document or various maintenance suggestions and recommendations given by the inspection report.
2. Suggestion are the useful feedback information that come from user end worker.
FEEDBACK MECHANISM
 It is the last step the application of corrective and control actions are available
on the basis of feedback mechanism. These corrective actions should be apply to response plant facilities at
the initial sage of maintenance planning or design.
SCHEDULE OF PREVENTIVE MAINTENANCE
It is simply a comprehensive list of all the incidents and their time of incidence. It gives the following useful
information regarding the maintenance work.
 What is to be done
 How is to be done
 When is to be done
SCHEDULING INDICATORS
Within the maintenance strategy you can use different scheduling indicators to
specify the type of scheduling you require
 Time based e.g. every 30 days
Time base by ley date
 e.g. every 30 day on the 30th day of the month
Time base by factory cylinder
 e.g. every 30 working days
Performance based
 every 50 operating hours or 100 operating hours
Maintenance activities that must be perform at the particular date or time are combined to maintenance
package
MAINTENANCE OF PRESSURISE VESSEL
Package 1.
Routine inspection monthly
Package 2.
Pressure check every six month
Package 3.
General checkup every 2 years
TOATL PRODUCTIVE MAINTEANCE 30-01-2019
T.P.M originated in japan in 1971 as a method for improved machine availability through better utilization of
maintenance and production resources.
 It can be considered as a medical science of machines.
 TPM is the maintenance program which involve a newly define concept for maintaining plant and
equipment.
 The goal of TPM program is to increase production while at the same time increasing the employ morale
and job satisfaction.
 TPM brings maintenance into focus as a necessary and vitally important part of the business.
 It is no longer regarded as the known profit activity.
 Do time for maintenance is scheduled as a part of manufacturing date and in some case as an integral part
of the manufacturing process.
 The goal is to hold emergency and shutdown maintenance to a minimum.
WHY TPM
TPM was introduced to achieve the following objectives
1. Avoid wastage in quickly changing economic environment
2. Producing goods without reducing product quality
3. Reduce cost
4. Produce a low batch quantity at the earliest possible time
5. Goods sent to the customer must be non-defective
COCCULUSION
 Today with competition in industry at all time high TPM may be only thing that stands b/w success and
total failure
 It has been proven to be a program that works. It can be adopted to work not only in industrial plants but
in construction, building management, transportation and in a variety of other situations
 If everyone involved in the TPM program does his or her part, and usually high rate of return, compare to
other sources invested may be expected.
PUMP MAINTENANCE
Pump is machine that convert mechanical energy into fluid energy. The fluid being incompressible ther are
two basic types of pumps
 Centrifugal or axial
 Reciprocating and rotary pump
MAINTENANCE PHILOSOPHY
Maintenance is done on the machine in order to improve system reliability.
PUMPS MAJOR COMPONENTS
Shaft, impeller, wear rings, stiffing box, diffuser, casing bearings.
FAULTS
Shaft run out, checks are made to determine the roundness conditions in the shaft, whether the shaft is
concentric or not. Run out occur due to
 Machining process
 Dent from handling
 Rust patches
 Rotor bow or sag due to thermal effects gravity or other loads.
BEARING
Defective or worn bearings in the machine or lathe spots. Providing support to the shaft for smooth running.
Lubrication prevents metal-metal contacts. Thrust bearing are used to compensate axial load. Bearing
inspection is very important during pump maintenance.
CAUSES OF BEARING FAILURE
Flaking, rust and corrosion, loss of lubrication.

Facts about corrosion 13-02-2019

 It is a natural process.
 It is an electrochemical process.
 It is reverse of extraction of matter and also known as weeping of matters.
 It leads to tremendous loss and it cannot be eliminated, however its extent can be minimized.
Methods to control corrosion;
 Design of structures.
 Material selection.
 Cathodic protection.
 Reduce the activity of cathode and electrolyte (polarization)
 Protection of anode(passivation)
 Alteration of the environment.
 Inhibitors
 Protective coating
Design of structure;
 Avoid sharp corners
 Complete draining of vessels
 Avoid sudden changes in suction
 Avoid contact b/w dis similar metals
 Weld rather than rivet
 Avoid excessive mechanical stress
Material selection
I. Metallic
Metal and alloy
II. Non metallic
Rubber, plastic, carbon, ceramics, graphite and wood.
Improvements of materials;
 Purification of metal.
 Making more noble by using platinum in titanium
 Passivating by adding chromium on steel

