Maintenance types Preventive Maintenance

Preventive maintenance can be defined as follows: Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. Advantages Cost effective in many capital intensive processes. Flexibility allows for the adjustment of maintenance periodicity. Increased component life cycle. Energy savings. Reduced equipment or process failure. Estimated 12% to 18% cost savings over reactive maintenance program. Disadvantages Catastrophic failures still likely to occur. Labor intensive. Includes performance of unneeded maintenance. Potential for incidental damage to components in conducting unneeded maintenance. Preventive maintenance is generally considered to include both condition-monitoring and life-extending tasks which are scheduled at regular intervals. Some tasks, such as temperature and vibration measurements, must be done while the equipment is operating and others, such as internal cleaning, must be done while the equipment is shut down. There is another, often overlooked, type of preventive maintenance inspection which can not be scheduled at regular intervals. These inspections can and should be done in conjunction with corrective maintenance. Preventive maintenance, where equipment is maintained before break down occurs. This type of maintenance has many different variations and is subject of various researches to determine best and most efficient way to maintain equipment. Recent studies have shown that Preventive maintenance is effective in preventing age related failures of the equipment. For random failure patterns which amount to 80% of the failure patterns, condition monitoring proves to be effective. Preventive maintenance is maintenance performed in an attempt to avoid failures, unnecessary production loss and safety violations. As equipment cannot be maintained

at all times, some way is needed to decide when it is proper to perform maintenance. Normally, this is done by deciding some inspection/maintenance intervals, and sticking to this interval more or less affected by what you find during these activities. The result of this is that most of the maintenance performed is unnecessary;[citation needed] it even adds substantial wear to the equipment. Also, you have no guarantee that the equipment will continue to work even if you are maintaining it according to the maintenance plan. The effectiveness of a preventive maintenance schedule depends on the RCM analysis which it was based on, and the ground rules used for cost-effectivity.[5] Corrective maintenance is defined as maintenance work which involves the repair or replacement of components which have failed or broken down. For failure modes which lend themselves to condition monitoring, corrective maintenance should be the result of a regular inspection which identifies the failure in time for corrective maintenance to be planned and scheduled, then performed during a routine plant outage. When corrective maintenance is done, the equipment should be inspected to identify the reason for the failure and to allow action to be taken to eliminate or reduce the frequency of future similar failures. These inspections should be included in the work plan. A good example is the failure of packing in a process pump. Packing can be monitored by checking leakage and the location of the gland follower, so repacking should not normally be a fixed-time maintenance task. It should be done at frequencies which depend on the operating context. During the process of repacking the pump, there are a number of simple inspections related to packing life which can be performed. These include:

Using a padded pry bar to lift the pump shaft to check for a failed bearing Checking the condition of the shaft or sleeve for excessive wear or surface irregularities (using a small light that can be inserted deep into the stuffing box) Checking that the packing sequence is correct and that the lantern ring is in the right location Checking the throat bushing for wear Checking that the packing is cut to the correct length and properly seated Checking the packing used is the correct type Checking the clearance behind the impeller, especially if it has back pump-out vanes Checking shaft run-out Checking seal water pressure Confirming that seal and cooling water connections are correct

Corrective maintenance
Corrective maintenance can be defined as the maintenance which is required when an item has failed or worn out, to bring it back to working order. Corrective maintenance is carried out on all items where the consequences of failure or wearing out are not significant and the cost of this maintenance is not greater than preventative maintenance. Corrective Maintenance activity may conist of repair, restoration or replacement of equipment. This activity will be the result of a regular inspection, which identifies the

failure in time for corrective maintenance to be planned and scheduled, then performed during a routine maintenance shutdown Corrective maintenance, where equipment is maintained after break down. This maintenance is often most expensive because worn equipment can damage other parts and cause multiple damage Corrective maintenance is probably the most commonly used approach, but it is easy to see its limitations. When equipment fails, it often leads to downtime in production. In most cases this is costly business. Also, if the equipment needs to be replaced, the cost of replacing it alone can be substantial. It is also important to consider health, safety and environment (HSE) issues related to malfunctioning equipment. Corrective maintenance can be defined as the maintenance which is required when an item has failed or worn out, to bring it back to working order. Corrective maintenance is carried out on all items where the consequences of failure or wearing out are not significant and the cost of this maintenance is not greater than preventive maintenance.