Maintenance System

A.K.Mohindru
Ex-General Manager
NTPC Ltd.
Presentation Overview
 Machinery Failure
 Maintenance Objectives
 Maintenance Types
 Maintenance Cost
 Availability
 Integration of Maintenance
 Maintenance Department
 Engineers Duties
 Efficient Maintenance Service
 Maintenance Records
 Overhaul Management
Machinery Failure

 Total damage
 Loss of asset
 Loss of
production
 Loss of life
Machinery failure

 Equipment malfunctions have a direct impact on:

 Production capacity
 Production costs
 Product and service quality
 Employee or customer safety
 Customer satisfaction
Problems in Maintenance
 Lack of management attention to maintenance

 Little participation by accounting in analyzing and

reporting costs

 Difficulties in applying quantitative analysis

 Difficulties in obtaining time and cost estimates for

maintenance works

 Difficulties in measuring performance

Problems Exist Due To:
 Failure to develop written objectives and policy

 Inadequate budgetary control

 Inadequate work quality

 Infrequent use of standards

 To control maintenance work

 Absence of cost reports to aid maintenance planning

and control system
Machinery Failure
Bath Tub Curve
Machinery failure
Routine failures
follow normal
Frequency of Failure distribution

Mean Time Between Failure (MTBF)

 Maintenance Objectives

1. Increased Availability
2. Maximize useful life of equipment
3. Reducing Cost of production
4. Safety Requirements
5. Customer Satisfaction

Increased Availability at optimum cost with safety

Maintenance Types

 Breakdown Maintenance
 Planned Maintenance
 Preventive Maintenance
 Predictive Maintenance
 Maintenance Types
Breakdown Maintenance
 Run the equipment till breakdowns No organized efforts to find out
reasons
 No services except occasional
lubrication unless failure occurs •No stock of spares
•
 No maintenance men on regular •No budget
basis
•No records and No Safety
 Maintenance done by sub-
contractors
* Initially it looks economical

Increased Down Time Increased costs & Pressures

Maintenance Types
Planned Maintenance
In this type of service, the emphasis is placed on the
machines condition

 What does the manufacturer prescribe?

 Is it working under normal load?

 Are the conditions as good as those envisaged by the

manufacturer?

 Do we allow for extra attention owing to corrosion, wear etc

Putting the machine in good condition timely e.g replacement of filter/oil, plant
overhaul based on manufacturer recommendation
Maintenance Types
Planned Maintenance advantages

 Instructions are more detailed than in routine

 Schedule is drawn with dates/Hrs

 Need for establishing the work-load for the crew

 Entails considerable planning effort, faithful

implementation
and recording

 Detailed instructions reduce the chance of missing any

activity. Unforeseen work is greatly reduced
Maintenance Types
Preventive Maintenence

 PM increases reliability

 PM reduces work-load

 PM reduces down time

 PM reduces unplanned work

 PM reduces maintenance cost

 Maintenance Types
Preventive Maintenance
 System which strives to reduce the likelihood of failures.

 Parts are replaced on time basis that could prevent failure

though the part maybe in good condition

 Locates weak spots of machinery and equipments

 Provides them periodic/scheduled inspections and minor

repairs to reduce the danger of unanticipated breakdowns

 Preventive Maintenance System is more expensive due to

more of planning and replacement of parts
Maintenance Types
Preventive Maintenance Schedule
Description Week
1 2 3 4 5 6 7 8 9 10 11 12
Check Oil Filter O O O
Replace Oil O
Inspect bearing O
Replace Bearing O
Check liner O O
condition
Check vibration O O O O
Tighten bolts O O O O
Check Motor O
Insulation
Check terminals O O
Maintenance Types
Predictive Maintenance Type ( Condition Monitoring)

System based on predicting the failure.

 In predictive maintenance, machinery conditions are

periodically monitored and this enables the
maintenance crews to take timely actions, such as
machine adjustment, repair or overhaul

 It makes use of human sense and other sensitive

instruments, such as audio gauge, vibration analyzer,
amplitude meter, pressure, temperature and resistance
strain gauges etc.

