PLANT MAINTENANCE

(ME-426)

Maintenance Types

` Assistant Professor
Adeel Ahmed Khan,
(MED)
Breakdown Maintenance
• Less attention to equipment or system & is allowed to function or operate till no
failure occurs.
• This approach of maintenance is ineffective and extremely expensive.
• Labour and materials are used inefficiently.
• The factors resulting to high maintenance cost are poor planning and incomplete
repair.
• Breakdown maintenance is referred to by many different names:
 Reactive maintenance
 Repair, fix when- fails
 Run-to-failure (RTF)
 Fire Fighting

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Breakdown Maintenance
• Equipment receives maintenance (e.g., repair or replacement) only when the
deterioration of the equipment’s condition causes a functional failure.
• Unexpected and unscheduled equipment downtime.
• If equipment fails and repair parts are not available, delays occur.
• If these parts are urgently required, a premium for expedited delivery must be paid.
• If the failed part is no longer manufactured or stocked, more drastic and expensive
actions are required to restore equipment function.
• There is no ability to influence when failures occur because no (or minimal) action is
taken to control or prevent them.
• Spare parts inventory are high.

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Breakdown Maintenance
Types of Break down Maintenance
Deferred Corrective Maintenance
It is not immediately carried out after fault detection but is delayed in accordance with
given maintenance rules.

Immediate Corrective Maintenance

It is carried out without delay after a fault has been detected to avoid unacceptable
consequences.

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Preventive Maintenance
• Preventive Maintenance attempts to prevent any probable failures/ breakdowns
resulting in production stoppages through periodic inspections, lubrication, calibration,
replacement and overhauls.
• It follows a slogan “Prevention is better than cure”.
• It involves
 Periodic inspection of equipment / machinery to uncover condition that leads to
production breakdown and harmful depreciation.
 Regular cleaning, greasing and oiling of moving parts.
 Replacement of worn out parts before they fail to operate.
 Periodic overhauling of the entire machine.

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Preventive Maintenance
Features of Preventative Maintenance:
• Proper identification of all items to be included in the maintenance programme.
• Adequate records covering, volume of work, associated costs etc.
• Use of checklists by inspectors.
• An inspection frequency schedule.
• A crew of well qualified inspectors.

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Predictive Maintenance
• This technique uses regular evaluation of the actual operating conditions of the plant
equipment.
• It supplies the necessary information which helps to improve or increase the
production capacity, product quality and overall effectiveness of production function.
• This is a method in which the service life of important part is predicted based on
inspection or diagnosis, in order to use the parts to the limit of their service life.
• It manages trend values, by measuring and analyzing data about deterioration and
employs a surveillance system, designed to monitor conditions through an on-line
system.

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Predictive Maintenance
Condition based Maintenance Techniques
Vibration monitoring: It determines the actual condition of equipment’s or machines by
studying the noise or vibration produced during functioning.
Thermography: It determines the condition of plant, machinery, systems, etc., by
studying the emission of infra-red energy (i.e.) temperature.
Visual inspection: It determines the conditions of working elements visually based on
the experience.
Tribology: It determines the dynamic condition of bearing lubrication, by adopting any
one of the techniques like lubricating oil analysis, spectrographic analysis and wear
particle analysis.

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