Maintenance

1. Maintenance KULBHUSHAN Regn No 11110182

2. Introduction: • Plant maintenance is an important service function of an efficient production system. • It helps in maintaining and increasing the operational efficiency of plant facilities. • Maintenance is the procedure of finding the faults in any equipment/Machine and also removal of fault. • It may be before the breakdown or after the breakdown.

3. Plant maintenance usually refers to the methods, strategies, and practices used to keep an industrial factory running efficiently. This can include anything from regular checks of equipment to make sure they are functioning properly. • The general aim of plant maintenance is to create a productive working environment that is also safe for workers.

4. Maintenance Objectives: • To increase functional reliability of production facilities. • To maximize the useful life of the equipment. • To maximize production capacity from the given equipment. • To minimize the total production cost. • To minimize the frequency of interruption in production by reducing breakdowns. • To enhance the safety of the manpower.

5. Maintenance objective

6. Importance of maintenance • It helps in identify the cause of failure , e.g whether the failure is due to design defect, or a wear out failure. • It also helps in deciding the type of maintenance and maintenance decision like replace and repair. • It provides the necessary information regarding the life and reliability of the equipment

7. Different type of maintenance:

8. Planned Maintenance- In planned maintenance the maintenance action is carried out with some fore thoughts, prior planning , record keeping and control action. These can be further classified as :- • Preventive maintenance • Corrective maintenance • Predictive maintenance

9. It is based upon the principle that ‘prevention is better than cure’. • It is a set of activities that are performed on plant equipment, machinery, and systems before the occurrence of a failure in order to protect them and to prevent or eliminate any degradation in their operating conditions. • Or the maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning and the effects limited. • It has three types • Running maintenance • Scheduled maintenance • Shut down maintenance

10. Running maintenance: • Running maintenance which includes those maintenance activities that are carried out while the machine or equipment is running. • Example – lubrication, adjustment of nuts and screws, tightening of loose nut and bolts.

11. Scheduled Maintenance: • Scheduled Maintenance is any variety of scheduled maintenance to an object or item of equipment. • Specifically, Planned Maintenance is a scheduled service visit carried out by a competent and suitable agent, to ensure that an item of equipment is operating correctly and to therefore avoid any unscheduled breakdown and downtime. • Good example of PM program is car maintenance. After so many kilometers or miles oil should be changed, parts renewed.

12. Shut Down Maintenance: • Which is a set of preventive maintenance activities that are carried out when the production line is in total stoppage situation. • These are performed generally after three or six months. • These involves the inspection of plant items which are known or suspected to occur.

13. Corrective maintenance: • In this type, actions such as repair, replacement, or restore will be carried out after the occurrence of a failure in order to eliminate the source of this failure or reduce the frequency of its occurrence. • It also include the different types of actions like typical adjustment of redesign equipment. • The difference between corrective maintenance and preventive maintenance is that for the corrective maintenance, the failure should occur before any corrective action is taken. • It is of two types • Breakdown maintenance • Shutdown maintenance

14. Breakdown Maintenance: • It is an emergency based policy in which the plant or equipment is operated until it fails and then it is brought back into running condition by repair. • The maintenance staff locate any mechanical, electrical or any other fault to correct it immediately. • It is feasible for the small factories where • There are few types of equipment. • Machine and equipments are simple and does not require any specialist. • Where sudden failure does not cause any serious financial loss.

15. Predictive maintenance: • As the names implies it involves the prediction of the failure before it occurs, identifying the root cause for those failures symptoms and eliminating those causes before they result in extensive damage of the equipment. • Type of maintenance performed continuously or at intervals according to the requirements to diagnose and monitor a condition or system. Also called condition based maintenance.

16. Unplanned Maintenance: • Maintenance action which is carried out without any fore thoughts or prior planning is called unplanned maintenance. • Emergency maintenance is one of the example of unplanned maintenance. • In this type of maintenance the maintenance action is executed with the help of all available maintenance resources in least possible time, without any major time lag. • Examples are gas leakage in chemical plant, fire hazards, breakdown of boiler, turbine etc.