Maintenance Methodology: By, Tanweer Saiyad Assistant Manager Mechanical PI Industries

MAINTENANCE METHODOLOGY
By,
Tanweer Saiyad
Assistant Manager
Mechanical
PI Industries
Created By - Tanweer Saiyad
OVERVIEW
 Introduction to Maintenance
 Types of Maintenance
 Bath Tub Curve
 Reactive Maintenance
 Preventive Maintenance
o Checking Belt Drive
o Lubrication
o Shaft Alignment Check
o A new shaft alignment method (Verti-zontal Alignment)
 Predictive Maintenance
o LLF trust your instinct
o Vibration Analysis
Introduction to RCM Created By - Tanweer Saiyad

Maintenance
The process of preserving a condition or situation or the state of

being preserved
• Zero Break Down

• Smooth Operation
• Efficient Working
• Well Lubricated Machinery
• Improve Productivity

Types of Maintenance
1) Reactive Maintenance
=> Repair
2) Preventive Maintenance
=> Greasing, Oil, Filters, Belt etc.
3) Predictive Maintenance
=> Inspections, LLF, Vibrations, Thermography etc.
BATH TUB CURVE
Most products go through 3 Distinct phases from product inception to wear out

Phase 1 Infant Mortality
• Many Components fail very soon after they are put into service
 Reasons
 Poor design
 Improper Installation
 Inappropriate Operation
 Rough Handling
 Environment Conditions etc.
 What to do ?
 Follow Operation Manual given by Vendor
 Choose appropriate machine for your application
 Continuous Monitoring of Machine till Phase 1 is over
Phase 2 Useful Life Period
• Machine will generally tend to remain trouble free over its
operating lifetime. Failure rate is constant and very low.
 Reasons
 Insufficient or Over Lubrication
 No periodic Maintenance
 No replacement for worn out parts
 Sudden change in operating condition
 Rough Handling
 What to do ?
 Follow Preventive Maintenance
 Condition Monitoring of Equipment at regular interval
 Checking and replacement for worn out part
 Follow SOP for operation of Created
Machine By - Tanweer Saiyad
Phase 3 Wear out / Ageing
• After a machine reaches a certain age, it enters the period where it
begins to wear out, and failures start to increase.
 Reasons
 Life cycle of components are over
 Periodic stress on moving parts
 Natural Phenomenon
 What to do ?
 Complete overhauling of Equipment
 While overhauling replace all worn out parts
 Replace the equipment

REACTIVE MAINTENANCE
“RUN IT TILL IT BREAKS”
• Noactions of efforts are taken to

maintain the equipment as the
designer originally intended to ensure
design life is reached
• Directly replace the whole equipment

•Advantages
• Low Maintenance Cost
• Less Staff Required
• Disadvantages
• Increased Cost due to unplanned downtime of equipment
• Increased labor cost, especially if overtime is needed
• Cost involved with repair or replacement of equipment
• Possible secondary equipment or process damage
• Insufficient use of staff resources
It is a schedule of planned maintenance actions aimed at
the prevention of breakdowns and failures. The primary
goal of PM is to mitigate degradation of a component or
system with the aim of sustaining or extending its useful life
through controlling degradation to an acceptable level.
• Advantages
 Cost effective in many capital-intensive processes.
 Flexibility allows for the adjustment of maintenance periodicity
 Increased component life cycle
 Energy Savings
 Reduced equipment or process failure
 Estimated 12% to 18% cost savings over reactive maintenance program
• Disadvantages
 Catastrophic failure still likely to occur
 Labor intensive
 Includes performance of unneeded maintenance
 Potential for incidental damage to components in conducting unneeded
maintenance
Belt Drive Maintenance
• Checking Pulley Condition

