P8

• Use routines and carry out maintenance on given electro, pneumatic and
hydraulic components and a given electro-pneumatic or electro-hydraulic
system

Lesson Objectives
 Understand the concept of maintenance and its importance
 Learn various maintenance types applicable for fluid power systems
 Apply the maintenance activities for the given situations
 Understand the concept of six-point technique for fault finding
• Maintenance is a set of organised activities that are carried
out in order to keep an item in its best operational condition
with minimum cost acquired.
• Frequency of maintenance:
• It is how often maintenance is done. It is defined as time interval over
which maintenance is done regularly.
• It can be annually (once in a year)
• Quarterly (four times per year)
• Monthly
• Weekly
• Daily once per shift
•Corrective maintenance: The set of tasks is destined to correct the defects to be found in the different
equipment and that are communicated to the maintenance department by users of the same equipment.
•Preventive Maintenance: Its mission is to maintain a level of certain service on equipment, programming the
interventions of their vulnerabilities in the most opportune time. It is used to be a systematic character, that is,
the equipment is inspected even if it has not given any symptoms of having a problem.
•Predictive Maintenance: It pursues constantly know and report the status and operational capacity of the
installations by knowing the values of certain variables, which represent such state and operational ability. To
apply this maintenance, it is necessary to identify physical variables (temperature, vibration, power consumption,
etc.). Which variation is indicative of problems that may be appearing on the equipment. This maintenance it is
the most technical, since it requires advanced technical resources, and at times of strong mathematical, physical
and / or technical knowledge.
•Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to review the equipment at scheduled
intervals before appearing any failure, either when the reliability of the equipment has decreased considerably so
it is risky to make forecasts of production capacity . This review is based on leaving the equipment to zero hours
of operation, that is, as if the equipment were new. These reviews will replace or repair all items subject to wear.
The aim is to ensure, with high probability, a good working time fixed in advance.
•Periodic maintenance (Time Based Maintenance TBM): the basic maintenance of equipment made by the
users of it. It consists of a series of elementary tasks (data collections, visual inspections, cleaning, lubrication,
retightening screws,…) for which no extensive training is necessary, but perhaps only a brief training. This type
of maintenance is the based on TPM (Total Productive Maintenance).
Preventive Maintenance:
• This maintenance performed in an attempt to avoid failures, unnecessary
production loss and safety violations.

• It consists of planned inspection and upkeep to avoid faults from occurring .

• This maintenance is done over fixed interval of time called frequency of

maintenance.

• Frequency can be annually, monthly, weekly ; it depends on the system.

• Preventive maintenance is very important in effective maintenance program.

Methods in Preventive Maintenance

Running Adjustment (pump speed, valve settings)

Lubrication (motor/turbine bearing, gear, piston)

Calendar Maintenance (oil change after 6 months)

Running Hour Maintenance (Engine oil change after 1000 hours of

operation)
Advantages of Preventive Maintenance :
• Saves money and energy

• Flexibility allows for the adjustment of maintenance

periodicity.

• Increases life of the system

• Reduces the failure

Corrective Maintenance:
• In this type, actions such as repair/replacement/restore
will be carried out after the failure happens.
• This maintenance is done to remove the source of failure
or reduce its frequency.
• It should be done by a trained person having all the
documents.
• How ??
• Fault Detection
• Fault Isolation
• Fault Elimination
• Verification of fault elimination
Benefits:
It maximize the efficiency of all components
The breakdown is reduced/minimized.
Avoid Unnecessary repairs
Predictive Maintenance (Condition Based Maintenance):
• These are techniques that help to determine the condition of in-service
equipment in order to predict when maintenance should be performed.
• It is a type of preventive maintenance that predict failures that can be
corrected before total failure.
• It can also determine that a failure is about to occur.
• For example, vibration analysis determines the normal vibration that is
acceptable; when the vibration starts to exceed this point, maintenance
can be scheduled when the equipment is not being used in order to
prevent a complete failure during operation.
• Other examples are ultrasonic detection, Infrared thermography, oil
analysis, inspection.
Benefits of Predictive Maintenance:
• Increases life of equipment
• Decreases the downtime
• Make possible the scheduled downtime
• Economical