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Maintenance

Definition: It's a group of (actions & works) done for the equipment to be in a good condition at any time.

Causes of maintenance: 1Equipment weakness design a. b. 2Unsuitable materials Unsuitable working environment

Decreasing in equipment efficiency during its life time


a.

Change in working environment condition Effect of external and internal elements Dynamic (Critical speed) Mechanical (over load) Chemical (excessive wearing)

b. c. d. e.

Maintenance Objectives

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Increase equipment efficiency. Restore the operating condition under which equipment

was designed.
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Insure safety for operator, equipment and environment,

and this will lead to: a. b. c. Increase equipment (reliability & availability) Increase equipment life time Reduce operating cost

Break downs Caused by: Unsuitable operations; such as:


-

Over load Long idling speed operation Suddenly loading & unloading Operation with failure signs (sound visual vibration

smell)

Effect on: -

General unit performance (Decrease) Production quality (Decrease) Operating cost (Increase) Benefits (Decrease) Crew moral (Decrease)

So, it is found that cost of break down repairs is three times cost of planned repair

Established successful maintenance

Good management (save all things for the crew)

Budget (save money)

Good crew (dealing with the equipment)

Start successful and organized maintenance

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Established & organized maintenance department Manage the maintenance Control the maintenance

* Manage the maintenance: Introduce maintenance planning Show how to perform the work Consider worker feeling and capability

* Control maintenance: Collecting data and information Analyzing Spare parts management Cost control

Causes of reduced maintenance quality: 1Lack of a. b. c. d. e. f. g. 234567Information data Maintenance instruction Spare part & spare part information Recording data Follow up procedures Analysis Expertise

Unsuitable planning Incompetent management Insufficient budget partial CMMS implementation staff overload or not enough poor communication

Before setting up maintenance program for any equipment, some important information should be taken into consideration: Age Design Manufacturer Operation Environment condition
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Old and New equipments

Comparison Design

Old equipment heavy weight low speed low power low

New equipment light weight high speed high power high

Manufacturer

accuracy
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accuracy complicated

simple

Operation

manufacture manual control


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manufacture automatic control continuousl

partially

operating Crew work at

y operating work at

normal load available crew crew low cost

maximum load optimize crew crew high cost

Maintenance types There are many type of maintenance which may be carried out for any equipment: abunplanned maintenance planned maintenance

Unplanned maintenance (OTF) Operate To Failure Apply in case of: Emergency Accident Break down Collapse Apply for: 123Cheep equipment Insensitive equipment Uncomplicated equipment

Planned maintenance is divided into four categories: 1preventive maintenance


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predictive maintenance corrective maintenance opportunity maintenance

1- Preventive maintenance: Depends on: Fixed time maintenance (FTM) Usage Based Maintenance (UBM) o o o Apply for: new equipment expensive equipment sensitive equipment complicated equipment Running hours Tones Number of operations

2- Predictive maintenance: (CBM) Condition Based Maintenance Depends on: Performance o o o Wear Power output Speed

Continuously checks o o o Temperature Pressure Leak

Periodical checks o o o Crack detection Lubricating oil analysis Vibration

Note: This type of maintenance is considered as a perfect type where it is apply before any break down occurs, but it needs: 1- high technology measurement devices 2- high technology analysis units

3- Corrective maintenance: Apply in case of failures that were expected but were not prevented because they were not critical for safety or economy. current repairs replacement recondition

It is the worst type of planned maintenance where it may cause: Equipment shut down Lost of time and money

4- Opportunity maintenance: This type of maintenance is carried out when available by chance as: Bad weather Labor strike National holidays

Factors affecting the content of mixing maintenance types: 123-

Nature of equipment (age, design, manufacture) Nature of operation (hours, overhauls) Performance requirements (availability, reliability) Time consume for maintenance Maintenance cost relative to equipment price Maintenance cost relative to different market prices

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Maintenance plan abbreviations definition

MTBF:

Mean Time Between Failure (or MTTF) Is the ratio between operating time to number of failures in between MTBF = operating time / no. of failures in between,

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MTBM:

Mean Time Between Maintenance

It is time between successive maintenance activities & set according to maker instructions. RTTM Remaining Time To Maintenance Is the residual time for carrying out the maintenance and is determined by maintenance department and the crew. BL: Back Logs It is the allowable time (running hours/weeks) for maintenance job late execution, determined by maintenance department and the crew Down time: It is the time consumed beginning from equipment break down until equipment operating - Equipment break down - Fined the expert - Detect the fault - Find spare part - Repair the fault - Equipment operate
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Re:

Reliability It is the actual time in hours that a system or machine can operate at optimum design conditions. Re = e (MTBM/MTBF)

Example: For some equipment through 4000 operating hours there was twice failures, if the maker MTBM = 1500 h, Determine the MTBF and the reliability Re. Then discuss the new one if we reduce the MTBM to 1000. Solution: MTBF = operating time / no. of failures in between, MTBF = 4000 / 2 = 2000 h Re = e (MTBM/MTBF) Re = e (1500/2000) Re = 0.472 New Re = e (1000/2000) New Re = 0.606

Av:

Availability

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Is the percentage of total production time to the actual production time (at any level of performance) Av = MTBF / (MTBF + Down times)

Example: Two motors A & B, Motor A has MTBF = 10 years MTBM = 1 year Down time = one month Motor B has MTBF = 20 years MTBM = 2 year Down time = two month

Estimate reliability and availability for each motor?

Solution: Motors A B Reliability Re 0.905 0.905 Availability Av 0.992 0.992

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