 Monitoring the condition of machine and its components

 Planning the maintenance based on deteriorating
condition parts are replaced when life is near to finish
Maintenance Types
Predictive Maintenance Monitoring Parameters

1. Temperature
2. Vibration
3. Cracks
4. Deterioration
5. Voltage/current
6. Performance evaluation
Maintenance Types

 Unusual sounds coming out of a rotating equipment predicts

a trouble

 An excessively hot electric cable predicts a trouble

 Simple hand touch can point out many unusual equipment

conditions and thus predicts a trouble
 Maintenance Types

Predictive Maintenance
Condition Monitoring
Condition Monitoring
Maintenance Cost

1. Overhead Expanses
2. Labour Cost
3. Spares and Consumables
4. Loss due to down time
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
Maintenance Cost
Availability
Mean-Time-between-Failures MTBF

MTBF = Total Operating Time = 1

. No Of failures n

Mean-Time-to-Repair, MTTR

MTTR = Total Outage Time = 1

. No Of failures r

Availability = ________Total Operating Time_______

. Total Operating Time + Total Outage Time
 Actions For High Availability
Failure Investigation
 Find the cause of break downs
 Analyze it
 Take corrective action in next shut down
 Monitor the performance

Resource Availability
 Keep spares well in advance
 Mobilize work force quickly
 Keep job area ready to work : lighting, scaffolding, power
supply etc
Integration of Maintenance
Company
Production
Administration
Dep't

Availability Spares
Procurement

Permit to Work Maintenance Manpower

Dep't
Trial Fire & Safety
Maintenance Departments

 A maintenance manager typically is a plant engineer

who reports to a plant manager

 Maintenance departments are usually split into two

groups:
 Buildings

 Equipment
Maintenance Departments
Maintenance Work Force

Engineer
Boiler Maintenance

Supervisor

Foreman Foreman
Pressure Parts Rotating Machines

Fitters/Technicians Fitters/Technicians

Riggers Riggers
Helpers Helpers
 Maintenance Departments
Repair Crews and Standby Machines
 Repairs often performed on an emergency basis to:
 Minimize interruptions to production

 Correct unsafe working conditions

 Improve product/service quality

 In emergency situations:
 Specialists may work overtime

 Supervisor/engineers are nearby to collaborate

 Standby machines may be quickly put in operation

Engineers Duties

 Preventive Maintenance Schedule

preparation
 Deliver the work order card with
Quality sheet to Supervisor
 Inspect the work being done as per
quality and safety
 Keep inventory control: procurement, store
 Follow safety guide lines
 Effort for zero breakdown/failures
 Mobilize resources for faster completion of work
 Prepare Reports
Computer Assistance in Maintenance

 Scheduling maintenance projects

 Maintenance cost reports by production department,

cost category, and other classifications

 Inventory status reports for maintenance parts and

supplies

 Parts failure data

 Operations analysis studies

Efficient maintenance Service

 Ensuring work quality

 Minimum repair time
 Ensuring safety
Efficient maintenance Service

Ensuring maintenance work quality

1. Developing Quality norms

2. Measurements- stage inspections
3. Corrections
4. Recording/report
 Efficient maintenance Service
 Work Order Planning and Control

 Efficient and effective maintenance requires detailed planning of repairs,

plant
 services, overhauls and projects.

This work must be co-ordinated with the requirements of production to have

the minimum effect on the overall production plan.

The maintenance plan should be easily modified to allow for major

emergency work, changes in production methods and improvements in
design.

Maintenance control indices can provide a method of assessing

maintenance activities. Control indices should function as part of the overall
maintenance information system and use dynamic data such as labour
costs, spares usage, and delay costs. Analysis of the data provides
feedback that the manager can use to assess actual performance against a
target, and so monitor the effect of changes in maintenance policy.
Efficient maintenance Service
Computerised Maintenance Management System

 A computerised maintenance management system will contain a

number of integrated programs or modules to improve the efficiency
and effectiveness of the maintenance engineering function.

 the system should be easy to use and provide the engineer with all of
the information that is required to make better decisions.

The basic modules or component part of the maintenance systems are :

 Preventive maintenance
 Asset register
 Maintenance stores system
 Purchasing
 Work order planning and control
 Plant history and analysis
Efficient maintenance Service
Asset Register

 This is an inventory of all of the plant, equipment and services for

which a manager has responsibility. Repair work that is generated
by the preventive maintenance system will in most cases need to be
planned and prepared.

