Maintainance of machinaery and instalation

By Ebrahim Ali DDU 1001739

Submission to: INS

Submission Date: 24/12/2021

Contents
1. Time-based Maintenance ...................................................................................................................... 3
Time-Based Maintenance Examples ......................................................................................................... 3
Advantages of TbM ................................................................................................................................... 4
Disadvantages TbM .................................................................................................................................. 4
situations where Time-based Maintenance is recommended ................................................................. 4
2. Failure finding maintenance ................................................................................................................. 5
3. Risk-based asset maintenance(RBM) ................................................................................................... 5
4. Condition-based Maintenance(CBM) ................................................................................................... 6
How Condition-based Maintenance Works.............................................................................................. 7
Advantages of Condition-based Maintenance ......................................................................................... 7
Disadvantages of Condition-based Maintenance ..................................................................................... 7
Situations where (CBM) is recommended ................................................................................................ 7
5. Predictive Maintenance(PdM) .............................................................................................................. 8
Difference Between Preventive and Predictive Maintenance ................................................................. 8
Advantages of PdM................................................................................................................................... 8
Disadvantages of PdM .............................................................................................................................. 8
Situations where (PdM) is recommended ................................................................................................ 9
Corrective maintenance .............................................................................................................................. 10
Corrective Maintenance Needed............................................................................................................ 10
Different Types of Corrective Maintenance ........................................................................................... 10
Advantages ............................................................................................................................................. 11
Disadvantages ......................................................................................................................................... 11
Examples .....................................................................................................Error! Bookmark not defined.
Run-to-Fail Corrective Maintenance ......................................................Error! Bookmark not defined.
Planned Corrective Maintenance ............................................................Error! Bookmark not defined.
Unplanned Corrective Maintenance .......................................................Error! Bookmark not defined.
Importance of Corrective Maintenance ................................................................................................. 11
Deferred maintenance ................................................................................................................................. 12
Emergency Maintenance (EM) ................................................................................................................... 12
Workflow of Emergency Maintenance (EM) : ........................................................................................ 12
Advantages : ........................................................................................................................................... 13
Disadvantages : ....................................................................................................................................... 13
 Types of maintenance

Preventive Maintenance is done before a failure occurs and consists of maintenance types like:-

Types Preventive Maintenance (PM)

• Time Based Maintenance (TBM)

• Failure Finding Maintenance (FFM)
• Risk Based Maintenance (RBM)
• Condition Based Maintenance (CBM)
• Predictive Maintenance (PDM)
• Knowledge based maintenance

1. Time-based Maintenance
Time-based maintenance (TbM), also called periodic maintenance, refers to routine maintenance tasks
performed on an asset at fixed time intervals, regardless of its condition. As a type of preventive
maintenance (PM), the goal of time-based maintenance is to prevent failures before they happen and improve
asset performance. However, because TbM may be performed whether it is needed or not, it does not always
strike a balance between risk and reward.

For example, changing the oil in your car every 1,000 miles as opposed to the manufacturer-recommended
3,000 miles may lead to fewer problems, but comes at a cost. While a lower risk of failure may be a reward in
itself, money and time are wasted performing the oil change more often than recommended.

Time-Based Maintenance Examples

Periodic, time-based maintenance is required to keep assets in proper operating condition. Examples include:
 • Tuning up a furnace every year before winter
• Clearing debris out of a gutter every 6 months
• Visually inspecting fire extinguishers each month
• Changing an air filter every quarter
• Lubricating pumps every 6 weeks

Advantages of TbM

Like other types of maintenance, TbM can be beneficial when used as part of a larger maintenance
management strategy.

• Minimal Training: Time-based tasks are relatively simple and usually don’t require extensive training
to learn.
• Lower Long-term Cost: Compared to breakdown or corrective maintenance (CM), time-based
maintenance is relatively inexpensive.
• is more predictable for assets that run continuously, allowing maintenance work to be scheduled at
regular intervals.

