Ch.

E 405
Maintenance Engineering
Ms SADIYA MUSHTAQ
 Course Outline
1. Types of maintenance and their applications
2.
3.
Maintenance management
Maintenance of pumps, machines, and piping
Preventive Maintenance 
Corrective Maintenance
4. Lubrication programs
5. Forms of corrosion, prevention, and inhibition Total Productive Maintenance (TPM)
6. Design considerations: layout and construction
7. Overall safety of plant and personnel
8. Fire and explosion
9. Health hazard
10. Accident prevention
11. Government regulations for industrial safety
 Corrective Maintenance
Corrective or Breakdown maintenance implies that repairs are
made after the equipment is failed and can not perform its
normal function anymore
 Corrective Maintenance Types
1.Fail-repair:
The failed item is restored to its operational state.
2.Salvage:
This element of corrective maintenance is concerned with disposal of non repairable material and
use of salvaged material from non repairable equipment/item in the repair, overhaul, or rebuild
programs.
3.Rebuild:
This is concerned with restoring an item to a standard as close as possible to original state in
performance, life expectancy, and appearance. This is achieved through complete disassembly,
examination of all components, repair and replacement of worn/unserviceable parts as per
original specifications and manufacturing tolerances, and reassembly and testing to original
production guidelines.
 Corrective Maintenance Types
4.Overhaul:
Restoring an item to its total serviceable state as per maintenance serviceability
standards, using the “inspect and repair only as appropriate” approach.

5. Servicing:
Servicing may be needed because of the corrective maintenance action, for
example, engine repair can lead to crankcase refill, welding on, etc. Another
example could be that the replacement of an air bottle may require system
recharging.
 Corrective Maintenance
Steps, Downtime Components, And Time Reduction
Strategies At System Level
 Corrective Maintenance Steps
Different authors have laid down different sequential steps for performing
Corrective Maintenance

Nine steps (as applicable):

localize, isolate, adjust, disassemble, repair, interchange, reassemble, align,
and checkout.

Seven steps (as applicable):

localization, isolation, disassembly, interchange, reassemble, alignment,
and checkout.
 Corrective
Maintenance Steps
For our purpose, we assume that corrective
maintenance is composed of FIVE major
sequential steps as shown In figure. These steps
are:

 Fault recognition
 Localization
 Diagnosis
 Repair
 Checkout
 Corrective Maintenance Downtime
The major corrective maintenance downtime components are active repair
time, administrative and logistic time, and delay time. The active repair
time is made up of the following subcomponents:
 Preparation time
 Fault location time
 Spare item obtainment time
 Fault correction time
 Adjustment and calibration time
 Checkout time
 Time Reduction Strategies At System Level
 Efficiency in fault recognition, location, and isolation
 Effective interchangeability
 Redundancy (Switching Mode)
 Effective accessibility
 Human factor considerations
 Time Reduction Strategies At System Level
Efficiency in fault recognition, location, and isolation
Past experience indicates that in electronic equipment, fault isolation and location consume the
most time within a corrective maintenance activity. In the case of mechanical items, often the
largest contributor is repair time. Factors such as well designed fault indicators, good
maintenance procedures, well-trained maintenance personnel, and an unambiguous fault isolation
capability are helpful in lowering corrective maintenance time.

Effective interchangeability
Good physical and functional interchangeability is useful in removing and replacing parts/items,
reducing maintenance downtime, and creating a positive impact on spares and inventory needs.
 Time Reduction Strategies At System Level
Redundancy (Switching Mode)
This is concerned with designing in redundant parts that can be switched in at the moment of
need so the equipment/system continues to operate while the faulty part is being repaired. In this
case the overall maintenance workload may not be reduced, but the equipment/system downtime
could be impacted significantly.

Effective accessibility
Often a significant amount of time is spent accessing the failed part. Proper attention to
accessibility during design can help reduce part accessibility time and, in turn, the corrective
maintenance time.
Time Reduction Strategies At System Level
Human factor considerations
Attention paid to human factors during design in areas such as readability of instructions, size,
shape, and weight of components, selection and placement of dials and indicators, size and
placement of access, gates, and readability, and information processing aids can help reduce
corrective maintenance time significantly.
Maintenance
Cost
Optimization
 Maintenance Cost
Cost

Breakdown Cost

Maintenance

Commitment
 Maintenance Cost
Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Cost
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Maintenance
Commitment
 Maintenance Cost
Cost
Total Maintenance Cost

PM Cost

Breakdown Cost

Optimal Maintenance
Commitment
Corrective Maintenance
Practice Task
 Assignment
Describe the possible corrective
maintenance steps for the
maintenance of a valve installed
in an industrial pipeline?

Submission Deadline:
11th May (Monday)