Palestine Polytechnic University

College of Engineering
electrical Engineering Department

Fault Diagnostic and IA system Maintenance

Type of maintenance

By:
Mohammad Shanti

Supervisor:

Dr : Abdelkarim Daud
Introduction :-
In this report we will talk about type of maintenance in our local
factory's ; but not all of our factories carry out all types of
maintenance, and we will explain this with examples . First we
will mention the definition of maintenance and its types .

Maintenance :-
Electrical maintenance covers all aspects of testing, monitoring,
fixing, and replacing elements of an electrical system. Usually
performed by a licensed professional with a complete knowledge of
the National Electric Code and local regulations, electrical
maintenance covers areas as diverse as:
– Digital communication
– Electrical machines
– Generators
– Hydraulics
– Lighting systems
– Pneumatics
– Surge protection
– Transformers

types of maintenance :-
1- Reactive Maintenance (Corrective maintenance)

is a maintenance task performed to identify and rectify the

cause failures for a failed system. The engineering equipment
gets many components and failure modes, and its failure
mechanism is very complicated. Failure of system-level might
occur due to failure(s) of any subsystem/component. Thus, the
symptom failure of equipment may be caused by multilevel
causality of latent failures.
Three (4) examples of Reactive maintenance are:
1- Repair maintenance due to equipment failure
2- Compliance maintenance repair of upgrade.
3- Repair or upgrade of equipment due to inadequate
operation of the equipment.
4- Corrective maintenance due to safety concerns.

1- Repair maintenance due to equipment failure

This is a probably the most common type of repair
maintenance. An example could be a conveyor in a
manufacturing maintenance environment fails. This results in
unexpected downtime and immediate repairs to restore
production capability. , using the above example if this is a
portable conveyor an replacement conveyor could be used
while the failed conveyor is being repaired or uisng corrective
maintenance like ifthe motor brekdown we have to replased
imeditly. This situation would still likely result in unexpected
downtime, however the downtime may be lessened.

In this case, the motor

must be replaced
because the failure is not
in the system but in one
of its equipment
2- Compliance maintenance repair of upgrade..
In this example, consider a food-processing environment
where oil is dripping into a product zone. The equipment is still
running and product is being manufactured,
however Performance is limited due to contaminated product
being discarded. In this case immediate corrective maintenance
must be performed.

3- Repair or upgrade of equipment due to inadequate

operation of the equipment.
This example is similar to the previous example in that capacity
is limited. In this case, the equipment is not capable of running
at its Ideal Cycle Time. Consider a commercial bakery that
generates 200 loaves of bread per minute, however due to a
faulty drive a particular conveyor is not running fast enough to
accept 200 loaves/minute. Additionally, this is the expected
production rate and all other equipment associated with this
system (i.e. packaging, shipping, etc. are prepared and capable
of this rate. This results in bakery downtime even though the
equipment is technically still running. In this case corrective
maintenance may be immediate or deferred.

4- Corrective maintenance due to safety concerns.

In addition to the obvious human factors involved with safety,
safety is big business. Immediate corrective maintenance must
be taken when safety in involved. An example of a corrective
maintenance for safety could be a case where electrical wiring
is exposed to personnel creating a shock hazard. Another case
could be where a chain guard was not properly replaced after
working on the equipment.
Corrective maintenance should always be tracked. Additionally,
equipment downtime should be tracked and used to prevent
future situations where corrective maintenance is required
(especially immediate). Using a software system to track
downtime is useful and generally worth the effort. If using
a CMMS software to manage this the work order system must
provide for any type of maintenance whether it is corrective,
preventive, predictive and so on.
2- Preventive Maintenance (PM)
Preventive maintenance (or preventative maintenance) is
maintenance that is regularly performed on a piece of
equipment to lessen the likelihood of it failing. It is performed
while the equipment is still working so that it does not break
down unexpectedly. In terms of the complexity of this
maintenance strategy, it falls between reactive (or run-to-
failure) maintenance and predictive maintenance.
Types of preventive maintenance
Preventive maintenance can be scheduled on a time or usage
based trigger. Let’s look at an example for each.

Time-based preventive maintenance

A typical example of a time-based preventive maintenance
trigger is a regular inspection on a critical piece of equipment
that would severely impact production in the event of a
breakdown.

Usage-based preventive maintenance

Usage-based triggers fire after a certain amount of kilometres,
hours, or production cycles. An example of this trigger is a
motor-vehicle which might be scheduled for service every
10,000km

In any case, we need preventive maintenance ????

1- PM is not needed

Case: Replace light bulbs in the women’s bathroom

every year.

