1.

1 TYPES OF MAINTENANCE
There are mainly four types of maintenance, but many different terms are used by different authors to
describe them, these types are outlined on figure 1.5

Breakdown maintenance (Repair maintenance, corrective maintenance, unscheduled maintenance,

emergency maintenance).This is type of maintenance which is done after failure has taken place. Failure,
in this situation can be either an abrupt, type failure or a gradual failure which was not noticed.

Preventive Maintenance (Scheduled maintenance, Regular preventive maintenance, planned

maintenance) Doing regular maintenance at a pre-planned time interval. These regular maintenance
activities can be accompanied by inspection which will clarify the condition of the equipment, but this
type of maintenance is mainly based on time interval. This can be done while the equipment is either
running or shut down.

Condition Based maintenance: (Predictive maintenance) this is a special type of preventive maintenance
in which a continuous monitoring of the condition of the equipment is done and maintenance is done only
when necessary. This can also be performed in either a running or shutdown condition.

Maintenance prevention: (Design out maintenance, renovative maintenance, improvement maintenance)

Design or redesign of the equipment or part of the equipment for minimal or, ideally, no maintenance.
The re-design of the equipment or part of the equipment can take place either while the equipment is
running or is shutdown.

Maintenance

Corrective Preventive
Maintenance Maintenance

Scheduled/Preventive/Maintenance

Condition Based Maintenance

Design out/Improvement Maintenance

Figure 1.5 Classifications of Maintenance Types

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Terminologies: - This section gives some of basic terminologies that are used in maintenance
engineering.

Maintainability: Maintainability can be defined as the inherent characteristic of a design or installation

that determines the ease, economy, safety, and accuracy with which maintenance action can be
performed.

Failure: Mechanical failure refers to inability of a component or part of a piece of equipment to perform
its designed function. Failure occurs at a point where stress toward which a part is subjected to exceeds
the strength of the part at that time.

Failure rate: Failure rate is defined as the number of failures per period of time during which failure can
occur. Failure rate is normally presented in terms of failures per hour or other multiples of hour. Failure
rate can also be presented in terms of the number of operations or number of cycles.

Corrective maintenance (breakdown) a type of maintenance done after failure has occurred. Normally,
this failure happens without any present signal of failure, it can be an abrupt or a gradual failure which
had not been monitored. Normally breakdown maintenance is done on trivial equipment whose failure has
no important consequences on production and/or safety on the operator.

Implementation of Corrective maintenance (breakdown maintenance)

The following criteria may be followed in selecting equipment or part of an equipment for breakdown
maintenance.
a Accessibility-the component should be easily accessible; preferably, it should an external part of
the equipment
b Time to fix: The component should take as minimal time as possible to fix and test the equipment
when there is a failure
c Safety; The failure of the component should not endanger the life of the personnel or the
equipment
d The failure of the component should not cause failure to another parts of the equipment
e Critical element: The failure should not cause failure excessive loss in production
f Corrective maintenance can be carried out in equipment that has a back-up or standby system.
The secondary system can be operated while the primary is being repaired.

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 g If the cost of dismantling the equipment for repair is lower than or equal to the cost of removing
the item found on inspection (preventive maintenance), then breakdown maintenance may as well
be conducted on such equipment.
h For equipment that has a long enough life to meet minimum equipment life without preventive
maintenance may be used without affecting production.

Preventive maintenance (PM)

Preventive maintenance is done on equipment whose reliability is of high importance. A failure of the
equipment, such as safety value, can be very disastrous not only to production, but also to the operator.
In other equipment, the failure is harmless to the operator, but will cause a very big loss to the company
and such a repair take very long time. In these two cases and others whereby high plant reliability is
of utmost importance, regular preventive maintenance is normally recommended.

Disadvantage of preventive maintenance

a) Operating period between planned maintenance cannot be determined precisely because
of differences between plants, operating condition and operator’s skill.
b) Over-maintenance problems sometimes occur.
c) An optimal preventive maintenance schedule requires trial and error experimentation. If
the frequency is too low failure can occur, and if is too high the maintenance costs soar
and become uneconomical.
d) Sometimes human error induces some defects in the equipment if the quality of
maintenance done is below standard.
e) It is difficult to introduce effective P.M. on a new plants because it requires some
knowledge of failure trends within the equipment after some period of time in operation.

