Maintenance and Safety Engineering

(ME323)
 Distribution of Marks
_

LTP 3 0 0
Credit 3
3 Lecture hours per week

Internal Assessments 20%

Mid Semester 30%

End Semester 50%

References:
⚫ P.Gopalakrishnan, Maintenance and Spare Parts Management, 2nd Edition,
Prentice Hall of India Pvt. Ltd., New Delhi, 2013
⚫ R. C. Mishra and K. Pathak, Maintenance Engineering and Management, 2nd
Edition, Prentice Hall of India Pvt. Ltd., New Delhi, 2012.
⚫ L. S. Srinath, Reliability Engineering, Affiliated East West press, 2005
⚫ Rolland P. Blake, Industrial Safety, 3rd Edition, Prentice Hall of India Pvt. Ltd., New
Delhi, 2003. 2
 SYLLABUS _

➢ MODULE-1: OBJECTIVE OF MAINTENANCE

Types of maintenance Breakdown, preventive and predictive maintenance -

Repair cycle – Repair Complexity, Lubrication and Lubricants. Maintenance of
Mechanical transmission systems and process plants.
➢ MODULE-2: PREDECTIVE MAINTENANCE

Vibration and noise as maintenance tool - wear debris analysis – Condition

monitoring concepts applied to industries - Total Productive Maintenance
(TPM) - Economics of Maintenance- Computer aided maintenance

➢ MODULE-3: RELIABILITY

Definition, concept of reliability based design, failure rate, MTTF, MTBF, failure
pattern, system reliability: Series, Parallel and Mixed configurations - Availability
and Maintainability concepts- Applications

3
 SYLLABUS _

➢ MODULE-4: SAFETY AND PRODUCTIVITY

Causes of accidents in industries accident reporting and investigation -

measuring safety performance - Safety organizations and functions - Factories
act and rules.

➢ MODULE-5: SAFETY CODES AND STANDARDS

General Safety considerations in Material Handling equipment - Machine Shop

machineries-pressure vessels and pressurized pipelines welding equipment
operation and inspection of extinguishers prevention and spread of fire
emergency exit facilities.

4
 MODULE-1 _

➢ Maintenance: Introduction, Definition, History, Objectives

➢Types of maintenance Breakdown, Preventive and predictive
maintenance
➢ Repair cycle – Repair Complexity, Lubrication and
Lubricants.
➢Maintenance of Mechanical transmission systems and
process plants.

5
 Introduction _

Objective of management:
▪ Max profit → Productivity → max
utilization of resources, min waste, min.
down time, defect free product →
maintain the equipments in best running
condition to get defect free products

6
 Introduction _

Scientific Management was two fold

1. To identify the best way to do a task and according to

that give training to all employees so that they work
in that best way

2. To have up to date maintenance of your plant so that

you have max. O/P and max. productivity from your
organization.

7
 Introduction _

Maintaining the production capability of an organization is an

important function in any production system.

British Standard Glossary of terms (3811:1993) defined

maintenance as:
“The combination of all technical and administrative actions,
including supervision actions, intended to retain an item in, or
restore it to, a state in which it can perform a required function”.

Maintenance is a set of organized activities that are carried out in

order to keep an item in its best operational condition with
minimum cost acquired.
8
 Introduction _

Maintenance is one of the most crucial area governing

organizations. Yet it is the most neglected aspect.

➢ In most industries in India, owing to a number of reasons,

the capacity utilization is less than 60%.

➢ This lowering of capacity utilization leads to higher inputs

and lower outputs. Increases the unit cost charged to the
customer.

➢ Maintenance, when neglected, leads to frequent

breakdowns, leading to costly repair and faster
deterioration of valuable equipment besides causing
incalculable loss of production.

9
 Introduction- Maintence Activities _

Activities of maintenance function could be either repair or

replacement activities, which are necessary for an item to reach
its acceptable productivity condition and these activities, should be
carried out with a minimum possible cost

10
 Introduction-Type _

Decision makers have two basic options with resect to

maintenance. One option is reactive and the other is proactive.