Disadvantages TbM

Organizations that rely heavily on time-based maintenance can face some challenges:

• Ignores Other Causes of Failure: Time-based maintenance assumes that failures are age-related and
does not take into account the actual condition of assets. As many maintenance professionals know,
many breakdowns and failures do not occur at regular, predictable intervals.
• Too Frequent Schedule Introduces Risk: A maintenance activity may introduce a risk of incorrect re-
assembly, misalignment, or other errors. A too frequent maintenance schedule heightens this risk.

situations where Time-based Maintenance is recommended

As with other preventive maintenance activities, time-based maintenance should be used to prevent failures on
assets that are critical to the organization. Using asset management KPIs such as mean time between Failure
(MTBF), historical maintenance data, manufacturer recommendations, and one’s own experience, the ideal
interval for time-based maintenance activities can be identified.

Safety-related activities, such as fire extinguisher inspections and smoke alarm tests, are well-suited for time-
based maintenance because the cost of asset failure is high, the cost of maintenance is very low,
and condition-based maintenance (CbM) is either impossible or costly. HVAC units, furnaces, and other
assets that require seasonal attention are also great candidates for time-based maintenance activities.
 2. Failure finding maintenance
Failure finding tasks are inspections we make of a particular piece of equipment to discover defects or hidden
failures. Therefore, they do not fit within a specific type of maintenance. In these cases, the goal is not to
maintain a certain asset, but to test whether it still works. Therefore, we can also call them “functional
checks”.
It is important to underline this aspect because this is what differentiates failure finding from preventive and
predictive maintenance. This process is not trying to prevent or predict a failure, it just are looking for it.
In short, failure finding tasks are necessary to have maximum reliability of security and backup mechanisms.
Here are some of the systems that need this type of screening and testing regularly:
• alarm systems such as fire alarms, smoke detectors, and motion detectors.
• systems and electrical circuits, to test the load and current capacity.
• relief systems, such as pressure relief valves or control valves.
• mitigation systems to minimize the effect of possible failures, such as fire extinguishers.
• backup systems, such as electrical backup generators or secondary water heating systems.

situations where failure finding is recommended

This type of maintenance is justified whenever a failure is not evident under normal circumstances or cannot
be detected through routine preventive maintenance tasks. Also, functional checks are justified when:

• there is no way to prevent the malfunction (and therefore any possibility of preventive maintenance is
excluded);
• tests and screenings can be performed without this implying any changes to the normal functioning of
the building;
• the risk of a “hidden” malfunction in a given system is high;
• the probability of the tests causing a serious malfunction is very low;
• the cost of failure fiding tasks is lower than the cost of reactive maintenance

3. Risk-based asset maintenance(RBM)

Risk-based maintenance (RBM) prioritizes maintenance resources toward assets that carry the most risk if
they were to fail. It is a methodology for determining the most economical use of maintenance resources. This
is done so that the maintenance effort across a facility is optimized to minimize any risk of a failure.

A risk-based maintenance strategy is based on two main phases:

1. Risk assessment
2. Maintenance planning based on the risk
The maintenance type and frequency are prioritized based on the risk of failure. Assets that have a greater risk
and consequence of failure are maintained and monitored more frequently. Assets that carry a lower risk are
subjected to less stringent maintenance programs. Implementing a risk-based maintenance process means that
the total risk of failure is minimized across the facility in the most economical way.
Risk assessment method

Assessing the risk of failure is one of the most important aspects of risk based maintenance. The more
accurately this is done, the better the risk based maintenance outcomes will be.

There is no one standard method for assessing risk. Qualitative, semi-quantitative and quantitative approaches
are used to determine the possible risks that exist. To estimate the likelihood of these risks, the methods that
are used include deterministic, and probabilistic approaches. 62 different approaches to assessing risk are
described in Tixier (2002). The most appropriate approach will depend on the data that is available to evaluate
each risk.

4. Condition-based Maintenance(CBM)
Condition-based maintenance (CbM) is a proactive maintenance technique that uses real-time data (collected
through sensors) to identify when an asset’s performance or condition reaches an unsatisfactory level. By
observing the state of an asset, a practice known as condition monitoring, maintenance professionals can
identify when an asset is about to fail or has failed. With CbM, maintenance work is performed only when
needed in response to the asset’s real condition, preventing unnecessary maintenance tasks.

An important concept within Condition Based Maintenance is the P-F curve shown in the figure below:

The curve shows that as a failure starts manifesting, the equipment deteriorates to the point at which it can
possibly be detected (point “P”). If the failure is not detected and mitigated, it continues until a functional
failure occurs (point “F”). The time range between P and F, commonly called the P-F interval, is the window
of opportunity during which an inspection can possibly detect the imminent failure and give you time to
address it.