• Checking Belt Condition
• Checking Belt Alignment
• Checking Belt Tension

LUBRICATION BASICS

WHAT IS A LUBRICANT EXPECTED TO DO ???
•Reduce Friction
•Minimize wear
•Cool Parts
•Prevent Corrosion
•Disperse Contamination
•Act as a sealant
•Transmit Power
FIVE RIGHTS OF LUBRICAITON
• Right Type of Lubrication

• Right Quality
• Right Amount
• Right Place
• Right Time

Selection of Lubricant depend on
• Speed
• Viscosity
• Load

Viscosity
Viscosity = Resistance to flow (cm2/sec)
Most important characteristic of an oil.
• Viscosity is a delicate balance
 Viscosity too high
 More heat from liquid friction
 Viscosity too low

 Mechanical Friction due to too thin
layer

Grease Lubrication
• Relatively easy to handle

• Require simplest sealing devices
• Easy to replace

How Grease is made ?
1) Base oil ( It defines main property of grease )
• Mineral Oil , Synthetic Oil
2) Thickening Agents ( Used to maintain Semi solid state of grease )
• Metallic Soap Type – Lithium, Sodium, Calcium
• Non Soap – Inorganic Type – Silica Gel, Bentonite
• Non Soap – Organic Type – Polyurea, Flourocarbon
3) Additives ( To improve basic properties and Efficiency )
• Ex. Anti-oxidents, High Pressure, Rust Prevention, Anti Corrosion
4) Consistency ( Index of hardness and fluidity of grease)
• The higher the number the softer the grease
• Determined by Amount of thickening agent and viscosity of base oil
5) Mixing of Greases ( Made from 2 types of grease )
• The consistency of grease will change
• Characteristics will change
• For mixing Same Base oil grease should be selected

Amount of Grease
 Depend on following
• Size and Shape of Bearing Housing
• Space Limitation
• Bearing Rotating Speed
• Type of Grease used
• Type of Bearing Installed
 Thumb Rule
• Bearing should be filled up to 30-40 % of their space (P. T. O.)
• Housing should be filled up to 30-60 % of their space
• Where speed are high and temperature rises use reduce amount of grease
Excessive amount of grease cause temperature rise which

in turn causes the grease to soften and may allow leakage.
With excessive grease fills oxidation and deterioration may
cause lubricating efficiency to be lowered
How to find bearing space ???
V = K x W V = Bearing space (cm ) 3
K = Bearing Space Factor (Table Below)

W = Mass of Bearing (kg)

Function of Lubrication Oil
• Lubricate parts and prevent wear
 Basic Function of oil. Keep moving parts separated
• Reduce Friction
 Film of oil reduce friction because no metal to metal contact
• Protect against Rust and Corrosion
 As oil degrade it form corrosive by product, for that anti-corrosive additives are
added
• Keep components clean
 Oil need to be very stable under heat and not cause system deposits
• Be compatible with seal
 The oil must Lubricate not deteriorate seal
• Prevent Foam
 Foam reduces the lubrication properties of the oil, so the oil must be resistance
to foaming Created By - Tanweer Saiyad
Properties of Lubricant Oil
• Kinematic Viscosity
• Viscosity Index
• Pour Point
• Flash Point

Kinematic viscosity
•Measure of internal resistance to flow “Thickness” of fluid
Recommendations
 Low Viscosity oils used
• High speeds
• Low pressure
• Low temperature
 High Viscosity oils used
• Low speeds
• High pressure
• High temperature