Breakdown maintenance: Reactive approach; dealing with

breakdowns or problems when they occur.

Preventive maintenance: Proactive approach; reducing

breakdowns through a program of lubrication, adjustment,
cleaning, inspection and replacement of worm parts

11
 Introduction – Maintenance need _

1. Protect the investment in machinery, plant and

buildings through regular and adequate
maintenance to ensure their long life.
2. Safeguard the return on investment by maximising
plant utilization with minimum down time.
3. Prevent waste of spares, tools and materials
4. Control and direct the maintenance labour force.
5. Maximize the labour and other resources
6. Ensure adequate technical information for
maintenance
7. Control maintenance cost and establish records
8. Assist in future budgeting
9. To evaluate plant performance as a guide to future
forecast.
12
 Maintenance History _

In the period of pre-World War II, people thought of maintenance

as an added cost to the plant which did not increase the value of
finished product.
Therefore, the maintenance at that era was restricted to fixing the unit
when it breaks because it was the cheapest alternative.

During and after World War II at the time when the advances of
engineering and scientific technology developed, people developed
other types of maintenance, which were much cheaper such as
preventive maintenance.

In addition, people in this era classified maintenance as a function

of the production system.
13
 Maintenance Development _

Influencing the development in the last four decades, five

significant stages may be noted:

1) Continuing transition from slow speed to high speed

production equipment, which means more production and
more wear of equipment.
2) Continuing movement from man-controlled to
automatically-controlled production equipment, which
requires high-grade engineering talent for maintenance.
3) Increased cost per hour of productive labour, which adds to
the cost of equipment down time.
4) Increased cost of production equipment, which intensifies
pressure for greater equipment utilisation.
5) Increased ratio of maintenance employees to production
employees, which means a fewer men on the do side of plant
operations and more on the keep-ready state.
14
 MaintenanceToday _

Nowadays, increased awareness of such issues as

environment safety, quality of product and services
makes maintenance one of the most important functions
that contribute to the success of the industry.

World-class companies are in continuous need of a

very well organised maintenance programme to
compete world-wide.

15
 Maintenance History _

Term terotechnology
-

introduced.
-Recognition of need to
present equipment failures.
Development of
Maintenance

-Models for preventive

maintenance developed. -Increased awareness of:
-Environment
-Safety
-Quality
Fix the equipment
-Need for reliable equipment.
when it breaks
-Reduction in costs.

Time
Pre-W orld W arII Post-World W arII 1980 Onwards

Maintenance History (Adapted From

Shenoy, Bhadury 1998)

16
 Maintenance Facilities Required _
a) Non-Destructive testing (NDT) testing – surveillance of plant
b) Data bank of information on plant problems on plant problems
and their solutions, preferably in a computerised form
c) Anti-corrosion treatment facilities
d) Welding and crack detection facilities- X-ray, dye-penetration
radiography, SEM, interferometry, magnetic particle testing and
many more.
e) Rotary machinery (e.g. centrifugal compressors, turbines and
bearing) need special apparatus for dynamic balancing, aligning,
vibration monitoring and so on
f) Calibration facilities
g) Proper documentation preferably computerised
h) Supporting services: Technical literature which includes
a) maintenance schedules b) maintenance instructions c) operational manuals
d) fault analysis charts/diagrams e)Drawings f)Specifications
g) An organization to provide genuine high quality spare parts
h) An organization to provide special tools and equipments
17
 Benefits of Maintenance Planning _

1. Reduction in down time-

▪ Introduction of maintenance planning
▪ Rapid fault-finding systems and the use of diagnostic charts
▪ Performance monitoring on critical plant items, but installing monitoring
facilities to obtain warning of failures
▪ Having efficient support organizations ensuring availability of genuine spare,
tools and test equipment
2. Staff development – training and providing technical
information
3. Resource utilization – planned properly using CPM
4. Machine life – regular planned maintenance
5. Cost of improvising

18
 Maintenance Objectives _

Maintenance objectives should be consistent with and subordinate

to production goals.
The relation between maintenance objectives and production goals
is reflected in the action of keeping production machines and
facilities in the best possible condition.