It is important to realise that CBM as a maintenance strategy does not reduce the likelihood of a failure
occurring through life-renewal, but instead is aimed at intervening before the failure occurs, on the premise
that this is more economical and should have less of an impact on availability.

In other words: condition monitoring does not fix machines and condition monitoring does not stop failures.
Condition monitoring only lets you find problems before they become a failure. A common rule of thumb is
that the interval between CBM tasks should be one-half or one-third of the P-F interval. How much more
effective CBM is above breakdown maintenance depends on how long the P-F interval is. With plenty of 4

How Condition-based Maintenance Works

Condition-based maintenance consists of three steps: 1) capturing sensor data, 2) communicating data, and 3)
performing maintenance work.

Advantages of Condition-based Maintenance

As part of an overall maintenance management strategy, condition-based maintenance provides the following
advantages:

• Optimized Time Spent on Maintenance: Condition-based maintenance is performed as needed,

maintenance teams can optimize the use of their time.
• Less Disruption of Production: Some issues identified by CbM can be corrected without shutting down
equipment, ensuring higher availability for production.

Disadvantages of Condition-based Maintenance

Every maintenance approach has drawbacks. The following list outlines some of the challenges with CbM:

• High Sensor Costs: Cost of purchasing, installing, and maintaining condition-monitoring sensors and
related software can exceed the total benefit of reduction on failures and downtime.
• Unpredictable Peak Times: Condition-based maintenance events are unplanned and may result in
periods where multiple assets need attention at the same time.
• Difficulty in Choosing Sensors: Sensors come in many different types, sizes, and shapes, making it a
challenge to select the right one.

Situations where (CBM) is recommended

The decision whether to use condition-based maintenance depends on the expected return on investment
(ROI). Organizations must assess the amount of risk involved if an asset fails by asking questions like:

• How critical are potential failures?

• What does it cost to resolve failures?
• Are those failures likely to recur?

Highly critical production assets with high repair and replacement costs are usually the best candidates for a
condition-based maintenance program. Typically, CbM is used in large, asset-intensive organizations
including automotive suppliers, oil and gas, facilities with complex building automation systems, utilities, and
organizations that rely on fleet vehicles.
 5. Predictive Maintenance (PdM)
Predictive maintenance (PdM) is a proactive maintenance technique that uses real-time asset data (collected
through sensors), historical performance data, and advanced analytics to forecast when asset failure will
occur. Using data collected by condition-monitoring devices during normal operation, predictive maintenance
software uses advanced formulas (called algorithms) to compare real-time data against known measurements,
and accurately predicts asset failure.

Advanced PdM techniques may also incorporate cutting edge technology such as machine learning and
artificial intelligence (AI). The result of PdM is that maintenance work can be scheduled and performed
before an asset is expected to fail with minimal downtime.

Difference Between Preventive and Predictive Maintenance

Preventive maintenance (PM) and predictive maintenance (PdM) share a common goal – to stop asset failures
before they happen. However, they differ in their approach.

In a typical PM program, maintenance activities are commonly scheduled according to the manufacturer’s
recommendations. Maintenance technicians can also identify the need for maintenance through regular
inspections. While useful, these methods are only capable of identifying the most obvious problems based on
one’s sense of sight, sound, touch, and smell. (For health reasons, we do not encourage anyone to diagnose
equipment problems via taste.) Once issues are discovered, maintenance activities are usually scheduled on a
strict, time-based or usage-based interval.

Predictive maintenance relies on sensors to identify the need for maintenance. Not only are sensors more
accurate than human senses, but they can detect internal wear that cannot be directly observed, is too
dangerous for humans to inspect, or would otherwise require equipment to be shut down and opened up.
Maintenance events are then scheduled based on an asset’s real condition and performance, and performed
only when needed. More about how predictive maintenance works is described in the following section.

Advantages of PdM

Remember that no maintenance technique should be used in a vacuum. A comprehensive maintenance

strategy will include a variety of approaches and techniques. Below are some of the advantages of PdM:

• Improved Ease of Maintenance Scheduling: Since the need for service is known well before work is
actually required, activities can be scheduled when equipment is available for maintenance.
• Increased Asset Uptime: Assets can remain in operation until maintenance is truly warranted. With
other maintenance strategies, excessive downtime is created from too much, too little, or unscheduled
maintenance work.