Viscosity index
• Measure of fluids change of viscosity with
temperature. Higher the VI lower will be the change
of viscosity with temperature
Pour Point
• Lowest temperature at which the fluid will flow
which indicates lowest operating point
Flash Point
• Lowest temperature above which the liquid will
ignite under flames which indicates safer operating
temperature for given oil
Types of Industrial Oils
• Hydraulic Oils
 Transmit force applied at one point in a system to another. Protect Seal, Lubricate and Transfer Heat
• Industrial Gear Oils
 Can work in High Load, high pressure, Low foam tendency, Excellent Thermal and Oxidation Stability,
Rust and Corrosion protection to metal parts
• Compressor & Refrigeration Oils
 High fluidity at very low temperature, resist deposit of formation, reduced tendency to foam, ensure
high condenser efficiency and reduced compressor valve maintenance due to low deposition.
• Heat Transfer Fluids
 High Oxidation and Thermal Stability, Low viscosity and High heat transfer Coefficient, Good
solvency, Non Corrosive, Low Vapor Pressure, Non toxic, easily disposable,
• Transformer Oils
 High flashpoint, Resists oxidation and deposit formation, compatible with material of transformer,
superior electrical properties

Shaft Alignment Concept
• What is Misalignment ???

• Types of Misalignment
 Offset Misalignment
 Angular Misalignment
• Signs of Misalignment

Shaft Alignment Concept
• Total Indicator Reading (TIR)

• Validity Rule
• True Position Sensing

Verti-Zontal Method of Alignment

LLF
LOOK
LISTEN
FEEL

IMPORTANCE OF CLEANLINESS
IN PLANT MAINTENANCE

Introduction to Vibration Analysis
• Vibration – Cyclic motion around the equilibrium position
• We can tell by touching that the machine is running or not because of the
transmission of forces generated by Rotational motion by different components of
machine
• Many parts of the machine are rotating and each one of these parts is generating its
own distinctive pattern and level of Vibration
• Human touch is not sensitive enough to discern these differences
• This is where vibration detection instrumentation and signature analysis software can
provide us the necessary sensitivity
• The magnitude of vibration is expressed as below :
DISPLACEMENT VELOCITY ACCELARATION
The total distance travelled by The rate of change of velocity.

A measurement of the speed
vibrating part from one Recognizing that vibrational forces
at which a machine or
extreme limit of travel to the machine component is moving are cyclic, velocity change from a
other extreme limit of travel. neutral or minimum value to some
as it undergoes oscillating maximum. Acceleration is a value
This distance is called “pick to
motion. representing the maximum rate
pick Displacement”
Created By - Tanweer Saiyad that velocity is increasing.
Why does vibration occur ?
• Shaft Bend/Run out
• Bearing defect
• Machine Components defect
• Damaged teeth of gear or other machine components
• Direct metal to metal contact
• Misalignment
• Impeller imbalance
• Foundation looseness
• Machine Wear Components
• Eccentric Coupling

Important Terminologies
• Frequency
 Rate at which something occur over a
period of time
• Amplitude
 The maximum extent of vibration or
oscillation
• Time
 Self Explaining
Vibration Analysis Introduction

ISO 10816

ISO 10816
• Class I: Individual parts of engines and machines, integrally connected to the
complete machine in its normal operating condition. (Production electrical
motors of up to 15 kW are typical examples of machines in this category.)
• Class II: Medium-sized machines (typically electrical motors with 15 kW to 75

kW output) without special foundations, rigidly mounted engines or machines
(up to 300 kW) on special foundations.
• Class III: Large Prime movers machine sets which have a power above 15 kW
and operating speeds between 120 and 15,000 RPM. This category includes
common industrial motors, pumps, generators, rotary compressors, blowers
and fans, and several types of turbines. Rigid Foundation Only.
• Class IV: Large prime movers and other large machines with rotating masses
mounted on foundations which are relatively soft in the direction of vibration
measurement
Vibration Analysis Introduction
• How Vibrations are generated ?
• Where to measure ?
• Vibration measurement basics
• Spectrum Analysis Basic

Reliability Central Maintenance
• Process of Determining most effective
maintenance approach
• It comply following
1. Reactive Maintenance
2. Preventive Maintenance
3. Predictive Maintenance
4. Proactive Maintenance