19
 Maintenance Objectives _

▪ Maximising production or increasing facilities availability at the

lowest cost and at the highest quality and safety standards.
▪ Reducing breakdowns and emergency shutdowns.
▪ Optimising resources utilisation.
▪ Reducing downtime.
▪ Improving spares stock control.
▪ Improving equipment efficiency and reducing scrap rate.
▪ Minimizing energy usage.
▪ Optimizing the useful life of equipment.
▪ Providing reliable cost and budgetary control.
▪ Identifying and implementing cost reductions.
20
 Maintenance Objectives _

PLANT

Maximising Production Reduce Breakdowns

M
A
Minimising Energy Reduce Downtime
Usage
I
N
Optimising Useful Life of T Improving Equipment
Equipment E Efficiency

N
Providing Budgetary Improving Inventory
Control A Control
N
Optimising Resources C Implementing Cost
Utilisation Reduction
E

Maintenance Objectives

The ultimate objective is PROFIT, the production infrastructure and

facilities are maintained at as minimum cost as possible with max
efficiency and operational availability.
21
 _

The maximisation efforts normally includes the following:

1) Preventive and planned maintenance

2) The health and safety of both workmen and machines
3) Planning and scheduling
4) Controls
5) Flexibility
6) Documentation

The main objective of a properly run maintenance

department is to have plant, equipment and
machinery available for productive utilisation during
the scheduled hours, operating to agreed standards
with minimum waste and minimum total cost. 22
TYPE OF MAINTENANCE _

23
 TYPE OF MAINTENANCE _

▪ Unplanned/ Run to Failure Maintenance (RTF)

▪ Planned Maintenance

➢ Preventive Maintenance (PM)

➢ Predictive Maintenance (PDM)

➢ Corrective Maintenance (CM)

➢ Improvement Maintenance (IM)

24
 RUN TO FAILURE MAINTENANCE (RTF) _

▪ The required repair, replacement, or restore action performed on a

machine or a facility after the occurrence of a failure in order to bring
this machine or facility to at least its minimum acceptable condition.

▪ It is the oldest type of maintenance.

It is subdivided into two types:

–Emergency maintenance: it is carried out as fast as possible in order to bring a
failed machine or facility to a safe and operationally efficient condition.
–Breakdown maintenance: it is performed after the occurrence of an advanced
considered failure for which advanced provision has been made in the form of repair
method, spares, materials, labour and equipment.

25
 RUN TO FAILURE MAINTENANCE (RTF) _
Disadvantages:

1. Its activities are expensive in terms of both direct and indirect cost.
2. Using this type of maintenance, the occurrence of a failure in a component can
cause failures in other components in the same equipment, which leads to low
production availability.
3.Its activities are very difficult to plan and schedule in advance.

Advantages:
This type of maintenance is useful in the following situations:

1.The failure of a component in a system is unpredictable.

2.The cost of performing run to failure maintenance activities is lower than
performing other activities of other types of maintenance.

3.The equipment failure priority is too low in order to include the activities of
preventing it within the planned maintenance budget. 26
 PREVENTIVE MAINTENANCE (PM) _

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.

British Standard 3811:1993 Glossary of terms defined preventive maintenance

as:

“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.”

27
 PREVENTIVE MAINTENANCE (PM) _

The advantage of applying preventive maintenance activities is to satisfy

most of maintenance objectives.

❑ It is good for those machines and facilities which their failure would
cause serious production losses.

❑ Its aim is to maintain machines and facilities in such a condition that

breakdowns and emergency repairs are minimized.
❑ Its activities include replacements, adjustments, major overhauls,
inspections and lubrications.

