1
PLANT MAINTENANCE ENGINEERING
Importance of the subject:
To have an uninterrupted profitable production in an industry, one have to have
proper maintenance of the facilities of the concern. This subject will give the
knowledge of importance of maintenance, types of maintenance, different
maintenance procedures etc.
Maintenance: The technical meaning of maintenance involves functional checks,
servicing, repairing or replacing of necessary devices, equipment, machines,
buildings in industrial business, Government and residential installations.
Intelligent maintenance systems
It predicts and forecast equipment/assets performance so "near zero breakdown"
states is possible. Near zero downtime focuses on maintenance performance
techniques to minimize production downtime.
Maintenance: Maintenance is a routine and recording activity of keeping a particular
machine or facility at its normal operational condition so that it can deliver its
expected performance or service without breakdown and loss of time on account of
accidental damage or breakdown.
Maintenance in the only way, on effective application of which, the gap between the
achieved and achievable productivity can be minimised.
An effective maintenance not only reduces the probability of breakage of machines
elements and shut down of machines, hampering the scheduled production, but at
the same time, such a function enhances the efficiency and accuracy of the
production machines, lengthening their span of life with usual reliability.
Objectives of maintenance:
2
The main aim of maintenance is to have maximum profitability by achieving the
optimum productivity. The objective of maintenance may be summarized as below:
(i) to minimise breakage.
(i) to maximize plant availability to enable the facilities to function at maximum
efficiency.
(iii) to ensure longer service life of the equipments, machineries and other facilities.
(iv) to ensure larger service life to the equipments, machines and other facilities.
(v) to ensure safety to the workers.
(vi) to create a satisfactory working condition.
(vii) to minimise the maintenance cost and to maximize the profitability.
(viii) to improve the quality of the product.
Maintenance policies
The ultimate objective of management is to spend less and earn more without
disturbing the design, accuracy, quality and other parameters of a product.
While formulating maintenance policies the following points should be considered:
(i) Maintenance budget
(ii) Functional scope of maintenance.
(iii) The level of maintenance work.
(iv) Systems to be followed and procedures to be adopted
(v) Inventory control planning.
(vi) Purchase procedure for maintenance system
(vii) Modification of projects in near future.
3
(viii) New investment if any.
(ix) Facility for research and development.
(x) Personnel policies
(xi) Indigenisation and standardisation.
The maintenance policies once framed may be reviewed continuously and changes,
if required to achieve the objectives, are to be adopted at proper time.
Types of maintenance:
Basically maintenance may be categorised as,
(i) Planned maintenance
(ii) Unplanned maintenance.
Planned maintenance:
Planned maintenance refers to any maintenance activity that is planned and
scheduled in advance. The aim of planned maintenance is to reduce downtime and
increases the production. Planned maintenance incorporates all the functions like
planning, scheduling, dispatching, recording, analysis and controlling.
Going into the details of maintenance procedure, finally the planned maintenance
may classified as,
(i) Scheduled
(ii) Productive
(iii) Preventive
Scheduled maintenance: It is ant maintenance work (repair, inspection, upkeep
work etc.) performed within a set time frame. Here a schedule is framed for an
instrument/ machine considering the instruction of the manufacturer and applying the
concept gained through the experience incorporating, inspection, lubrication, repair
and overhaul. Replacing of an air filter in an i.c. engine, washing of water tank filter,
overhauling a machine are some examples of scheduled maintenance.
4
Predictive maintenance:
Predictive maintenance is a newer term coming into use. Sensing, measuring or
monitoring techniques are followed normally to recognize the cause of any change of
physical conditions of a system. Now-a-days , a large number of commercial
instruments such as vibrator analyser, axial displacements monitors, optical devices,
non-contacting sensors etc. are available to conduct tests and to predict the need for
repairing of any particular component of a system.
The main advantage of such a predictive is to provide means to inspect the troubles
of any internal part without disassembly. But predictive maintenance cannot be
applied in general although it minimises the risk of failure and extends the service
life. It involves too much maintenance cost.
