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    Preventive Maintenance

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    Muhammad Aqeel Ashraf
    This document discusses predictive maintenance techniques, with a focus on thermography and tribology. It begins by explaining the importance of maintenance and different maintenance management systems, highlighting how predictive maintenance has advantages over breakdown and preventive maintenance. Key predictive techniques discussed in depth include thermography, which uses infrared imaging to detect thermal anomalies, and tribology, which analyzes lubricant condition. The document stresses that a comprehensive predictive program incorporates multiple techniques. It concludes by describing the philosophy of total productive maintenance and calculating overall equipment effectiveness.

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    Attribution Non-Commercial (BY-NC)

    Preventive Maintenance

    Uploaded by

    Muhammad Aqeel Ashraf
    748 views20 pages
    This document discusses predictive maintenance techniques, with a focus on thermography and tribology. It begins by explaining the importance of maintenance and different maintenance management systems, highlighting how predictive maintenance has advantages over breakdown and preventive maintenance. Key predictive techniques discussed in depth include thermography, which uses infrared imaging to detect thermal anomalies, and tribology, which analyzes lubricant condition. The document stresses that a comprehensive predictive program incorporates multiple techniques. It concludes by describing the philosophy of total productive maintenance and calculating overall equipment effectiveness.

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    Basic introduction to industrial maintenance

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    © Attribution Non-Commercial (BY-NC)

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    This document discusses predictive maintenance techniques, with a focus on thermography and tribology. It begins by explaining the importance of maintenance and different maintenance management systems, highlighting how predictive maintenance has advantages over breakdown and preventive maintenance. Key predictive techniques discussed in depth include thermography, which uses infrared imaging to detect thermal anomalies, and tribology, which analyzes lubricant condition. The document stresses that a comprehensive predictive program incorporates multiple techniques. It concludes by describing the philosophy of total productive maintenance and calculating overall equipment effectiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    748 views20 pages

    Preventive Maintenance

    Uploaded by

    Muhammad Aqeel Ashraf
    This document discusses predictive maintenance techniques, with a focus on thermography and tribology. It begins by explaining the importance of maintenance and different maintenance management systems, highlighting how predictive maintenance has advantages over breakdown and preventive maintenance. Key predictive techniques discussed in depth include thermography, which uses infrared imaging to detect thermal anomalies, and tribology, which analyzes lubricant condition. The document stresses that a comprehensive predictive program incorporates multiple techniques. It concludes by describing the philosophy of total productive maintenance and calculating overall equipment effectiveness.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    of 20
    At a glance
    Powered by AI
    The key takeaways are the importance of maintenance, different maintenance management systems like breakdown, preventive and predictive maintenance, and an overview of predictive maintenance techniques like thermography and tribology.

    The different maintenance management systems discussed are breakdown maintenance, preventive maintenance, predictive maintenance and proactive maintenance.

    Some predictive maintenance techniques mentioned are vibration monitoring, thermography, tribology, ultrasonic and process parameters, visual inspection and nondestructive testing.

    Predictive

    Predictive Maintenance
    (With in-depth explanation of Thermography and Tribology)
    Speaker : M.Aqeel Asharf (NUST-SMME)

    Maintenance engineering

    Mechanical Engineering

    Objective:
    Know what maintenance is and why it is important

    Know different maintenance management systems


    Know why predictive maintenance has an edge over other maintenance management systems

    Know different predictive maintenance techniques


    Know in-depth details of Thermography and Tribology A total-Plant predictive maintenance program Know what is World-Class Maintenance
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    CONTENTS
    1.1 Maintenance and its importance 1.2 Maintenance Management Systems 1.2.1 Breakdown Maintenance 1.2.2 Preventive Maintenance 1.2.3 Predictive Maintenance 1.2.4 Proactive Maintenance 1.3 Predictive Maintenance Techniques 1.4 Thermography 1.5 Tribology 1.6 A Total-Plant Predictive Maintenance Program 1.7 What is World Class Maintenance?

    1.1 Why Maintenance !!!


    Maintenance Engineering is applying of engineering concepts for the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment

    Facts and Figures .


    Each year over $300 billion are spent on plant maintenance and operations by U.S. industry. The typical size of a plant maintenance group in a manufacturing organization varied from 5 to 10% of the total operating force.
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    1.2 Maintenance Management systems

    Breakdown Maintenance
    The basic philosophy behind breakdown maintenance is to allow the machinery to run to failure and only repair or replace damaged components just before or when the equipment comes to a complete stop.

    Preventive Maintenance
    The philosophy behind preventive maintenance is to schedule maintenance activities at predetermined time intervals, based on calendar days or runtime hours of machines.

    1.2 Maintenance Management systems cont'd Predictive Maintenance


    This philosophy consists of scheduling maintenance activities only when a functional failure is detected.