28
 PREVENTIVE MAINTENANCE (PM) _

The factors that affect the efficiency of preventive maintenance:

1. The need for an adequate number of staff in the maintenance department in
order to perform this type of maintenance.
2.The right choice of production equipment and machinery that is suitable for
the working environment and that can tolerate the workload of this environment.

3.The required staff qualifications and skills, which can be gained through
training.

4. The support and commitment from executive management to the PM

programme.

5.The proper planning and scheduling of PM programme.

6.The ability to properly apply the PM programme.

29
 PREVENTIVE MAINTENANCE (PM) _

Researchers subdivided preventive maintenance into different kinds according

to the nature of its activities:

1.Routine maintenance which includes those maintenance activities that are

repetitive and periodic in nature such as lubrication, cleaning, and small
adjustment.

2.Running maintenance which includes those maintenance activities that are

carried out while the machine or equipment is running and they represent
those activities that are performed before the actual preventive maintenance
activities take place.

30
 PREDICTIVE MAINTENANCE (PDM) _

Predictive maintenance is a set of activities that detect changes in the

physical condition of equipment (signs of failure) in order to carry out the
appropriate maintenance work for maximizing the service life of equipment
without increasing the risk of failure.

It is classified into two kinds according to the methods of detecting the

signs of failure:

– Condition-based predictive maintenance

– Statistical-based predictive maintenance

31
 PREDICTIVE MAINTENANCE (PDM) _

1. Condition-based predictive maintenance depends on continuous or

periodic condition monitoring equipment to detect the signs of failure.

2. Statistical-based predictive maintenance depends on statistical data

from the meticulous recording of the stoppages of the in-plant items and
components in order to develop models for predicting failures.

32
 PREDICTIVE MAINTENANCE (PDM) _

The drawback of predictive maintenance is that it depends heavily on

•
information and the correct interpretation of the information.

Some researchers classified predictive maintenance as a type of

•
preventive maintenance.

• The main difference between preventive maintenance and predictive

maintenance is that predictive maintenance uses monitoring the condition of
machines or equipment to determine the actual mean time to failure whereas
preventive maintenance depends on industrial average life statistics.

33
 Predictive maintenance
Preventive maintenance
_______ _________________________ ______________________________
Preventive maintenance
( P M ) is w o r k that is
Predictive m a i n t e n a n c e ( P d M ) is w o r k
scheduled based on
D e finitio n that is s c h e d u l e d a s - n e e d e d b a s e d o n
calendar time, asset
runtime, or s o m e other real time conditions of assets.
period of time.

Workflow

T rigg e r T im e C o n d ition

Cost L o w Medium/High

Cost
1 2 % to 1 8 % [1] 2 5 % to 3 0 % [1]
S a ving s

• M a inte n a n c e
• Ma i n t e n a n c e software for
software for
scheduling
scheduling
• M a i n t e n a n c e s c h e d u le r (for
• Maintenance
R e s o u rce larger organizations)
s Needed s c h e d u le r (for larger
• Condition monitoring software
organizations)
• Condition monitoring tools a n d
• Preventive
sensors
m a i n te n a n c e
• P d M training
checklists
34
 _

• Better than reactive • M a i n t e n a n c e is p e r f o r m e d a s

maintenance needed
Pros
• Relatively e a s y to • R e d u c e s m a x i m u m a m o u n t of
implement downtime

• Risk of over-maintaining
• Expensive technology needs
(e.g. over-lubrication c a n
purchased
Cons d a m a g e asset)
• Time-intensive to implement
• Labor intensive (not
correctly
performed as needed)

A n organization wants to
decrease unplanned downtime A n organization has assets with slow-speed
and emergency maintenance but b e a r i n g s t h a t f r e q u e n t l y fa i l . P r e v e n t i v e
does not have a large m a i n t e n a n c e is alr ead y in p lace b u t th e
maintenance budget. A s a organization suspects that assets are being
Use solution, they implement a P M over-greased. T o perform maintenance with
Case p r o g r a m for select assets. W o r k m o r e precision, they use ultrasound
orders are scheduled for analysis (good for slow-speed bearings).
inspections, lubrication, filter N o w , w o r k orders for greasing are only
replacements, and parts scheduled w h e n certain ultrasound
replacements based on measurements are reached.
recommendations from O EMs.