History
• In 1950 UAL (United Airlines) found that cost of maintenance for airlines is high
enough to warrant a special investigation into the effectiveness of those activities
• In 1960, A taskforce was formed to investigate capabilities of preventive maintenance
• As a result in 1968 MSG-1 (Maintenance Steering Group Doc 1) was formed and
applied to Boeing 747 Aircraft, First ever maintenance program to apply RCM Concept
• They got huge success by comparing with other aircraft maintenance cost and
effectiveness
• In 1974 the US Department of Defense commissioned United Airlines to write a
report on the processes used in the civil aviation industry for the development of
maintenance programs of aircraft
• The report published in 1978, was entitled Reliability Centered Maintenance
• Rigorous RCM analysis has been used extensively by the aircraft, space, defense, and
nuclear industries where functional failures have the potential to result in large losses
of life, national security implications, and/or extreme environmental impact.

Definition
• It is a high level maintenance strategy to

optimize maintenance of a facility
• Result of an RCM program are maintenance
strategies that should be implemented on all
facility assets
• Maintenance strategies are optimized so that
the plant functionality is maintained using
various techniques
Predictive Maintenance
Proactive Maintenance
RCM
Reactive Maintenance
Preventive Maintenance

3 Steps to RCM
1. Preserve Equipment function by establishing

criticality levels
2. Identify and prioritize failure modes that can
affect system function so
we avoid them
3. Implement RCM using
effective and applicable
approaches
Criticality Levels
1. Safety and Environmental

2. Production Stoppage
3. Repair Expense
4. Effect on systems
5. Redundancy

Establishing Criticality Sample Level 1
• Significant Impact (level 1)
1. Results in loss of life, body part or
permanent disability
2. Results in a reportable
environmental emission
3. Impact on production immediately
resulting in a revenue loss > X Rs.
4. Results equipment loss/damage
5. No redundant back up systems in
place

• Measurable Impact (Level 2)
1. Potential injury to personnel
2. Potential Reportable
environmental emission
3. Impact on production immediately
resulting in revenue cost >X rs
4. Results n equipment Loss Damage

• Potential Impact (Level 3)
1. Potential for injury to personnel
but temporary
2. Potential for revenue loss of > X rs
but adequate stocking is kept
during operation
3. Potential repair cost > X Rs
4. Minimum redundant back up
systems in place

• No Impact (Level 4)
1. No Safety effects
2. No reportable environmental
emission
3. No impact on production resulting
in revenue loss
4. Potential repair cost < X Rs
5. Multiple Redundant Systems

First of all Depart the Major system
Major System
Major Assemblies
Minor Assemblies Minor Assemblies
Components Components Components Components
Components Components
Accessories/ Accessories/ Accessories/ Accessories/ Accessories/ Accessories/

Parts Parts Parts Parts Parts Parts


System/Equipment Hierarchy Sample
Compressed Air System
Compressor Assemblies
Compressor Unit Piping Systems
Compressor Controls Air Receiver Dryer 2
Motor Dryer 1
Heating Heating
Starter Cooler Indicator Valves
Elements Elements
Winding Oil Pump Pressure Handle Desiccant Desiccant

Switches Wheels
Breaker Valves Alarms Springs Control Control

Identify Components
• List all of the components that can fail
and cause the loss of the function
• Group the components where possible
• All Manual Valves
• All Local Indicators
• All Control Loops
• Redundant Equipments

FMEA WORKSHEET
System : Compressed Air Subsystem : Air Compressor
Assembly
Function : Provide Compressed air at 6 kg/cm2
Components Failure Mode Failure Likelihood Failure Effects Recommende
Mechanism d Actions
Compressor
Motor
Valves

Failure Mode
• For each component list the ways that they can fail
and cause the loss of the function
1. Transformer: no output or degraded output
2. Motor : Stops, Fails to start
3. Control Valve : Fails to close or open
4. Pump: No lifting, Bearing Failure
5. Instrumentation : Fails to provide signal inaccurate signal

FMEA WORKSHEET
Assembly
Mechanism d Actions
Compressor Seizes
Motor Fails to Start
Valves Fails to Close