Preventive maintenance:
It is the maintenance that is performed on a piece of equipment to lessen the
probability of its failure. It is performed while the equipment is still working so that it
does not breakdown unexpectedly.
It is the procedure followed in most of the concerns to maintain desirable and reliable
operational conditions of equipments and machineries. It is a fact that a preventive
maintenance procedure will not only prevent breakdown or reduce operating costs
but also will improve output or quality of product. Preventive maintenance contain
certain basic activities and are as follows:
(1) Periodical inspection of assets and equipments of the plant to detect conditions to
breakdowns.
(2) Upkeep the plant to adjust or rectify such conditions while they are at minor
stages.
Advantages of preventive maintenance
(1) Less production downtime, because of fewer breakdowns.
(2) major repairs and repetitive repairs can be avoided.
5
(3) product rejection comes down to minimum level, minimising the chance of
spoilage.
(4) better quality control facilities.
(5) lengthen the life expectancy for better conservation of assets and equipments.
(6) less standby equipments are needed, thereby reducing capital investment.
(7) spare parts control is better, leading to minimum inventory.
(9) Provide greater safety and protection to the workers
(10) Manufacturing cost per unit is lower.
Breakdown maintenance is suitable only for small scale industries, because of less
direct cost involvement but the indirect cost eventually becomes more and it does
not provide any guarantee of reliability to the smooth production running. In case of
large scale industry breakdown of a single machine may create an alarming loss to
the industry as due to breakdown of one machine the whole unit may be stopped.
Maintenance planning
A successful maintenance, specially a preventive maintenance is logically dependent
on the skill and efficiency of the maintenance personnel. But technically it is having a
complete dependence on the following basic features:
(1) Planning and scheduling
(2) Controlling
(i) Corrective measure
(ii) Monitoring
Planning means formulation of work in advance and scheduling is the time phase of
the sequential activities.
"What is to be done" and "when it should be done" are the major criteria of
successful maintenance.
Some of the terms should be clear for effective maintenance planning:
6
Repair cycle: The repetitive performance of different maintenance activities in
between two overhauling is termed as Repair cycle. So to formulate a schedule,
classify the maintenance work into following activities:
(1) inspection (I)
(2) minor repair (R1)
(3) medium or major repair (R2)
(4) overhauling (O)
The time period of a repair cycle is dependent on the time in between activities.
The planning of time intervals may be scheduled, considering the past data of the
machine, following manufacturing instructions and as per the complexities of the
instruments or machine tools.
An index is generally used to communicate a complexity of different machines. Such
an index has been finalized, taking into account the power transmission devices.
Hydraulic units, guide surfaces, mechanisms associated with the functioning of the
machine. This index is technically known as "repair complexity number" for example,
repair complexity number for a boiler may be 12, for an air compressor it may be 8
for a turbine may be 14.
Repair complexity number is helpful to the maintenance department to finalize the
maintenance staff size, to estimate the inventory required or to forecast
"maintenance cost" etc.
Equipment history card
Past data regarding date of installation, maintenance work performed are very much
helpful in maintenance planning. The best way is to have a 'history card' for each
machine or instrument. Analysis of past data can only enable the management to
build a confident work planning structure.
Master schedule card: The record of total maintenance schedule for a particular
period is recorded in a schedule which is known as master schedule card. The
7
period may be six months or a year. Master schedule may be broken into part-work
step-by-step and then necessary work order may be issued.
Work activities
Work like cleaning, lubrication etc. are associated with all types of maintenance.
Work order
After completion of scheduling the next phase is dispatching, that is to issue work-
order to start work. Before issuing work-order, the authority should check:
(a) Assurance on the availability of the equipment.
(b) The availability of the required tools and spares, if necessary.
(c) If any necessary drawing is to be attached with the work-order for proper
understanding of the job.
Maintenance and reliability
It is "the probability of performing a specified function without failure, under given
conditions for a specified period of time.
Spare parts planning
Success of maintenance also depends on proper spare parts planning.