Advantage of preventive maintenance

a) Maintenance work can be planned ahead of time and all activities scheduled and
coordinated will ahead of time. This results in shorter maintenance time and thus greater
cost effectiveness.
b) It increase plant availability and reliability
c) Reduces conflicts on production and maintenance management on priorities.
Increased productivity and good coordination between departments. The down time can
easily be coordinated and managed.
d) A good PM system can lead to better spare parts management. Reduce un necessary
inventory
e) With an effective PM there is no need for standby equipment as the plant will be in good
operating condition at all time. PM is corned out before any failure has occurred.
f) Less labour requirement. Results into optimum utilization of labour.

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Implementation of Preventive Maintenance
The following criteria may be used in selecting equipment for preventive maintenance
a) Cost: the overall cost of preventive maintenance should not exceed the total cost of
breakdown repair and the cost of lost production.
b) Safety: PM should be enforced in elements whose failure will endanger the personnel
and/or integrity of the system.
c) Government regulations: Failure may be disastrous to either personnel or environment.
In those types of equipment, it is required by the government regulations to do a regular
PM and keep a log-book of maintenance work done.
d) Insurance need. So as to qualify for compensation maintenance so as to save the
equipment, before the failure occur.

Formula for (a) PM= D (A+B+C)

ExF

A – Cost of breakdown
B – Cost of lost production
C – Cost of repairing other equipment involved in the breakdown
D – No. of breakdown per year
E – Is the cost of PM activity (average)
F – Is the No. of PM cycles per year

Condition Based Maintenance CBM

Condition based maintenance is a type of maintenance whereby a piece of equipment or part of

it is constantly monitored to enable its condition to be known and so that any incipient
deterioration and faults can be detected early enough so that proper actions can be taken to stop
a total failure.

Plant: diagnosis is analogous to a medical approach of identifying a malady by studying and

understanding one or more of its symptoms in that, for condition monitoring techniques,
different symptoms of plants malfunctions and diagnosed to determine the real cause of
malfunctions.

Diagnosis of plants condition can be divided into three steps as described in the figure;
Signal Sensing; processing of the sensing; and identifying the cause.

DETECTION DATA DIAGNOSIS

SIGNAL PROCESSING CAUSE
SENSING ABNORMALITY IDENTIFICATI
FINDING ON
Three steps of Plant condition monitoring.

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The first step is to detect the signal by different techniques (such as vibration, temperature and
noise) to identify the signal from the plant under test. The signal can be at any state provided
that it gives the indications of the health of the plant.

Disadvantage of condition Based maintenance

a) CBM is applicable only to the machine components with a gradual type of failure. Thus
it cannot be applied to a component with sudden type of failure for example of electronic
devices.
b) The monitoring equipment itself can lead to an increased level of Plant failure the
reliability of a monitoring device must be higher than the reliability of the equipment to
be monitored.
c) False alarm of the monitoring device, can lead into a false action. In cases device can
shoe that there is a failure in a component, while the component is alright, or showing the
equipment is okay while there is a failure.
d) Most monitoring devices can only show that there is a failure in the equipment but they
cannot show which part of the equipment has failed.
e) Some monitoring devices are too expensive to be used by small firms.

Advantage of Condition based Maintenance

a) An Optimum maintenance can be obtained through CBM. In CBM, maintenance work is
carried out only when it is necessary to do so. This result in an overall reduction on
maintenance costs.
b) Impending failure can be predicted for away up stream, thus with effective CBM. There
is no need of standby plant.
c) CBM increases plant availability and reliability due to reduction in both planned and
unplanned breakdown.
This reduces the problem of over maintenance found in regular PM. CBM eliminates the
problem of un necessary shutdown of the plant.
d) It is the safest maintenance system.
e) Increases confidence and motivation to maintenance personnel they know the reason for
maintenance; and it is easier to convince the management of maintenance activities and
costs.

1.1.1 Availability Performance in Different Production Systems

The total availability performance is different depending on how the different units in a system are
connected. This section gives the calculation methods for serial, parallel and redundant system
arrangement.
Reliability: Reliability in a common language, reefers to ability to perform a required task satisfactorily
without failure. Mechanical reliability is the probability that a component, device or system will perform
its prescribed duty without failure for a given time when operated correctly in a specified environment

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Reliability is the probability that an item will perform satisfactorily for a specified period of time under a
specified operating condition.

Availability performance
Availability performance can be defined as the proportion of time during which a piece of equipment is
in operational or able to run if required
Total time, in this case, is the time during which the equipment was supposes to be running/operating.

AVAILABILITY=Total time-(Scheduled& unscheduled downtime)

Total time.