35
 CORRECTIVE MAINTENANCE (CM) _

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.

In the British Standard 3811:1993 Glossary of terms, corrective maintenance is

defined as:

“The maintenance carried out after recognition and intended to put an item into
a state in which it can perform a required function.”

36
 CORRECTIVE MAINTENANCE (CM) _

This type of maintenance is subdivided into three types:

1.Remedial maintenance, which is a set of activities that are performed to

eliminate the source of failure without interrupting the continuity of the
production process. The way to carry out this type of corrective maintenance is by
taking the item to be corrected out of the production line and replacing it with
reconditioned item or transferring its workload to its redundancy.

2. Deferred maintenance, which is a set of corrective maintenance activities that

are not immediately initiated after the occurrence of a failure but are delayed in
such a way that will not affect the production process.

3. Shutdown corrective maintenance, which is a set of corrective maintenance

activities that are performed when the production line is in total stoppage
situation. 37
 CORRECTIVE MAINTENANCE (CM) _

The main objectives of corrective maintenance are

• The maximisation of the effectiveness of all critical plant systems,

• The elimination of breakdowns,

• The elimination of unnecessary repair, and

• The reduction of the deviations from optimum operating conditions.

38
 CORRECTIVE MAINTENANCE (CM) _

The difference between corrective maintenance and preventive maintenance is

that for the corrective maintenance, the failure should occur before any
corrective action is taken.

Corrective maintenance is different from run to failure maintenance in that its

activities are planned and regularly taken out to keep plant’s machines and
equipment in optimum operating condition.

39
CORRECTIVE MAINTENANCE TYPE _

40
 CORRECTIVE MAINTENANCE TYPE _

1. Fail-repair: The failed item is restored to its operational state.

2. Salvage: This element of corrective maintenance is concerned

with disposal of nonrepairable material and use of salvaged
material from nonrepairable equipment/item in the repair,
overhaul, or rebuild programs.

3. Rebuild: This is concerned with restoring an item to a standard

as close as possible to original state in performance, life
expectancy, and appearance. This is achieved through complete
disassembly, examination of all components, repair and
replacement of worn/unserviceable parts as per original
specifications and manufacturing tolerances, and reassembly
and testing to original production guidelines.

41
 CORRECTIVE MAINTENANCE TYPE _

4 Overhaul: Restoring an item to its total serviceable state as per

maintenance serviceability standards, using the “inspect and repair
only as appropriate” approach.

5. Servicing: Servicing may be needed because of the corrective

maintenance action, for example, engine repair can lead to
crankcase refill, welding on, etc. Another example could be that
the replacement of an air bottle may require system recharging.

42
 CORRECTIVE MAINTENANCE (CM) _

The way to perform corrective maintenance activities is by conducting four

important steps:

I. Fault detection.
II. Fault isolation.

III. Fault elimination.

IV. Verification of fault elimination.

In the fault elimination step several actions could be taken such as

adjusting, aligning, calibrating, reworking, removing, replacing or
renovation.

43
 CORRECTIVE MAINTENANCE (CM) _

Corrective maintenance has several prerequisites in order to be carried out

effectively:

1. Accurate identification of incipient problems.

2. Effective planning which depends on the skills of the planners, the availability
of well developed maintenance database about standard time to repair, a
complete repair procedures, and the required labour skills, specific tools, parts
and equipment.

3. Proper repair procedures.

4. Adequate time to repair.

5. Verification of repair.

44
 IMPROVEMENT MAINTENANCE (IM) _

It aims at reducing or eliminating entirely the need for maintenance.

This type of maintenance is subdivided into three types as follows:

1. Design-out maintenance which is a set of activities that are used to eliminate
the cause of maintenance, simplify maintenance tasks, or raise machine
performance from the maintenance point of view by redesigning those
machines and facilities which are vulnerable to frequent occurrence of
failure and their long term repair or replacement cost is very expensive.