Disadvantages of PdM

Even with all its benefits, be aware of some of the potential drawbacks of predictive maintenance.
 • Large Upfront Cost: A predictive maintenance program requires a large investment in condition
monitoring hardware, advanced analytical software, employee training, and man-hours to purchase
and install.
• Required Expertise: Employees must be trained to use monitoring equipment, interpret the data
received from sensors, and analyze reports generated by PdM software.
• Not Cost-Effective for All Assets: In facility-centric environments, other maintenance techniques are
often cheaper and more effective than predictive maintenance. The cost of setting up PdM on low-
value assets may outweigh any potential benefits.

Situations where (PdM) is recommended

The decision whether to use predictive maintenance depends on the return on investment (ROI), which is to
say, will the money saved on a reduction in asset failures meaningfully exceed the costs of maintenance.
Organizations should also consider an asset’s cost and criticality. It is most appropriate for manufacturing and
production assets that are critical to the organization and assets with high repair and replacement costs.
Organizations with remote or mobile assets, such as the oil and gas industry or those involved with fleet
maintenance, can also benefit from predictive maintenance.

6. Knowledge based maintenance (KnBM)

The concept of knowledge-based maintenance is a part of the evolution process in the industrial maintenance.
It is a dynamic research field that can be used to improve the preventive maintenance of materials, machines
and/or buildings.

Knowledge based maintenance assumes that competitive advantage for stabilizing maintenance process and
reducing unplanned cost are achieved through holistic consideration of production process. Rather than
automatic inspection of all/influential components.

The main objective of KnBM is to develop generic concept to optimize maintenance through comprehensive
consideration of maintenance consequence, system conditions, organization, and process.

Importance and application of knowledge-based maintenance

➢ Quicker problem solving

➢ Improved organizational agility
➢ Increase rate of innovation
➢ Better communication between maintenance professionals
➢ Improved business process
➢ Better and faster decision making
➢ Information sharing between experts
 2. Corrective maintenance
Corrective maintenance covers maintenance tasks that are undertaken to identify, isolate and repair a fault in
order to restore equipment, a machine or a system to an operational condition so it can perform its intended
function.

Corrective maintenance is often associated to breakdowns or reactive maintenance and can include
troubleshooting, disassembly, adjustment, repair, replacement and realignment.

Corrective Maintenance is Needed

Corrective maintenance tasks can be either planned or unplanned and occur for three different reasons:

1. When condition monitoring highlights an issue

2. When a potential fault is detected through routine inspection
3. When a piece of equipment breaks down

Corrective maintenance is often unavoidable, with maintenance teams having to respond to equipment
breakdown or failure. However, it can be a bad idea to rely solely on corrective maintenance over other types
of maintenance such as preventive maintenance.

Corrective maintenance is fine for when an asset can be easily repaired or replaced and parts are freely
available but, in some instances, it can lead to unexpected and costly downtimes. Experts tend to agree that
80% of your maintenance should be preventive and just 20% corrective.

Different Types of Corrective Maintenance

Types of corrective maintenance task can be placed into different categories. For example, the United States
Army uses five categories of corrective maintenance in their Engineering Design Handbook: Maintenance
Engineering Techniques:

1. Fail Repair - Restoring a failed asset to an operational state

2. Overhaul – Fully restoring an asset to its service state as outlined by maintenance standards
3. Salvage – Disposing of parts that cannot be repaired and replacing them with salvaged parts from
unrepairable assets
4. Servicing – Final fixes following larger corrective actions
5. Rebuild – Disassembling parts and replacing worn components in line with original standards and
specifications

Each of these five categories of corrective maintenance task can either be scheduled or unscheduled.

Unscheduled (or unplanned maintenance) refers to repairs that are done immediately, while scheduled (or
planned corrective maintenance) are those tasks that can be deferred until a later date. This delay can take
account of budgets, time constraints, or staffing.
Scheduled / Planned Maintenance

Planned maintenance can fall into two groups; run-to-failure maintenance and preventive maintenance. Run-
to-failure is where an asset is allowed to run until it breaks, at which point it is repaired or replaced. This type
of corrective maintenance strategy is only suitable for non-critical or redundant systems that are easy to
replace or repair. Preventive planned maintenance, which is often performed as part of condition-based
maintenance, is where problems are identified and addressed during maintenance inspections.

