Session 03

Introduction to Bioenergy Plant

Maintenance
BST 42212- Bioenergy Plant Maintenance
Bachelor of Biosystems Technology Honors (BBST Hons) Degree Programme
Faculty of Technology
Sabaragamuwa university of Srilanka

Prepared by: Eng. Prasad Amarasinghe

Content
• Downtime of maintenance
• Measuring downtime of maintenance
• Maintenance Costs
Downtime of maintenance
“Period during which an equipment or machine is not functional or
cannot work. It may be due to technical failure, machine
adjustment, maintenance, or non-availability of inputs such as
materials, labor, power.”

There are two types of downtimes.

❖Planned downtime
❖Unplanned downtime
Measuring downtime of maintenance
Downtime = Planned Production Time – Run Time
Measuring downtime of maintenance
Example
if the company is in operation for 8 hours/day, 20 days/month and a
particular asset is down for one day during the month (8 hours), then
the downtime on that particular asset is:
Maintenance Costs
 The traditional view attempted to
balance preventive and breakdown
maintenance costs
 Typically this approach failed to
consider the true total cost of
breakdowns
 Inventory
 Employee morale
 Schedule unreliability
Maintenance Costs
Total
costs

Preventive
Costs maintenance
costs

Breakdown
maintenance
costs

Maintenance commitment
Optimal point (lowest
cost maintenance policy)

Traditional View
Maintenance Costs

Total
costs

Full cost of
breakdowns
Costs

Preventive
maintenance
costs

Maintenance commitment
Optimal point (lowest
cost maintenance policy)
Full Cost View Figure 17.4 (b)
Maintenance Cost Example
Maintenance Cost Example
Should the firm contract for maintenance on
their printers?
Number of Number of Months That
Breakdowns Breakdowns Occurred
0 2
1 8
2 6
3 4
Total: 20

Average cost of breakdown = $300

Maintenance Cost Example
Maintenance Cost Example
1. Compute the expected number of
breakdowns
Number of Frequency Number of Frequency
Breakdowns Breakdowns
0 2/20 = .1 2 6/20 = .3
1 8/20 = .4 3 4/20 = .2

Expected number of
breakdowns = ∑ Number of
breakdowns x
Corresponding
frequency

= (0)(.1) + (1)(.4) + (2)(.3) + (3)(.2)

= 1.6 breakdowns per month
Maintenance Cost Example
2. Compute the expected breakdown cost per
month with no preventive maintenance

Expected Expected number of Cost per

breakdown cost = breakdowns x breakdown

= (1.6)($300)
= $480 per month
Maintenance Cost Example
3. Compute the cost of preventive
maintenance

Cost of expected
Preventive = Cost of
maintenance cost breakdowns if service + service contract
contract signed

= (1 breakdown/month)($300) + $150/month
= $450 per month

Hire the service firm; it is less expensive

How Maintenance is Performed

Maintenance Manufacturer’s field Depot service

Operator
department service (return equipment)

Competence is higher as we
move to the right
Preventive
maintenance costs less and
is faster the more we move to the left
THANK YOU….