For effective planning of spare parts, the following factors should be followed:
(1) Codification of spares: Codification means to employ a definite code for a
definite spare. It simplifies the work of identification. Otherwise one may purchase
the materials which are already available in the store. Codification of spares ensures
proper items as is requisitioned. Codes may be of different types. For example, for a
code number, the first two digits may indicate a main group, a later part may indicate
its chief characteristics. It is also having limitations. Because to meet the varieties,
the number of digits may increase too much which may confuse in identifications.
So generally an acceptable method is to limit the codes within eight digits.
System Coordination
8
(1) alphabetic system -
Sulphuric acid - AC SU
Nitric acid - AC NI
(2) simple numeric or square system - 1, 2 .....
(3) communication system - M-20, A-20
(4) block system - 1800 - 1899
(5) numeric system - 712 78 5001
(6) decimal system - 7.0, 7.1 .....
(7) Mnemonic system -
Furniture - FU
Cast Iron - CI
Raw Material - DJ
(8) alpha-numeric system - AS-03-C2425
(9) colour code - private care - white
Taxes number plate - yellow
(2) Preservation of past data - Each and every replacement of spares should be
recorded in a card for each and every machine or equipment. Such data card will
ultimately provide information to quantify the average requirement of spares.
(3) Practice to use standard spares - It is always recommended to purchase
standard spares. Such a practice assures the reliability of fitting and operation and
on the other hand easy procurement is also ensured.
9
(4) Effective purchase procedures - Purchase section of the concern should have
control on inventories. They should be in a position to detect the manufacturer or
suppliers of spares instantly, they should know the lead time of procurement etc. to
maintain the right spares in sufficient quantity and equal and better quality.
Identify true or false statement
(1) most and why quite mint is needed in case of preventive maintenance.
(2) breakdown maintenance is suitable for large scale industries.
(3) predictive maintenance is a type of unplanned maintenance.
(4) repair complexity number is helpful to forecast the maintenance cost.
(5) codification of spares main complicate its identification.
(6) codification is generally limited to eight digits.
(7) the repetitive performance of current maintenance activity in between two
overhauling is called repair cycle.
(9) in case of preventive maintenance the total planning should be reflected in
a master schedule card.
(9) higher the repair complexity index, higher number of activities are involved
in a repair cycle.
(10) qualification of spares ensures issue of proper items.
Limits, fits & tolerance
Introduction
No two parts can be produced with identical measurements by any manufacturing
process. In any production process, there is a certain amount of natural variability
regardless of how well it is designed or how carefully it is manufactured. These
variations are random in nature and are the effect of many small and uncontrollable
10
causes. Usually, variability arises from error adjusted machines, operators error, tool
error, defective raw materials etc. So to overcome this difficulty we must produce
parts with some variation.
Interchangeability: It is the ability to select components for assembling at random
and fit them together that don't need any adjustment and meet the definite purpose.
Interchangeable system - The system where the parts can be assembled randomly
within the designed fit to meet any definite purpose. If a definite limit of deviation for
a particular work-piece is maintained, it will enable the production engineer to
produce parts for an assembly with a freedom of interchangeability, that is, the
mating parts can be assembled randomly within the limits of designed tightness or
looseness to meet any definite purpose.
Different terms associated with an assembly
Nominal size: It is the dimensions shown in the drawing for general identification.
Basic size: Basic size is the size with reference to which all other variations are
determined.
The nominal size of an assembly of a shaft and a hole may be common say 60 mm,
whereas the basic size of the shaft may be 59.5 mm and that of the hole may be 60
mm.
actual size: It is the dimensions of a component which results after the final
machining.
Limit: The actual size may be having some deviations from the nominal size, the
extent of deviation allowed in the design and drawing is called as 'Limit'.
Limits are permissible on both the higher and lower sides of nominal size, denoting
'Higher' and 'Lower' Limit of the shaft or hole.
Tolerance: It is the difference between the maximum and minimum limits or sizes.
