Standard

Maintenance
Practice of Power
Station
MD. MIZANUR RAHMAN
What is maintenance?

Maintenance is defined as the collection of

tasks carry out in an installation/equipment, in
order to avoid, analyse the degradation of
installation/equipment over time or usage.

Both the mere passage of time and the usage of

equipment, systems and installations generate
different mechanisms of degradation on them.
Objective of Maintenance:

The main objective of the maintenance

department of an installation is
- to avoid the degradation/break down
- compare it with the initial one and
- analyze whether that happens progressively or
suddenly with the usage and/or pass of time.
The most important and common forms of degradation
are the followings:
* Corrosion
* Abrasion
* Erosion
* Deterioration
* Material loss
* Out layer paint loss
* Fatigue
* Thermal creep
Most common forms of degradation:
* Deformation
* Stretching or elongation
* Mechanical loosening
* Cavitation
* Excessive friction
* Obstruction or blockage
* Deposition of solids
* Pollution
* Cable cut or break
* Loosening of electrical connection
* Dirt in electrical contact
Why maintenance:
* Effectivemaintenance is one of the most cost-
effective methods for ensuring reliability, safety
and energy efficiency.
* Inadequate maintenance of energy-using systems is
a major cause of energy waste in the power
station.
* Energy losses from steam, water and air leaks,
uninsulated lines, maladjusted or inoperable
controls, and other losses from poor maintenance
are often visible.
* Good maintenance practices can generate
substantial energy savings and should be considered
a resource
Effect of adequate and timely maintenance and repairs on
the service life of an equipment:
Why maintenance:

Fig: Component failure rate over time

* The initial infant mortality period of the curve is characterized by
high failure rate followed by a period of decreasing failure. Many of
the failures associated with this region are linked to poor design, poor
installation, or misapplication.
* The infant mortality period is followed by a nearly constant failure
rate period known as useful life. There are many theories on why
components fail in this region, most acknowledge that poor O & M
often plays significant role. It is also generally agreed that preventive
and predictive elements can extend this period.
* The wear-out period is characterized by a rapid increasing failure rate
with time.
Standard maintenance practice includes:

* Placing the right person in right place.

* Using appropriate tools
* Avoid any faulty or un-calibrated/non tested equipment
* Mark or dump the faulty equipment
* Conducting a Tool Box Talk (TBT) before attending any
task
* Sharing knowledge among the officers and staffs
* Using PPE
* Follow the MSDS before handling any chemical
* Follow SAFETY FIRST procedure
* Follow MAN-MACHINE-WORK procedure
Standard maintenance practice includes:

* FollowPTW rules before attending any work- operation will

ensure isolation, maintenance will confirm and attend
* Using proper equips/rules during work at height
* Using proper equips/procedure during working at confined
space
* Using proper equips/procedure during hot work
* During working in gas line, purge with N2 first
* Avoid tools that will create spark during working in gas line
* Open the drain and vent before attending any pressurized
line
* Take and study the corresponding drawing before attending
* DO NOT open any points if you do not have the
consumables/like gasket with you
* Avoid using mobile phone during working at critical point.
Factors affecting standard maintenance practice:
* Maintenance policy and strategy: Whether pro-active maintenance
or reactive maintenance.
* Planning and scheduling: This includes maintenance planner and
schedulers, training and development plan for maintenance,
practice for conducting risks assessment, standard work order
procedure (PTW), Computerized Maintenance Management System
(CMMS) for job planning and spare parts management, prioritizing
the workable job.
* Materials management: This includes materials movement,
tracking, quality of the supplied materials based on the standard
specification of the contract etc. Now a days computerized
materials management software is available.
* Maintenance management and maintenance culture: Use the right
people in a right place for effective and efficient output, making
several groups with expert and raw people in each group. No need
to be more serious in presence of supervisor.
* Maintenance task execution: Tasks to be identified and clearly
defined, responsibility clearly defined, team work approach, proper
performance benchmark system in identifying the gaps and
establishing improvements or corrective measures.
Factors affecting standard maintenance practice:
* Budget: This includes effective maintenance budgetary allocation
so as to cope with business competition in the market.
* Renovationsystem/program: Effective renovation/ rehabilitating
to be enhanced.
* Data recording and storage: This includes maintaining equipment
register and equipment history, various data records and storage
and updated the information/data.
* Reliability Analysis: This includes the analysis of root cause of any
failure. For example, if a boiler tube is getting cracked, no root-
cause of the crack is done. In this regards, the corrective
measures taken could only be temporally measures, as the
solution of the problem will not be technically and professionally
obtained.
* Resource planning: Effectively planning and utilizing available
resources for good service delivery, Skills to be well identified
and utilized, funds to be allocated based on the priority of the
equipment and its implication to core business.
Factors affecting standard maintenance practice:

* Legislation and Environmental laws: Maintenance

activities to be complied with the international and
government environmental rules and regulations.
* Information and communication technology: Planning
and scheduling of maintenance tasks are best and
effectively practiced through the use of computerized
maintenance system (CMMS).
* Contract Management: The management of contracts
enables obtaining of appropriate contractors,
monitoring plant maintenance contracts, achieving best
maintenance standards.
Industry Standard Solution for Plant Maintenance
(ISPM):

*IDENTIFY: failure of the equipment

*ANALYZE: Analyze the cause of the failure
*RESOLVE: Implement and prioritize corrective
measures
Documentation for standard maintenance:

** Daily maintenance documentation-

1 Defect register
2. Log book
3. Trouble report receiving record
4. Work permit record
5. Man power report
6. Daily equipment monitoring check list
7. Daily maintenance report
8. Equipment un-availability report.
9. Daily consumable consumption report
10. Plant safety information report
Annual meeting and testing certification:
* Annual technical audit
* Annual safety audit
* Annual maintenance schedule and report
* Annual performance report
* Annual lifting equipment load testing report
* Annual Boiler testing report
Maintainable documents:
* Installation documents
* Commissioning report
* Piping and Instrumentation Diagram (P & ID)
* As built drawing
* MSDS for chemical area
* Maintenance check list
* ISO or other standard docs
* Welding procedure documents
* Maintenance procedure documents
O & M Management:

Below Five well-defined elements are badly needed of an

effective O&M program.

The overall O & M program should contain five very distinct

functions making up the organization: Operations,
Maintenance, Engineering, Training, and Administration—
OMETA.
O & M Management:

Operations:
• Administration – To ensure effective implementation
and control of operation activities.
• Conduct of Operations – To ensure efficient, safe,
and reliable process operations.
• Equipment Status Control – To be cognizant of
status of all equipment.
• Operator Knowledge and Performance – To ensure
that operator knowledge and performance will support
safe and reliable plant operation.
O & M Management:
Maintenance

• Administration – To ensure effective implementation and

control of maintenance activities.
• Work Control System – To control the performance of
maintenance in an efficient and safe manner such that
economical, safe, and reliable plant operation is optimized.
• Conduct of Maintenance – To conduct maintenance in a
safe and efficient manner.
• Preventive Maintenance – To contribute to optimum
performance and reliability of plant systems and equipment.
• Maintenance Procedures and Documentation – To provide
directions, when appropriate, for the performance of work
and to ensure that maintenance is performed safely and
efficiently.
O & M Management:

Engineering Support
• Engineering Support Organization and Administration –
To ensure effective implementation and control of
technical support.
• Equipment Modifications – To ensure proper design,
review, control, implementation, and documentation of
equipment design changes in a timely manner.
• Equipment Performance Monitoring – To perform
monitoring activities that optimize equipment reliability
and efficiency.
• Engineering Support Procedures and Documentation –
To ensure that engineer support procedures and documents
provide appropriate direction and that they support the
efficiency and safe operations of the equipment.
O & M Management:
Training

• Administration – To ensure effective implementation and

control of training activities.
• General Employee Training – To ensure that plant personnel
have a basic understanding of their responsibilities and safe
work practices and have the knowledge and practical abilities
necessary to operate the plant safely and reliably.
• Training Facilities and Equipment – To ensure the training
facilities, equipment, and materials effectively support
training activities.
• Operator Training – To develop and improve the knowledge
and skills necessary to perform assigned job functions.
• Maintenance Training – To develop and improve the
knowledge and skills necessary to perform assigned job
functions.
O & M Management:
Administration:
• Organization and Administration – To establish and
ensure effective implementation of policies and the
planning and control of equipment activities.
• Management Objectives – To formulate and utilize
formal management objectives to improve equipment
performance.
• Management Assessment – To monitor and assess
station activities to improve all aspects of equipment
performance.
• Personnel planning and Qualification – To ensure that
positions are filled with highly qualified individuals.
• Industrial Safety – To achieve a high degree of
personnel and public safety
Sustainable maintenance practices:
* Good maintenance practices can cut production costs immensely, whereas poor
maintenance procedures can cost a company millions of dollars to effect repairs
and correct poor quality and production lost.