 This includes technical details, serial numbers, location,

manufacturer etc. and most important a list of the spare parts used
on the machine together with the current stock balance.

 The purpose of the asset register is to centralise this data for use in
planning
 maintenance work.

 In addition to providing rapid access to information, the manager

can be sure that the relevant data is always available and has not
been misplaced.
Maintenance Records

 History Record:
 When job is done?

 What activities were done?

 When completed?

 How was the machine performance?

 Planning Sheet:
 When next to be done?

 What resources will be required?

 What will be the duration?

Maintenance Records

Equipment Identification

 Identify the equipments

 Prepare the specs (Number plate details)
Maintenance Records

Equipment Identification

 ID Fan1A
 ID Fan 1B
 FD Fan 1A
 FD Fan 1B
 PA Fan 1A
 PA Fan 1B
 Boiler Feed Pump 1A
 Maintenance Records
Work Instruction
Singrauli Super Thermal Power Station
Equipment: Boiler Feed Pump RPM: 3600 KW 1500 Kw

Scope: Mini Overhauling of Boiler feed Pump Doc No: QSR/039/8

1. Decouple pump from drive turbine or hydro coupling

2. Open the bearing top covers
3. Check bearing conditions
4. Check Thrust collar conditions
5. Check pump centering
6. Check bearing clearances
7. Check pump floats
8. Adjust as per requirements
9. Repair/replace worn out parts
10. Box up bearings
11. Align pump w.r.t drive turbine/hydro coupling
12. Take trial run of pump
13. Refer QSR/039/9/AUX/011 for checks and records
Maintenance Records
Work Protocol
S.N. Decription Measured Value
1. Bearing Condition: Fine scrtch marks seen
Scratch marks: Nil Bluish color from sides
Color: No discoloration No pittings
Pitting Nil

2 Bearing side clearance: 0.020-0.025mm 0.022mm

3 Bearing top clearance: 0.030-0.045mm 0.030 mm

4 Coupling Alignment : < 0.07mm 0.06mm

5 Shaft run out: <0.086 mm 0.089 mm

6 Bearing level 1D < 0.02mm/m 0.011 1D

00

0.5D
Maintenance Records
Operation Guidance Note

The Care and maintenance of Pumps

(Describes Standard Maintenance Practice)
1. Objective
2. Operational History
3. Inspection and maintenance
4. Modifications
5. Vibration requirements
6. Bearing Temperature
7. NPSH
8. Pump casing distortion
9. Overspeed test
10. Pump efficiency
Overhaul Management

 Machine needs regular overhaul

 Periodicity is based on experience or on
manufacturers recommendations
 Boiler tubes errosion normally in 2 years
 Burner life is 1 year Boiler Overhaul : every year for 10 days
 Furnace deposition 1 year

 Turbine efficiency drops 0.5%-1% in 5 years

 Turbine blade cracks appear in 5-6 years
 Turbine overhaul : 5years for 45 days
Overhaul Management

 Preparation of resources:
 Engineering Declaration: 12 months advance
 Contract: 3 months in advance
 Spares procurement; 12 months advance
 Shut down planning ; rolling plan

 Mobilization
 Pert Chart activitiy listing
 Allocation of executive team to monitor
 Daily work progress meeting
 Overhaul Execution
PERT & CPM
CPM
What is CPM?
Critical Path Method

What is Critical Path?

CPM is a mathematically based algorithm for scheduling a set of project

activities.


• A list of all activities required to complete the project,



• The dependencies between the activities, and



• The estimate of time (duration) that each activity will take to completion.

The longest time is determined

CPM example

Hang a picture on the wall

 Choose a place on the wall

 Buy the screws
 Choose the picture Drill a hole
 Screw in the screws
 Hang the picture
The actions “drill a hole,” “screw in the screws” and “hang the picture” form a
sequence of tasks that must be performed in a specific order, one right after the
other, to ensure a successful result. Such tasks are called “sequential” activities
CPM

 you cannot start some activities until the

others are finished. These activities need to
be completed in a sequence, with each stage
being more-or-less completed before the next
stage can begin
 CPM
The critical path consists of the longest
sequence of activities from project start to
end that should be started and completed
exactly as scheduled to ensure the project is
completed by a certain date in the future