Inhibiting
Adding arsenic and anti-money in brass.
Cathodic protection.
It is a technique to control the corrosion of a metal surface by making it work as a cathode of a
electrochemical cell. This is achieved by placing in contact with the metal to be protected another more easily
corroded meal to act as the anode of the electrochemical cell. Cathodic protection system are most commonly
used to protect steel, water or fuel pipe lines and storage tanks.
19-02-2019
Polarization.
This is an effect which reduces the actual chemical potential deriving of the cell. If the thermodynamic force
deriving the ion into the solution is reduced, this is polarization. Example: by lowering the electrolyte
temperature we find that it is usually less corrosive.
Inhibitors.
These are the chemicals which slow corrosion some of them do this by promoting the polarization of the
cathode.
Environment factors effecting the corrosion.
 Dust particles and manmade pollution (nitrogen oxide, methane etc.)
 Temperature (high temperature and high humidity accelerate corrosion)
 Excess washes and rain fall
 Air pollution.
Inhibitors:
These are the material that may be injected into the system. They played out on the surface and inhibit the
information of corrosion cell. They are commonly used in pipe lines and other vessels that contain material
that are corrosive. Some metals such as gold and platinum corrode very slowly or not at all. Choosing a
corrosion resistant material can reduce rate of corrosion.
Overall plant safety and personals
Why work safely;
Work safely for most important people in your life that is your family. Work related injuries cause not only
time away from production activities at work but also time away from activities with your family.
What is working safely?
 Wearing required (PPE)
 Completing every task in correct way not taking hazardous short cuts.
 Paying attention to task
 Asking for instructions when completing unfamiliar task.
Use of fork lift or man lift.
 Only licensed and certified are certified operators are authorized to operate forklift and man lift.
 Don’t operate mobile equipment until you pass the required training and certified.
 Never stand on raised fork or pallet on the fork lift
 Never place anybody part under raised forks, pallet or other load.
 Always keep a distance of at least 6feet from all directions of possible travels
 Always insure the lift operators that you are in front or behind the deriver
 Never stand In an area where the load could fall off forks and strike you
 Ever ride on the fork lift as the passenger
Personals protective equipment (PPE)
 Safety glass and face shield
 Hearing protection/air plug
 Gloves
  Hard hats
 Safety shoes
 Respirators, dust mask
Care of PPE
 Inspect all the PPE prior to use each time. If any part of your PPE is damage, seek repair or
replacement
 Store all PPE in a clean, dry, and secure place
Limitations of PPE
I. Hard hats will protect you only from falling bolts and light weight material but nit heavy falling
material
II. Leather gloves can be cut through
Eye safety
i. never rub your eyes and face with dirty hands or while wearing the gloves
ii. if you get something in your eyes never rub it with your fingers, this will make it worse.
iii. If something is in your eye blink it several time and use an eye wash
Hearing protection
a. Always wear hearing protection in required areas
b. Prolonged exposure to noise it out protection will cause permanent hearing loss.
c. To insert ear plug up on the top of ear and insert
d. Ear muff should cover the entire outer of ear
Electrical safety
1) only trained maintenance employ are authorized to conduct troubleshooting or electrical repair
2) do not attempt any maintenance activity you are not trained or authorized to conduct
3) never use a damage extension chord or ay piece of damaged equipment
4) never use electrical equipment in a wet area
Lock out /tag out
1) It refers to specific practices and procedures which safeguard employ from unexpected energization
or start up of machinery
2) If you ever see a red lock, yellow lock, or danger tag on a machine it is locked out for repair
3) Never try to start a locked out machine
4) Never remove lock or tags
5) Only trained or authorized maintenance employ an lock out a machine
Hazardous communication;
a) All chemicals must be labeled with the name of the chemical and the manufacturer
b) Bulk chemicals and the chemicals with the hazards must be labeled with the hazard management
system.
c) The higher the number rating the more hazardous the chemical
MSDS
It provides in depth information on health hazards, reactivity, flammability, chemical properties guide lines
on usage and storage
Confined spaces
Never enter an area labeled as a confined space. Confined space need to be locked out and checked to insure
the atmospheric conditions are safe before any entry is made. only trained and authorized employ may enter
a confined space.
House keeping
It is important to maintain a high level of housekeeping trough out the facility. Water /spills cause slip hazards.
Cleanup or immediately notify your supervisor of these conditions.
Working at heights
Never enter an area here a fall hazards of four feet or greater without appropriate PPEs. Training is required
for all employ prior to using fall protection.
Medical emergency
If someone needs emergency medical care follow the guidelines below
 Summon a first responder to the injured person and call emergency medical center
 Insure a employ stand at the entrance direct to the emergency medical crew to the injured employ
 Inform your supervisor of the situation
Fire procedure
if you find a smaller fire try to put it out. Anything larger, sound the alarm. Notify your manager and evacuate
the building. Assemble in your designated area outside. Report any missing co-worker to the manager. fire
extinguisher only control the small fire. To use fire extinguisher
 Pull the pin
 Aim the base of fire
 Squeeze the fire
Injuries and accidents
All injuries and accidents must be reported to your manager immediately. This include first aid injuries and
close calls.
Disciplinary actions
Not wearing require PPEs
Not immediately reporting an injury or damage
Committing an unsafe act such as standing in an unsafe zone or travelling on a lift truck, crane as
passenger
Operating a piece of equipment you are not authorized to operate such as crane, fork lifter or dumper
truck.