‘Why sustainable maintenance practices and not just

maintenance practice?’

* Sustainability is ‘meeting the needs of present without compromising the ability

of future generations to meet their own needs’.
* sustainable maintenance practices are practices of
1. high quality aimed at increasing machines performance
2. improved functionality of parts using safe, secure technologies and methods
3. utilizing optimal resources
4. reducing or eliminating machine downtime, mean time to repair (MTTR)
5. Reducing products wastes
6. providing maximum usability and reusability of parts/components
7. enhanced production benefits, economic impact and making the organization
to a profitable one.
Elements of sustainable maintenance practices:

Sustainable Maintenance Practice (SMP)

SMP=F (M, D, P, C, F, M, E)

Where,
M is the machine records keeping,
D is diagnostic technique,
P stands for prognostic technique and
C is the machine condition monitoring technology.
F, M and E are acronyms for machines functionality,
manufacturability and environmental impact, respectively.
Sustainable maintenance practices:

The four factors in green boxes are internal factors associated

with data keeping, whereas the other three factors in orange
boxes are external factors imposed on the machines due to
demand pressure that may arise in the course of production.
1. Machine records keeping:
Name of Periods of activities carried out (weeks)
components 1 2 3 4 5 6 7 8 9

Electric Motor- ABL ABL ABCL ABL ABL ABCL ABL ABL ABCL
1

Gearbox-1 ABL ABDL ABL ABL ABDL ABL ABL ABDL ABL

Bearings AB AB AB AB AB AB AB AB AB

* Example of a simple preventive maintenance schedule.

* A = visual check, D = lubrication analysis, B = temperature check,
L = lubrication check only, C = vibration check
2. Prognostic tools: These are the tools meant to predict
the future performance of components by assessing the
extent of deviation or degradation of a system from its
expected normal operating conditions.

3. Diagnostic tools: Diagnostics is required when fault

prediction of prognostics fails and a fault occurs.

4. Machines condition monitoring technology: A condition

monitoring program can be used to do diagnostics or
prognostics, or both. The condition monitoring technology
employs data acquisition on machinery vibration, its
acoustic, oil analysis and temperature, pressure, moisture,
humidity, weather or environment through the use of
versatile sensors.
5. Functionality: Functionality is based on the condition at
which the product to be produced is required. Some
products require high precision, accuracy and
uncompromised quality. If machines meant to produce such
products are not fully sustained and maintained, then the
aim for producing such products will be jeopardized as they
will not be able to meet their functionalities in the
intended field of operations. In other words, for
maintenance strategy to be proposed for such set of
machines, the maintenance manager must put this factor
into consideration.

6. Manufacturability: This presents about the various

approaches by which manufacturing of products can be
achieved. Parts of these approaches are lean
manufacturing, just in-time manufacturing approach,
conventional approach, automated processes.
7. Environmental impact: This is also a factor to be
considered when aiming at perfect sustainable
maintenance. Air intake filter in different season.

Maintenance strategies::
Maintenance strategies can be categorized into four
major types:
1. Reactive/corrective/breakdown maintenance: This is
also termed to be run to failure maintenance or
corrective maintenance or breakdown maintenance. These
are operations carried out to restore a machine to
operative condition after a breakdown, accident, wear,
etc. Since these activities are generally not known in
advance and therefore cannot be scheduled, they are
often referred to as unscheduled, emergency or repair
maintenance.
2. Preventive maintenance: Preventive maintenance is
hinged on activities put in-place prior to machinery
breakdown or failure of its component parts.
* 2A. Periodic maintenance:
* 2B: Predictive maintenance: Predictive maintenance
allows failures to be forecasted through analysis of the
equipment’s condition
2A1: Routine maintenance: These are maintenance, not
involving disassembly or replacement of components and
comprising mainly of cleaning and adjustments, which are
carried out regularly such as every hour, every day, or every
week.
2A2: Schedule maintenance: This is maintenance in which
preventive activities are scheduled for fixed intervals that
are much longer than routine intervals. Moreover, these
activities include oiling, greasing, adjustments,
replacement of parts, etc.
* 2B1:
Condition monitoring maintenance: Examples are
measurement of the viscosity of engine oil in a working
machine or the amplitude of vibration of rotating
machinery.
* 2B2: Condition based maintenance: Maintenance carried
out in response to a significant deterioration in a plant
unit as indicated by a change in a monitored parameter
of the unit condition or performance is called condition-
based maintenance. It uses the machine condition
monitoring tools discussed above vis-à-vis: vibration
monitoring tools, thermal monitoring tools, sound
monitoring tools, acoustic emission monitoring tool,
lubricant monitoring tools, corrosion monitoring tools
etc.
3. Design-out (improvement) maintenance:
Considering scientific values and overall cost implication,
design-out maintenance is the most effective maintenance
strategy to be embarked on. It aims at eliminating the
effect of failure. Design-out maintenance is usually a
phenomenon for areas of high maintenance cost resulting
from poor design. In a nut-shell, design-out maintenance is
to pre-act to eliminate failure instead of reacting to
failure.