Failure Mechanism
• What causes the failure mode ?
1. Corrosion
2. Erosion
3. Parts Fails
4. Out of Calibration
5. Loose connection
6. Vibration

FMEA WORKSHEET
Assembly
Mechanism d Actions
Bearing
Compressor Seizes Failure
Motor Fails to Start Winding Short
Valves Fails to Close Stem Frozen

Likelihood Table
Level Likelihood
Remote Fails no more than once in 3 years
Very Low Fails no more than once in a year
Low Fails no more than once in every 6 months
High Fails no more than once per month
Very High Fails no more than once every two weeks
Extreme Fails Everyday

Effect Descriptions
Level Effects (Any of Following)
Loss of Life, Body part or lost time accident, Unit Shut
1 Down, Immediate penalty cost, Regulatory non-
compliance
2 Definite loss of production probable penalty cost or

personal injury Equipment Damage
3 Possible Loss of Production, Could Lead to penalty

cost or personal Injury, Possible Equipment Damage
4 No Effect on production, No Regulatory non-

compliance, Very less Equipment Damage cost
Minimal No effect on production Minimal Repair Costs

FMEA WORKSHEET
Assembly
Components Failure Mode Failure Likelihood Failure Effects Recommended
Mechanism Actions
Bearing
Compressor Seizes Failure 1 1
Motor Fails to Start Winding Short 2 1
Valves Fails to Close Stem Frozen 3 3

Recommended Actions
• Is condition monitoring task applicable and effective ?

• Is a time-directed task applicable and effective ?
• Is a combination of activities applicable and effective ?
• Should Equipment be modified ?
• Should Operating procedures be changed ?
• Should Different parts be used ?
• For human error can barriers be installed to minimize probable
failure ?

FMEA WORKSHEET
Assembly
Components Failure Mode Failure Likelihood Failure Effects Recommended
Mechanism Actions
Bearing Maintain
Compressor Seizes Failure 1 1 Lubrication
Maintain
Motor Fails to Start Winding Short 2 1
Cleanliness
Valves Fails to Close Stem Frozen 3 3 Cycle Valve

RCM Team
• At least one person with follow expertise
1. Mechanical Maintenance
2. Electrical Maintenance
3. Process Control
4. Operations
5. System Engineering (Design)
6. Facilitator
• May Include
1. OEM representative
2. Experts from other sites

OU
K Y
A N
TH

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MAINTENANCE METHODOLOGY

Introduction to RCM Created By - Tanweer Saiyad

The process of preserving a condition or situation or the state of

• Zero Break Down

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

• Noactions of efforts are taken to

• Directly replace the whole equipment

Created By - Tanweer Saiyad

• Checking Pulley Condition

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

• Right Type of Lubrication

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

 Viscosity too low

Created By - Tanweer Saiyad

• Relatively easy to handle

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Excessive amount of grease cause temperature rise which

K = Bearing Space Factor (Table Below)

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

• What is Misalignment ???

Created By - Tanweer Saiyad

• Total Indicator Reading (TIR)

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

DISPLACEMENT VELOCITY ACCELARATION

The total distance travelled by The rate of change of velocity.

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

• Class II: Medium-sized machines (typically electrical motors with 15 kW to 75

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

• It is a high level maintenance strategy to

Created By - Tanweer Saiyad

1. Preserve Equipment function by establishing

1. Safety and Environmental

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Accessories/ Accessories/ Accessories/ Accessories/ Accessories/ Accessories/

Accessories/ Accessories/ Accessories/ Accessories/ Accessories/ Accessories/

Accessories/ Accessories/ Accessories/ Accessories/ Accessories/ Accessories/

Winding Oil Pump Pressure Handle Desiccant Desiccant

Breaker Valves Alarms Springs Control Control

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Created By - Tanweer Saiyad

Motor Fails to Start

Valves Fails to Close

Created By - Tanweer Saiyad