Chapter

GENERAL CONCEPT OF
PREVENTIVE MAINTENANCE

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 1 MAINTENANCE MAIN ACTIVITIES

MAINTENANCE MAIN ACTIVITIES

Compensation Cleaning & Checking Checking of Removal

of Washing of tightness correct of Recording
exploitation & operation of discovered of results.
materials equipments
fixing of & defects and
aggregates mechanisms repair of
& their small
adjustments failure

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 2. FACTORS AFFECTING MAINTENANCE PLANNING

FACTORS AFFECTING MAINTENANCE

PLANNING

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Manufacturers Design Cost of Expert Reserve Environment Utilization On site Diagnostics
recommended Features requirements
down time Systems Needs. maintenance
maintenance
Programs capability

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 3 MAINTENANCE
(1)
Preventive
The maintenance that
usually performed
periodically without regard
to the equipment technical
state (good / worse) where
the frequency of its
implementation depends on
equipment design.
environmental conditions,..
etc
Planned
MAINTENANCE
(2)
Predictive
Maintenance to be done in
emergency due to
diagnoses of the equipment
operational regime and its
technical state with regard
to expectations and future
trends of the equipment
technical state.
Emergency
(3)
Corrective
It is tile maintenance to be
done for trouble shooting
of failures . operational
faults;
disturbance of mutual
operational adjustment , ..
etc at any time and when it
will be discovered.
Emergency
(4)
Control-inspections
It is the different types of
checks to be done during
equipment operation, shut
down and maintenance
performance to be assure
about equipment technical
states.
Planned
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 4. PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE

PERIODICAL MAINTENANCE

Annual Medium
Daily Weekly Shut down Monthly Semi annual Yearly terms Long term

Adjustments Repairs .
Compensation Cleaning Replacement.
Mainly inspection activities. & Compensation Major adjustment
Cleaning activities. activities.

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6. Economical Importance of Correct E. Equipment Operation

 Optimum operational conditions:

(1) (2)
- They are the conditions which secure the reliable, trouble free and
(3)
economical work "operation" of the E. Equipment for a time long
as possible .

OPTIMUM OPERATIONAL CONDITIONS

related to

Environmental Loading Adequacy of

Operational
Condition. Condition and its Equipment
staff skills
Regime. Design.

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 5. Engineering Service for E. Equipment
ENGINEERING SERVICE FOR E. EQUIPMENT
includes 2 pails
Technical part
Causes of wear of components &
aggregates.
Causes of failures origin and mater
of their removal.
Influence of the intensity of wear on
Equipment service life.
Problems of economy of operation.
Choice of rational "most suitable"
operating condition.
Maintenance and Adjustment of
aggregates .
Peculiarities of equipment operation
at different operational Condition
Technical condition for storing &
preservation
Organization part
Organization of T.M in steady
and variable load .(kinds of
technical maintenance, planning
... etc ).
Planning of operation.
Organization of operators &
maintenance persons training.
Organization of storing and
preservation.
Principles of material supply.
Problems of mechanization of
work during maintenance.
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 Motor Preventive Maintenance

Any electric motor PM program should be designed with these four

elements in mind:

1. Inspection and test

2. Lubrication and impregnation

3. Cleaning

4. Protection and safety measures

The four element approach contains the following steps:

1. Inspection. We need to determine what is to be inspected, the

equipment has to be examined, visible defects have to be
identified, and we have to make sure that minor adjustments are
made and major defects are being reported. General motor
inspection should be directed toward these components:

a) Air passages.

 Inspect rotor and stator air passages for obstructions on

explosion- proof motors and totally enclosed fan cooled
motors.
 Air filters on weather-protected (WP II) motors.
 Inertia filters, filter media and remote fans on pipe
ventilated motors.

b) Bearings.

 Inspect for over greasing or under greasing.

 Inspect for dirt and foreign matter in bearing housings.
 Check periodically for proper alignment to avoid bearing
overloads.

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 c) Motor windings.

 Keep them cool.

 Keep them clean.
 Inspect stator winding air gaps.

d) Squirrel cage rotors.

 Inspect for heat checked end rings.

 Inspect for fractured rotor bars.

e) Winding insulation values.

f) Vibration monitoring.

 Set limits for small motors as a function of speed.

 Set limits for large motors.

2. Lubrication. Lubrication practices on antifriction bearing motors

vary widely. We should determine proper lubricants, quantities,
and equipment. After establishing a lubrication schedule, it has to
be implemented.

3. Cleaning. We need to determine cleaning standards and

requirements, establish a cleaning schedule and implement it.

4. Protection and Safety. Safety requirements have to be

established, safety equipment installed, and its effectiveness
monitored.

The task that follows now is the building of appropriate check lists for
each PM element. It should contain the following information:
1. Motor name and “yard” number.
2. Location.
3. Frequency designation of PM activity.
4. Operation sequence number.
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 5. A simple description of the PM operation using verbs at the
beginning of a sentence.
6. Required tools and/or special equipment and instruments.
7. Required replacement parts.
8. Required time to perform PM activity.
9. Space for the inspector’s comments or any other special comments.

After the various electric motor PM checklists have been developed,

thought should be given to the implementation of the program. Two main
considerations will help in the implementation of the motor PM program.
They are motor criticality and the cost of the program.
To determine whether an electrical motor is critical, one has to look at the
cost implications of a failure. For instance, the breakdown of an unspared
4,000 horsepower ethylene refrigeration compressor drive motor would
have a different financial impact than a small motor driving a fully
spared water pump in a batch type cleaning operation. As to the case of
the 4,000 HP pipe-ventilated induction motor, there would be no question
as to whether a PM program should be considered. Frequently, cleaning
and inspection of this critical motor becomes an integral part of the
process plant’s turnaround preparations. Figure 9 illustrates the elaborate
fixture necessary to accomplish the task on site in an economical way.
However, there are a multitude of cases where a decision to do or not to
do PM on motors does not appear that straightforward. Questions that
should be answered during the development of the implementation
schedule
for an electric motor PM program are:
1. How critical is the motor?
2. What will operation downtime cost?
3. Is similar or alternate equipment available?
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 4. Are spare motors available or easy to obtain?
5. Are major spare parts such as winding coils and bearings available?
6. What is the motor failure experience?
7. What is its age?
8. What is the motor operating severity?
In conclusion, it is necessary to determine the benefits and costs of an
electrical motor PM program. Only after its cost factors have been
compared to current maintenance practices and other related downtime
costs can it be determined if a motor PM program will truly support itself.

Figure 9. Field removal of rotor for winding cleaning and

inspection of a large pipe ventilated induction motor.

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