4. Terotechnology: Terotechnology is the technology of

installation, commissioning, operation, maintenance and
feedback to design of plan, machinery and installation.
* United States analysis:
• >55% Reactive
• 31% Preventive
• 12% Predictive
• 2% Other.

Note that more than 55% of overall maintenance

resources and activities of an average facility are still
reactive.
O & M Ideas for Major Equipment:

• Learn equipment descriptions and operating principles

for the major equipment types.
• Discuss the key maintenance components of that equipment.
• Highlight important safety issues.
• Point out cost and energy efficiency issues.
• Provide recommended general O&M activities in the form of
checklists.
• Where possible, provide case studies
Few Steps to O & M Efficiency :

Step 1: Strive to increase management awareness and appreciation of the

operations and maintenance program/department --- Begin the development
of the OMETA linkages

Step 2: Commit to begin tracking Operations and Maintenance activities---

• Need to understand where O&M time is spent.
• Need to understand where O&M dollars are spent.
• Consider (strongly) purchasing or enhancing a Computerized Maintenance
Management System and commit to its implementation and use

Step 3: Through tracking begin to identify your troubled equipment and

systems.
• Make a list of these systems and prioritize them
Step 4: Commit to addressing at least one of these troubled
systems--- Find out
- System operations and history.
- System maintenance and history.
- System costs, time to service, downtime, resulting overtime,
etc.

Step 5: Commit to striving for O & M Efficiency of this system.

• Strive to understand how to properly operate this system.

- Define and complete operator training needs.
• Strive to understand how to properly maintain this system.
- Define and complete maintenance training needs.
Step 6: Commit to purchasing or contracting for some form(s) of
diagnostic, metering, or monitoring equipment

Step 7: Commit to trending the collected tracking and diagnostic

data.

Step 8: Select, request funding for, and complete first “Operational

Efficiency” project
-- Carefully document all findings

Step 9: Strive to highlight this success

-- Consider writing an internal success story/case study.
-- Submit finding to trade publication or industry conference.

Step 10: Commit to choosing the next piece of equipment...go to Step

3.
-- Steps 1 and 2 are ONGOING ACTIVITIES!
IMP: Diesel fire water pump- cooling water line modification.
Few Basic Mechanical Tools:

Open Ended wrench: wrenches have two open ends of

different sizes and the main use of this wrench is to loosen
and tighten nuts and bolts.
Box Ended Wrench:

On each end of this wrench, the circle is different sizes

and convenient when the open-ended wrench is not
useful.
Combination wrench:
wrenches are open and box ends in one convenient
wrench. So, if you don’t like to carry both carry one.
Adjustable wrench:
Wrenches are open at one end but have an adjustable
feature that allows you to shrink or expand it to the size
of the nut or bolt you are working on.
Ratchet wrench:

Socket fits completely over the nut or bolt and remains

in place. These wrenches are useful when you are in a
hurry to get a job done.
Torque wrench:

Wrenches are used for a precise tighten on the bolt.

Line wrench:

LINE wrenches are somewhat like a box-end and an open-

end wrench. These wrenches are made to deal with a
more fragile nut or bolt.
Hammer wrench:
Box End—

Open spanner–-

Adjustable wrench --
Pipe wrench:
Spark Plug wrench:
Used to tighten or loosen spark plugs.
Lug wrench:

LUG wrenches are crossed armed wrenches with four

heads for different sized bolts. They are specifically used
for the tires of automobiles.
Allen key/wrench:
Screw driver:

Minus type, star type and hammer type:

Ruler:
Measuring Tape:

-- One of the most basic tools for measurement.

-- Even the measurement can be done with a digital readout.
Vernier Scale:
Vernier:
Micrometer:
Level:
Square:
when you need to find right angles
Angle Gauge:

An angle gauge is capable of measuring angles so that

we can determine if everything is at true level.
“Thank You”

NWPGCL
Sirajganj, Unit-03
Q & A?????