45
 IMPROVEMENT MAINTENANCE (IM) _

2. Engineering services which includes construction, modification, removal

and installation, and rearrangement of facilities.

3. Shutdown improvement maintenance, which is a set of improvement

maintenance activities that are performed while the production line is in a
complete stoppage situation.

46
_

47
 Repair Cycle _

Generally, the maintenance scheduling embraces the following activities.

⦁ Inspection ⦁ Repair ⦁ Overhauling

Hence the term repair does not reflect the any proper meaning where time
duration is a major factor. Based on the time the repair may be minor one like
regulating or replacing a anti-friction bearing, adjustment of belt tension, etc,
or major one like conditioning the bed surfaces, guide ways and cleaning of
bearings etc.

So to create maintenance scheduling program, the various maintenance

activities may be classified into four categories which are as follows.
⦁ Inspection (I)
⦁ Minor Repair (R1)
⦁ Medium or major Repair (R2)
⦁ Overhauling (O)

The term “Repair Cycle and Repair Complexities” will help to plan a
maintenance cycle.
48
 Repair Cycle and Repair Complexity _

The repeated performance of all/ some of the above mentioned activities in

sequence between two successive overhauling is termed as Repair cycle”.

The figure shows the activities to be carried out during overhauling of

equipments.

It is clear that first an inspection activity (I1) is scheduled followed by Minor

Repair (R11) and Medium/major (R21) repair activities is planned. Then again an
inspection (I2) takes place followed by a minor repair (R12). Again a third
inspection (I3) is followed by major repair (R22) then second Overhauling (O2) and
completes one repair cycle. The set of these activities between two consecutive.
Overhauling is defined as a repair cycle. This typical repair cycle covers three
inspection and two minor and two major repair activities. This can be represented
O1 – I1 – R11 – R21 – I2 – R12 – I3- R22 – O2 50
 Repair Cycle and Repair Complexity _

From it is understood that the repair cycle is mainly time dependent between activities. If
it is three months, then complete time duration of this referred cycle is two years.

The planning of time interval between two activities can be scheduled using past data of the
machine, following manufacturing instructions and as per the complexities of the
instruments or machine tools.

An index number generally known as repair completely number is used to

communicate a comparative complexities of different machines. This index is finalized
taking into account the power transmission devices, hydraulic units, guide surfaces,
intricate mechanisms associated with the functioning of the machine like for boiler it may be
12, air compressor -8 or turbine-14.

The repair complexity number is helpful to the maintenance department to finalize the
‘ maintenance staff-size’, to design the ‘inventory required’ or to forecast ‘maintenance
cost’etc.

It may be noted more the complexity number more will be the activities involved and in
turn more staffing requires to complete the repair cycle (inspection – minor and major
repairs).
51
______________________________________________________________

For

51
Maintenance Planning _

52
______________________________________________________________

Installation, Servicing and Maintenance by S.N. Bhattacharya 53

 _

Installation, Servicing and Maintenance by S.N. Bhattacharya 54

______________________________________________________________

Installation, Servicing and Maintenance by S.N. Bhattacharya 55

 _

Installation, Servicing and Maintenance by S.N. Bhattacharya 56

______________________________________________________________

Installation, Servicing and Maintenance by S.N. Bhattacharya

56
______________________________________________________________

57
Installation, Servicing and Maintenance by S.N. Bhattacharya
CONTROLLING _

Installation, Servicing and Maintenance by S.N. Bhattacharya 58

 Optimum Maintenance Cost _
The main objective of a properly run maintenance department is to have
plant, equipment and machinery available for productive utilisation during
the scheduled hours, operating to agreed standards with minimum waste
and minimum total cost.

The total cost is the sum of maintenance labour costs and material cost
plus cost of loss in production.

(a) If maintenance cost (M-curve) is at zero, then it indicates the maintenance is

being carried out at that point and cost of production (P curve) is at the
highest or at its peak.