    Proactive Maintenance
    This philosophy lays primary emphasis on tracing all failures to their root cause. Each failure is analyzed and proactive measures are taken to ensure that they are not repeated. It utilizes all of the predictive/preventive maintenance techniques discussed above in conjunction with root cause failure analysis (RCFA).
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    1.3 Predictive Maintenance Techniques

    Vibration monitoring

    Thermography

    Tribology

    Ultrasonic
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    Others : process parameters, visual inspection and nondestructive testing techniques (NDTs)

    1.4 Thermography Overview: A predictive maintenance technique that can be used to monitor the condition of plant machinery, structures, and systems. It uses instrumentation designed to monitor the emission of infrared energy (i.e., temperature) to determine operating condition. By detecting thermal anomalies (i.e., areas that are hotter or colder than they should be), an experienced surveyor can locate and define incipient problems within the plant.
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    1.4.1 Infrared Basics:


    It is based on the fact that all objects with a temperature above absolute zero emit energy or radiation. The intensity of infrared radiation from an object is a function of its surface temperature. Three sources of thermal energy can be detected from any object: energy emitted from the object itself, energy reflected from the object, and energy transmitted by the object . Only the emitted energy is important in a predictive maintenance program. A perfect emitting surface, is called a blackbody and has an emissivity equal to 1.0. These surfaces do not reflect. Instead, they absorb all external energy and re-emit it as infrared energy. Surfaces that reflect infrared energy are called gray bodies
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    1.4.3 INFRARED THERMOGRAPHY SAFETY

    Equipment included in an infrared thermography inspection is almost always energized. Therefore, a lot of attention must be given to safety. The following are basic rules for safety while performing an infrared inspection: Plant safety rules must be followed at all times. Notify area personnel before entering the area for scanning. A qualified electrician from the area should be assigned to open and close all panels. Where safe and possible, all equipment to be scanned will be online and under normal load with a clear line of sight to the item.
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    1.5 Tribology
    It refers to design and operating dynamics of the bearing-lubrication-rotor support structure of machinery. Several tribology techniques can be used for predictive maintenance: Oil Analysis tests, ferrography, and wear particle analysis.
    Oil Analysis Tests

    Typically, the following tests are conducted on lube oil samples: 01: Viscosity 02: Contamination 03: Fuel Dilution 04:Fuel Soot 05: Oxidation 06:Nitration 06: Total Acid Number (TAN)
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    Wear Particle Analysis


    Wear particle analysis provides direct information about the wearing condition of the machine-train.

    Types of Wear
    Five basic types of wear can be identified according to the classification of particles: 01: Rubbing wear 02: Cutting wear, 03: Rolling fatigue wear 04: Combined rolling and sliding wear 05: Severe sliding wear.

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    Ferrography
    First, ferrography separates particulate contamination by using a magnetic field. Because a magnetic field is used to separate contaminants, this technique is primarily limited to ferrous or magnetic particles.

    The second is that particulate contamination larger than 10 microns can be separated and analyzed. Normal ferrographic analysis will capture particles up to 100 microns in size and provides a better representation of the total oil contamination.

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    1.6 A Total-Plant Predictive Maintenance Program It would be convenient if a single system existed that would provide all of the monitoring and analysis techniques required to routinely monitor every critical piece of equipment. Unfortunately, this is not the case !!!!!!!! How do you decide which techniques will provide a cost-effective method of controlling the maintenance activities in your plant? The answer lies in determining the type of plant equipment that needs to be monitored. Example: Plants with a large population of electrical equipment should use thermographic or infrared scanning as their primary tool. Plants with a large population of mechanical machines and systems should rely on vibration techniques.
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    ( a) Predictive Maintenance Techniques Most plants have large populations of mechanical systems, vibration techniques will be the primary method required to implement a total-plant program. Secondary methods must be used to gain this additional information. At a minimum, a comprehensive predictive maintenance program should include: Visual inspection Ultrasonic Thermography Tribology
    ( b) Predictive is not enough !!!

    At a minimum, the overall maintenance management methods must include effective planning and scheduling, preventive maintenance tasks, motivations, and record keeping.

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    1.7 World Class Maintenance OR: Total Productive Maintenance (TPM) Moving from a breakdown maintenance mindset toward a concept of proactive maintenance organized around a well-trained staff, within a carefully defined plan, and with meaningful participation of employees.

    Developing partnership among the manufacturing or production people, maintenance, engineering, and technical services to improve what is called overall equipment effectiveness (OEE). Equipment breakdowns Setup and adjustment slowdowns Idling and short-term stoppages Reduced capacity Quality-related losses Startup/restart losses
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    Calculating OEE ( overall equipment effectiveness)

    Availability = Operating time/planned production Performance = Ideal Cycle Time / Total Pieces or (total pieces / Operating time)/Ideal Run time

    Quality = (Total Pieces-Defective pieces) / Total Pieces


    OEE = Availability X Performance X Quality

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    Involving Operators in Daily Maintenance Improving Equipment Effectiveness

    Designing and Managing Equipment for Maintenance Prevention

    Fundamental of
    World-Class performance Improving Maintenance Efficiency and Effectiveness Educating and Training

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    Thanks for your patience listening !!


    Acknowledgement:
    I here acknowledge the support of my teachers and friends during preparation of this presentation Reference book: Introduction to Predictive Maintenance (2nd Edition) Author: R. Keith Mobley Publisher: Plant Engineering

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