The worst-case scenario is that a bulb burns out. The

bathroom has multiple lights, so worst case, not so bad. The
likelihood of a bulb going out at some point is pretty high
and the cost to do a PM on these lights every year is quite
high given the relative impact it has. With that said, do you
think it makes sense to do a PM on bathroom lights?
Probably not. Let’s just wait until a bulb burns out and get a
work request to replace it.
2- PM is needed
Case: Lube chains for critical equipment every seven
days.

If there is a breakdown on a critical piece of equipment, that

could stop production. This could mean a loss of thousands,
maybe millions, of dollars. Also, the likelihood of a
breakdown is probably very high because the equipment is
constantly running. It’s probably a good idea to do a PM in
this case .

Examples :-

Lubrication for this machine

The machine needs lubrication in the upper area of the door
when locking (like what is shown in the following picture). This
area contains your spring to press the door and not move due
to the presence of pressure under the door in the operating
position, and lubrication is done monthly, according to the
work pressure .
3- Predictive Maintenance
Predictive maintenance is a technique that uses condition-
monitoring tools and techniques to track the performance of
equipment during normal operation to detect possible
defects and fix them before they result in failure.

Ideally, predictive maintenance allows the maintenance

frequency to be as low as possible to prevent unplanned
reactive maintenance, without incurring costs associated
with doing too much preventive maintenance.

How does predictive maintenance work?

Predictive maintenance uses condition-monitoring
equipment to evaluate an asset’s performance in real-time. A
key element in this process is the Internet of Things (IoT).
IoT allows for different assets and systems to connect, work
together, and share, analyze and action data.

IoT relies on predictive maintenance sensors to capture

information, make sense of it and identify any areas that
need attention. Some examples of using predictive
maintenance and predictive maintenance sensors include
vibration analysis, oil analysis, thermal imaging, and
equipment observation.

Choosing the correct technique for performing condition

monitoring is an important consideration that is best done in
consultation with equipment manufacturers and condition
monitoring experts.
 A 600 kw electric generator on which a
computerized system is installed to see all errors
and appear on the screen as shown in the picture.

Here all errors

appear
 4- Reliability Centered Maintenance (RCM) :
Reliability centred maintenance (RCM) is a corporate-level
maintenance strategy that is implemented to optimize the
maintenance program of a company or facility. The final result
of an RCM program is the implementation of a specific
maintenance strategy on each of the assets of the facility. The
maintenance strategies are optimized so that the productivity
of the plant is maintained using cost-effective maintenance
techniques.

There are four principles that are critical for a

reliability centred maintenance program:

1- The primary objective is to preserve system function

2- Identify failure modes that can affect the system function
3- Prioritize the failure modes
4- Select applicable and effective tasks to control the failure
modes

7 questions that need to be asked for RCM

An effective reliability centred maintenance implementation
examines the facility as a series of functional systems, each of which
has inputs and outputs contributing to the success of the facility. It is
the reliability, rather than the functionality, of these systems that are
considered. The SAE JA1011 has a set of minimum criteria before a
maintenance strategy can be called RCM (Gulati). The seven
questions that need to be asked for each asset are:
1- What are the functions and desired performance standards of
each asset?
2- How can each asset fail to fulfill its functions?
3- What are the failure modes for each functional failure?
4- What causes each of the failure modes?
5- What are the consequences of each failure?
6- What can and/or should be done to predict or prevent each
failure?
7- What should be done if a suitable proactive task cannot be
determined
Example :-
In this link there are a report to (rcm).
https://www.reliasoft.com/images/documents/rcm_report_sample.pdf

In this summary, this report includes the following forms:

Report Summary
Functional Failure Analysis
Failure Effect Categorization (One per Effect)
Maintenance Task Selection (One per Cause)
Tasks .
This image from the report.

Refrains:-
1- https://www.tpctraining.com/blogs/news/what-is-electrical-maintenance
2- https://www.tandfonline.com/doi/abs/10.1080/00207549408957005 L. J.
KRAJEWSKI
3- https://www.sciencedirect.com/science/article/abs/pii/S1350630713003178
4- https://www.quora.com/What-are-three-example-of-corrective-maintenance
5- https://books.google.ps/books?hl=en&lr=&id=SjqXzxpAzSQC&oi=fnd&pg=PP1&dq=Pre
dictive+maintenance&ots=iFwSJBCl9i&sig=XAFf4l0PQeymRWVCqfqA6TPK_uA&redir_es
c=y#v=onepage&q=Predictive%20maintenance&f=false
6- https://www.fiixsoftware.com/maintenance-strategies/preventative-maintenance/
7- https://www.onupkeep.com/blog/preventive-maintenance-cost-savings/

End