(b) As maintenance effort is gradually being introduced and increased, the

production loss slowly decreases.

(c) The total cost curve (T-Curve) pattern, the efforts mentioned in point (b) holds
true till the minimum combine cost level at point A. Thereafter, any additional
maintenance effort being applied increases the cost.

So maintenance optimising technique indicate that point A on the T-Curve is the

objective for the maintenance to achieve.
60
_

61
 LUBRICATION _

In industrial equipments/machineries, the surface of the mechanical parts will

have physical contact on the neighboring parts to establish a relative motion
between them.

During the operation of the equipments, those contacting surfaces are subjected
to friction. This leads to progressive damage resulting in material loss which is
defined as wear. Friction and wear also generate heat and responsible for the
overall loss in system efficiency. All these contribute to significant economic costs
due to equipment failure, cost for replacement and downtime.

Lubrication is a procedure to separate the surfaces with a film of lubricant to

minimize the friction and to restrict wear and tear as well. The substances used
for this purpose are called ‘Lubricants’.

The primary objective of lubrication is to reduce wear and heat between

contacting surfaces in relative motion. By means of lubrication co-efficient of
friction (which depends on area of contact and amount of load acting) could be
reduced and intern heat and wear of the surfaces.

59
 FUNCTIONS OF LUBRICATION: _

❖To minimize friction in the mating surfaces.

❖To minimize the wear and tear of the surfaces.
❖To protect the surface from corrosion
❖To carry out the heat generated due to friction, leaving the
assembly cool as far as practicable
❖To reduce the noise from moving components of the
machine
❖To lengthen the service-life of the components by
performing the above functions

It may be noted that the lubrication can produce the desired

results, depending on the:
a) Physical, chemical and mechanical properties of the selected
lubricants
b) The Lubricating method
Installation, Servicing and Maintenance by S.N. Bhattacharya 63
PROPERTIES OF LUBRICANTS _

Installation, Servicing and Maintenance by S.N. Bhattacharya 64

PROPERTIES OF LUBRICANTS _

Installation, Servicing and Maintenance by S.N. Bhattacharya 65

 TYPES OF LUBRICANTS _

➢ Solid Lubricants: used when oils or greases are unsuitable

or not permissible, such as very low or high temperature.
Ex- soap, Talc, mica, molybdeum-disulphate.
Graphite is also used in mixing it with oils. PTFE is also
popularly used.
➢ Semi-liquid lubricant: Grease → It has got a number of
grades and depending on the type of lubrication required,
the grades is selected. Grease is basically a mineral or
synthetic oil and is thickened with thickening agents.
The grease may be of various types such as non-soap grease,
lithium base greases, Calcium base greases, etc.
➢ Liquid Lubricants: Mineral oil, vegetable oil and Animal
Oil.

Installation, Servicing and Maintenance by S.N. Bhattacharya 66

 ADDITIVES _
To use very common lubricants, different additives are sometimes added with
them to use the lubricant purposefully to establish an optimum operating
condition. Viscosity-index improvers, corrosion resistant etc. act as additives
to allow the lubricants to function at an atmosphere over the temperature
range or to retard corrosion and rusting of metals etc.
Different types of additives are discussed below:
1. Antifriction Additives which are generally fatty acids and natural or
synthetic fats. They are used mostly to improve the power transmission
capacities as such additives retain on the metal surface .
2. Anti wear Additives: They are generally derivatives of Phosphorous and
Phosphoric acids. They are operable up to a temperature of 200 °C. Such
additives reduce the wear of rubbing surfaces at moderate temperatures.
3. Extreme Pressure Additives: They can withstand high contact temperature
and loads. They are generally organic derivatives of sulphur and chlorine.
Such additives actually resist the effect of scuffing of the mating surfaces.

