ELECTIVE -III

PLANT ENGINEERING AND MAINTENANCE

PLANT ENGINEERING

 Branch of engg. deals with

 instellation

 Operation

 Maintenance

 Modification

 Modernisation

 protection
 Multi disciplinary
 Mech engg.
 Elect engg.

 Civil engg.

 Chemical engg.

 Plant engineer is a facility manager – he

ensures the facility, safety and reliability of
the system.
 Plant :- place where men, materials and
machines come together & convert the raw
material in to a required product.
 Responsibilities of plant engr.
 Ensure the reliability of the plant and equipment
 Optimisation of the operation and maint cost

 Implement all Safety, environment, labour norms

 Short term and long term planning

ACTIVITIES
 Design – design of devices required in the plant
 Construction
 Instellation
 Provide utilities and services
 Maintenance
 Improvement
 Planning
 Administration
 Purchasing
 coordination
MAINTENANCE

 Care and upkeep

 Machinary

 Equipment

 Facility

 Property

Preserving physical asset to enhance the life,

maintain the efficiency and improve the
productivity.
 All actions necessary for retaining an item, or
restoring to it, a serviceable condition,
include servicing, repair, modification,
overhaul, inspection and condition
verification
 Increase availability of a system
 Keep system’s equipment in working order
IF NO MAINTENANCE

 Losses due to breakdown

 Operators less able to do repairs themselves

 Machine and product failure can have effect

on company’s operation and profitability
 Idle workers, facility
MAINTENANCE IN SERVICE INDUSTRY

 Hospital
 Restaurants

 Transport companies

 Banks

 Hotels and resorts

 Shopping malls / retail

 Gas station
 MAINTENANCE IN MANUFACTURING
 Electronic
 Automotive

 Petrochemicals

 Refinery

 Furniture

 Ceramics

 Food and beverages

OBJECTIVE OF MAINTENANCE

 To prevent frequent breakdown (down time)

 To prevent accidents
 To prevent damage
 To prevent wastage
 To enhance the life ( minimise the deterioration)
 To increase reliability
 To know replacement
Maintenance affects all aspects of business such as
the product quality, cost, availability etc.
MAINTENANCE FUNCTIONS

 Replace – unserviceable with serviceable

 Repair – troubleshooting, making
adjustment, re conditioning or correcting the
fault
 Overhaul – highest degree of maintenance ,
complete service
 Rebuild – modification in design or
renovation
 Service / lubricate - clean, drain, paint, oil
change
 Inspect/check – examining the serviceability
 Test – verify serviceability by measuring and
comparing with established standards
 Adjust – change the settings to get the
required performance.
 Calibrate – measuring instruments
 Install – seating and fixing into position and
connecting the services required for the
proper functioning.
 Secondary functions
 Store keeping and inventory management
 Plant protection

 Waste disposal

 Recycling and reusing

 Safeguard the environment

 Proper documentation

 Fialure analysis
MAINTENANCE BENEFITS
 Reduction in cost or expenses (maint cost,
production cost, etc)
 Better process stability and capability
 Extended life
 Reduced spare parts inventory
 Reduced overtime and out-sourcing
 Improved safety and housekeeping
 Environment friendly
 Improved confidence of employee / employer
NOTE

 Skill developed from experience , knowledge

and commonsense is the important tool of
maintenance.
 Planning, scheduling and controlling are the
important elements needed for the
systematic maintenance.
QUESTION?
 Why do we need maintenance?
 What are the costs of doing maintenance?
 What are the costs of not doing
maintenance?
 What are the benefits of maintenance?
 How can maintenance increase profitability
of company?
PROBLEMS IN MAINTENANCE
 Lack of management attention to maintenance
 Little participation by accounting in analyzing and
reporting costs
 Difficulties in applying quantitative analysis
 Difficulties in obtaining time and cost estimates for
maintenance works
 Difficulties in measuring performance
MAINTENANCE COSTS

 Cost to replace or repair

 Losses of output

 Delayed shipment

 Scrap and rework

 Indirect losses
 15S-20

TWO BASIC OPTIONS

Reactive Maintenance:
 Breakdown maintenance
 Reactive
approach; dealing with breakdowns or
problems when they occur
Proactive Maintenance:
 Preventive maintenance
 Proactive approach; reducing breakdowns
through a program of lubrication, adjustment,
cleaning, inspection, and replacement of worn
parts
 15S-21