Unscheduled / Unplanned Maintenance

Corrective maintenance is unplanned either when a breakdown occurs unexpectedly. This can be because no
maintenance plan was in place, or because an asset fails before its scheduled inspection or maintenance
action.

Advantages

Corrective maintenance can offer a range of advantages when used as part of a broader maintenance
programme. These advantages include:

• Reduced Planning: Corrective maintenance requires less planning than preventive maintenance, even
when scheduling repairs
• Simple Process: Corrective maintenance is a simple process that is need-based, allowing maintenance
teams to focus on other areas until required
• Lower Short-Term Costs: This type of maintenance can be more cost-effective in the short term as
work is only done when needed. This is true for simple repairs or replacements, such as a blown
lightbulb that can be fixed quickly without the time and expense of a preventive maintenance plan
• Improved Resource Planning: If corrective maintenance work orders are prioritised and scheduled they
can allow for labour and financial resources to be optimised. This can lead to fewer service
interruptions as maintenance teams can resolve problems before production is impacted or services are
interrupted

Disadvantages

Despite the advantages of corrective maintenance, there are also some disadvantages with this method,
especially where there is no supporting preventive maintenance strategy. These disadvantages include:

• Higher Long-Term Maintenance Costs: Simply running assets until they break can lead to higher long-
term maintenance costs as the condition of equipment deteriorates before problems are discovered.
This can lead to other components being affected and more parts requiring repair or replacement along
with the associated labour costs
• Safety Issues: Pressure to reduce unexpected maintenance costs can also create safety issues as repair
work may be rushed and not completed correctly. Also, running a machine until it breaks can cause
potential hazards for staff using the machine

Importance of Corrective Maintenance

Corrective maintenance is important as it allows a facility to return to full efficiency following an equipment
failure. Maintenance tasks involve the replacement or repair of items after they have failed and can be
prioritized according to how critical they are. This priority includes factors relating to safety as well as
production and downtimes.

Unscheduled corrective maintenance tasks can slow production lines, but usually the downtime associated
with these corrective tasks is low in comparison to a total equipment failure. Performing these corrective
actions in a timely manner should restore your asset to full working order as quickly as possible.

Types of Corrective Maintenance (CM)

• Deferred Corrective Maintenance
• Emergency Maintenance (EM)

1. Deferred maintenance
Deferred maintenance is repairs to infrastructure and assets that get delayed and backlogged because of
budget limitations and lack of funding.

Compelling research shows that delaying maintenance can increase future costs and capital expenditures by as
much as 600%. Despite the extraordinary consequences of delaying important repairs, deferred maintenance is
common inside facilities and manufacturing plants. It also contributes to safety hazards, energy inefficiency,
and reputational damage for organizations.

Deferred repairs are often put into a maintenance backlog that creates a vicious cycle. As necessary upgrades
are postponed, system failures start increasing at a greater volume and frequency. This puts maintenance
teams in a mode of reactivity with less focus on preventive maintenance.

2. Emergency Maintenance (EM)

Emergency Maintenance (EM) is an immediate action that is needed to be taken whenever any unexpected
failure of asset occurs or assets get broken down. These unexpected failures can be dangerous and might
cause greater damage to health, safety as well as working environment. Emergency maintenance is
something that if failed equipment is not repaired immediately after failure, then it might cause greater
damage, affects health, and results in production loss.
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Workflow of Emergency Maintenance (EM) :

Advantages :

• One of main advantages of emergency maintenance is that there is no initial planning involved
so initial cost involved to maintain equipment before failure occurrence is safe.
• As no planning is involved, number of team members require to resolve issues will be less.
• EM usually guides technicians to take preventive measures to prevent system from greater
damages.
• EM also helps one to immediately identify major cause of failure and then restore asset or
equipment to its normal working condition. In turn, it minimizes loss.

Disadvantages :

• Unpredictability is one of main disadvantages of Emergency maintenance as one does not when
failure is going to occur. This might result in delays in production, decrease in product quality,
increase labor costs, etc.
• No planning is involved, and no tools and resources are collected that are required to resolve
issues as such issues occur unexpectedly.
• Emergency maintenance does not increase lifetime of equipment. In fact, it generally reduces
lifespan of equipment.
• It can be more costly than expense of regularly implementing preventive maintenance.
• Everyone’s main priority is not to deal with such type of maintenance. But no matter what, one
has to plan to overcome such emergency situations.