Installation, Servicing and Maintenance by S.N. Bhattacharya 67

 Selection of lubricant _

The best selection of a lubricant for a particular type will be the simplest and
cheapest one, which will of course, meet the requirements:
• In general, in any assembly without any feed mechanism, a small quantity
of mineral oil is ideal. Again, a small quantity may not be functional when
wear debris creates problem or heat generation more. In that case, an oil-
feed system may be preferred.
• When cooling is not much required but sealing is the criterion, 'grease' is
the choice. But under high temperature range or for special requirements
e.g. low flameability or low carbonisation, synthetic oil is preferred.
• Generally, oil of lower viscosity is suitable for high-speed mechanisms and
for high load and low-speed mechanisms, highly viscous oil or grease is
used.
• If the temperature becomes too high or too low, no product contamination
is acceptable, if extremely long life is required, the best choice may be a
SOLID LUBRICANT.

Installation, Servicing and Maintenance by S.N. Bhattacharya 68

 MODES OF LUBRICATION _

The modes of lubrications are usually characterised by the friction and wear
behaviour of surface layers. It is generally of three types.
(a) Boundary lubrication;
(b) Fluid film lubrication; and
(c) Mixed lubrication.

Installation, Servicing and Maintenance by S.N. Bhattacharya 69

 MODES OF LUBRICATION _
(a) Boundary lubrication
This type of lubrication mode is generally found in machine tool slide ways and most
commonly in door-hinges. The principle is shown in Fig. 9. I. I and 2 represent the
underlying materials. The area 4 is the boundary lubricant and the area 3 is the
protective film which may be present, due to the physical and chemical reactions
between the surface layer and the lubricant. It is generally an oxide film.

Boundary lubrication happens when

•A shaft starts moving from rest.
•The speed is very low.
•The load is very high.
•Viscosity of the lubricant is too low.

70
MODES OF LUBRICATION _

Installation, Servicing and Maintenance by S.N. Bhattacharya 71

___________________________________________________________ _

Installation, Servicing and Maintenance by S.N. Bhattacharya 72

______________________________________________________________

Installation, Servicing and Maintenance by S.N. Bhattacharya 73

 _

Lubrication of A Machine Tool

-10  C

Installation, Servicing and Maintenance by S.N. Bhattacharya 74

_____________________________________________________________ _

Installation, Servicing and Maintenance by S.N. Bhattacharya 75

 _

Installation, Servicing and Maintenance by S.N. Bhattacharya 76

1) High thermal conductivity for cooling
2) Good lubricating qualities
3) High flash point, should not entail a fire hazard
4) Must not produce a gummy or solid precipitate at ordinary working
temperatures
5) Be stable against oxidation.

Installation, Servicing and Maintenance by S.N. Bhattacharya 77

_

78
 Belt Drives _

Belt and pulley drive is extensively used in industry for transmission of power.

79
Belt Drives _

Installation, Servicing and Maintenance by S.N. Bhattacharya

76
 CHAIN DRIVE _

Silent chains are made up of stacked

Roller chain consists of a series rows of flat link plates with gear-type
of short cylindrical rollers held contours designed to engage sprocket
together by side links. It is driven teeth in a manner similar to the way
by a toothed wheel called a rack engages a gear as shown in the
a sprocket. It is a simple, reliable, figure. The links are held together at each
and efficient for power chain joint by one or more pins, which
transmission. also allow the chain to flex. 77
CHAIN DRIVE _

Installation, Servicing and Maintenance by S.N. Bhattacharya 78

 GEAR _

79
Installation, Servicing and Maintenance by S.N. Bhattacharya
 GEAR
____________________________ ___________________________ _
______

84
_

85
_

86
_

87
_

88
_

89
_

90
_

91
_

92
_

93
_

94
_

95
_

96
 _

Installation, Servicing and Maintenance by S.N. Bhattacharya 97

GEAR _

Installation, Servicing and Maintenance by S.N. Bhattacharya 98

 GEAR _

Installation, Servicing and Maintenance by S.N. Bhattacharya 99

GEAR _

Installation, Servicing and Maintenance by S.N. Bhattacharya 10