11
The higher and lower limits are always termed as the limiting sizes with respect to
the nominal size. Considering the limiting dimensions the tolerance may be
represented as a zone in between the higher and lower limits. The dimension
+0.0.01
denoted by 50 -0.01 indicates the higher limit is 50.01 mm while the lower limit is
49.99 mm to the amount of tolerance in attached is (50.01 mm - 49.99 mm) 0.02
mm.
For example, a shaft has to be manufactured to a diameter of 40 mm with a
deviation of 0.02 mm.
This means that the shaft, which has a basic size of 40 mm be acceptable if its
diameter lies anywhere between the limits of sizes, that is an upper limit of 40.02 mm
and lower limit of 39.98 mm, then the permissible tolerance is equal to 40. 02 - 39.98
= 0.04.
The basic purpose of providing tolerances is to permit dimensional variations
in the manufactured components, adhering to the performance criterion as
established by the specification and design.
Classification of tolerance
Mainly tolerance can be classified into following categories.
(i) unilateral tolerance (ii) bilateral tolerance.
Unilateral tolerance: When the tolerance distribution is only on one side of the basic
size, it is known as unilateral tolerance. Example:
Bilateral tolerance: When the tolerance destination lies on either side of the basic
size, it is known as bilateral tolerance. Example:
12
Unilateral tolerance are very much common in interchangeable system, specially
when a precision fit is in question. On the other hand bilateral tolerance commonly
used in mass production, as it simplifies the machine setting.
Deviation: It is the algebraic differences between a size and it's corresponding basic
size. It may be positive, negative or zero.
Upper deviation: It is the algebraic differences between the maximum limit of size
and its corresponding basic size. It is designated as 'ES' for a hole and as 'es' for a
shaft.
Lower deviation: It is the algebraic difference between the minimum limit of size
and its corresponding basic size. This is designated as 'EI' for a whole and 'ei' for a
shaft.
Zero line: It is a straight line to which the deviations are referred in a graphical
representation of limits and fits. The zero line is the line of zero deviation and
represents the basic size.
Fundamental deviation: It is a term which may be applicable to either of the two
deviations which is conventionally chosen to define the position of the tolerance zone
in relation to zero line.
Shaft: In an assembly, there is one 'enveloped surface', which is termed as shaft.
Hole: In an assembly there is one 'enveloping surface', which is termed as hole.
Allowance: The difference between a hole diameter and a shaft diameter is called
'Allowance'. It may be positive or negative. When the shaft diameter is less than a
hole diameter it is positive and when the shaft diameter is more it is negative.
Clearance: It is the positive difference between shaft and hole.
13
Maximum allowance = largest hole size - smallest shaft size.
Minimum allowance = smallest hole size - largest shaft size.
Fit: The degree of looseness and tightness with respect to the mating parts is called
fit. The main objective of Fit is to maintain the desired level of accuracy while two
mating parts are fitted together.
Types of fit: (1) clearance fit, (2) interference fit (3) transition fit.
Clearance fit: It is the fit where largest shaft diameter is less than smallest hole
diameter.
Interference fit: It is the fit where the smallest shaft diameter is greater than the
largest hole diameter.
Transition fit: It is the fit at the boundary between clearance and interference fit.
Clearance fit:
(a) sliding
(b) easy slide
(c) running
(d) slack running
(e) loose running
Interference fit:
(a) shrink
(b) heavy drive
(c) light drive
Transition fit:
(a) force
14
(b) tight
(c) wringing
(d) push
Grades of tolerance
Grade: It is the indication of the tolerance magnitude, the lower the grade finer the
tolerance.
As per Indian standard xxx are 18 grades of standard tolerance.
Standard tolerance:
This grades of tolerances are the expression of the amount of tolerance a zone and
is designated as IT01, IT0, IT1......IT16, IT15 etc. Here IT01, IT0 etc. are the finest
tolerance where as IT16, IT15 are the most coarse tolerance.
Deviations on the other hand are denoted by letters.
Capital letters are used for holes and small letters are used for shafts.
Totally 25 types of fundamental deviations are available as per Indian Standard
System.
A B C D xxx
a b c d xxx
As per ISO system there are 28 standard deviations.
