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Definition: It's a group of (actions & works) done for the equipment to be in a good condition at any time.
Causes of maintenance: 1Equipment weakness design a. b. 2Unsuitable materials Unsuitable working environment
Change in working environment condition Effect of external and internal elements Dynamic (Critical speed) Mechanical (over load) Chemical (excessive wearing)
b. c. d. e.
Maintenance Objectives
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Increase equipment efficiency. Restore the operating condition under which equipment
was designed.
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and this will lead to: a. b. c. Increase equipment (reliability & availability) Increase equipment life time Reduce operating cost
Over load Long idling speed operation Suddenly loading & unloading Operation with failure signs (sound visual vibration
smell)
Effect on: -
General unit performance (Decrease) Production quality (Decrease) Operating cost (Increase) Benefits (Decrease) Crew moral (Decrease)
So, it is found that cost of break down repairs is three times cost of planned repair
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Established & organized maintenance department Manage the maintenance Control the maintenance
* Manage the maintenance: Introduce maintenance planning Show how to perform the work Consider worker feeling and capability
* Control maintenance: Collecting data and information Analyzing Spare parts management Cost control
Causes of reduced maintenance quality: 1Lack of a. b. c. d. e. f. g. 234567Information data Maintenance instruction Spare part & spare part information Recording data Follow up procedures Analysis Expertise
Unsuitable planning Incompetent management Insufficient budget partial CMMS implementation staff overload or not enough poor communication
Before setting up maintenance program for any equipment, some important information should be taken into consideration: Age Design Manufacturer Operation Environment condition
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Comparison Design
Manufacturer
accuracy
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accuracy complicated
simple
Operation
partially
y operating work at
Maintenance types There are many type of maintenance which may be carried out for any equipment: abunplanned maintenance planned maintenance
Unplanned maintenance (OTF) Operate To Failure Apply in case of: Emergency Accident Break down Collapse Apply for: 123Cheep equipment Insensitive equipment Uncomplicated equipment
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1- Preventive maintenance: Depends on: Fixed time maintenance (FTM) Usage Based Maintenance (UBM) o o o Apply for: new equipment expensive equipment sensitive equipment complicated equipment Running hours Tones Number of operations
2- Predictive maintenance: (CBM) Condition Based Maintenance Depends on: Performance o o o Wear Power output Speed
Note: This type of maintenance is considered as a perfect type where it is apply before any break down occurs, but it needs: 1- high technology measurement devices 2- high technology analysis units
3- Corrective maintenance: Apply in case of failures that were expected but were not prevented because they were not critical for safety or economy. current repairs replacement recondition
It is the worst type of planned maintenance where it may cause: Equipment shut down Lost of time and money
4- Opportunity maintenance: This type of maintenance is carried out when available by chance as: Bad weather Labor strike National holidays
Nature of equipment (age, design, manufacture) Nature of operation (hours, overhauls) Performance requirements (availability, reliability) Time consume for maintenance Maintenance cost relative to equipment price Maintenance cost relative to different market prices
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MTBF:
Mean Time Between Failure (or MTTF) Is the ratio between operating time to number of failures in between MTBF = operating time / no. of failures in between,
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MTBM:
It is time between successive maintenance activities & set according to maker instructions. RTTM Remaining Time To Maintenance Is the residual time for carrying out the maintenance and is determined by maintenance department and the crew. BL: Back Logs It is the allowable time (running hours/weeks) for maintenance job late execution, determined by maintenance department and the crew Down time: It is the time consumed beginning from equipment break down until equipment operating - Equipment break down - Fined the expert - Detect the fault - Find spare part - Repair the fault - Equipment operate
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Re:
Reliability It is the actual time in hours that a system or machine can operate at optimum design conditions. Re = e (MTBM/MTBF)
Example: For some equipment through 4000 operating hours there was twice failures, if the maker MTBM = 1500 h, Determine the MTBF and the reliability Re. Then discuss the new one if we reduce the MTBM to 1000. Solution: MTBF = operating time / no. of failures in between, MTBF = 4000 / 2 = 2000 h Re = e (MTBM/MTBF) Re = e (1500/2000) Re = 0.472 New Re = e (1000/2000) New Re = 0.606
Av:
Availability
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Is the percentage of total production time to the actual production time (at any level of performance) Av = MTBF / (MTBF + Down times)
Example: Two motors A & B, Motor A has MTBF = 10 years MTBM = 1 year Down time = one month Motor B has MTBF = 20 years MTBM = 2 year Down time = two month
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