TOTAL MAINTENANCE COST

Figure 15S.1

Total Cost
Cost

Preventive
maintenance cost

Breakdown and
repair cost

Optimum Amount of
preventive maintenance
TYPES OF MAINTENANCE

 Maintenance may be classified into two

categories:
 1. Un planned Maintenance

Corrective / breakdown maintenance

Opportunistic maintenance
2. Planned Maintenance
scheduled maintenance
preventive maintenance
Predictive maintenance (CBM)
Proactive maintenance
reliability centred maintenance
CORRECTIVE OR BREAKDOWN MAINTENANCE

 Corrective or Breakdown maintenance

implies that repairs are made after the
equipment is failed and can not perform its
normal function anymore
 Quite justified in small factories where:

 Down times are non-critical and repair

costs are less than other type of
maintenance
 Financial justification for scheduling are not
felt
DISADVANTAGES OF CORRECTIVE MAINT.
 Breakdown generally occurs inappropriate
times leading to poor and hurried
maintenance
 Excessive delay in production & reduces
output
 Faster plant deterioration
 Increases chances of accidents and less
safety for both workers and machines
 More spoilt materials
 Direct loss of profit
 Can not be employed for equipments
OPPORTUNISTIC MAINTENANCE

 Do the maint. When an opportunity gets

 When we do the maint on a m/c , check the
other component and do repair or replace if
required
 Cost of replacing parts together (group
replacement) is much less than individual
replacement.
 Useful in non monitored system
ROUTINE MAINTENANCE

 Simple work done as routine

 Cleaning

 Lubrication

 Minor adjustments

 It reduces the rate of failure and large failure

 Normally done by the operator

 Once in a day or in a shift

PREVENTIVE MAINTENANCE

 Planned maintenance to improve the m/c life

and performance. It includes
 Painting

 Lubrication

 Cleaning

 Adjusting

 Repair

 replacement
 15S-29

PREVENTIVE MAINTENANCE

 Preventive maintenance: goal is to

reduce the incidence of breakdowns or
failures in the plant or equipment to
avoid the associated costs
 Preventive maintenance is periodic
 Result of planned inspections
 According to calendar
 After predetermined number of hours
 15S-30

EXAMPLE 15S-1

Frequency of breakdowns

Number of breakdowns 0 1 2 3
Frequency of occurrence .20 .30 .40 .10

If the average cost of a breakdown is

$1,000, and the cost of preventative
maintenance is $1,250 per month, should
we use preventive maintenance?
EXAMPLE 15S-1 SOLUTION

Number of Frequency of Expected number of

Breakdowns Occurrence Breakdowns
0 .20 0
1 .30 .30
2 .40 .80
3 .10 .30
1.00 1.40

Expected cost to repair = 1.4 breakdowns per month X $1000 = $1400

Preventive maintenance = $1250
PM results in savings of $150 per month
15S-31
ACTIVITIES IN PM

 Non destructive testing

 Periodic inspection

 Servicing

 Minor replacement

 Maintenance schedule
ADVANTAGES OF PM

 Eliminates the premature replacement of m/c

 Reduces breakdown and down time

 Reduces over time

 More economic use of maint workers

 Reduces large scale repair

 Reduces rejection, rework, scrap, etc.

 Improves safety and quality

RISKS IN PM

 Damage to an adjacent m/c during PM

 Damage to m/c due to improper work

 Life of m/c reduces if maint done by unskilled

workders
PM FLOW CHART
PREDICTIVE MAINTENANCE

 The failure of m/c is predicted in advance of

failure through inspection and by using
instruments.
 Normal servicing of a car is PM

 If we use sensor to know the oil change, it is

predictive maintenance.
 It uses human senses and instruments like

 Vibration measurement, thermography, etc

 15S-37

PREDICTIVE MAINTENANCE

 Predictive maintenance
 An attempt to determine when best to
perform preventive maintenance activities
 Total productive maintenance
 JIT approach where workers perform
preventive maintenance on the machines
they operate
 15S-38

REPLACEMENT

 Trade-off decisions
 Cost of replacement vs. cost of continued
maintenance
 New equipment with new features vs.
maintenance
 Installation of new equipment may cause
disruptions
 Training costs of employees on new equipment
 Forecasts for demand on equipment may
require new equipment capacity
 When is it time for replacement?
CONDITION BASED MAINT (CBM)

 A type of predictive maintenance

 It uses condition monitoring

 It uses advanced technology to determine

the condition of equipment
 Vibration measurement and analysis

 Infrared thermography

 Oil analysis and tribology

 Ultrasonic, motor current analysis