Maintenance Philosophy and Methodologies

Maintenance
Philosophy and Methodologies
MCB4633 Plant Equipment Maintenance and Reliability
January 2015 Semester

2
Lesson Objectives
Understand the various maintenance methodologies

that are typically applied to industrial equipment.
Breakdown Maintenance (Reactive)
Preventive Maintenance
Predictive Maintenance
Proactive Maintenance
Understand the Key performance indicators for
Maintenance
MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

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What is Failure?
Failed to perform the function that the equipment is

designed for.
Functional failures:
Unable to operate
Unable to operate at the required rate
Unable to meet the quality standard
Unable to meet the environment, health and safety
standards

4
Why does system fail?

The
strength
Strength distributio
n widens
and falls
over time.
Likelihood of
failure is higher
Load in this region
Equipment replaced here Few Problems! Time/Load Cycles

Log Scale
Equipment replaced here Lots of Problems!

5
Causes of Failures
25-35% of equipment reliability issues are due to engineering/design
Poor Equipment Selection
Motors, pumps, couplings, gear box
Improper sizing of equipment
Improper piping design practices
Pipe strain on equipment
Torque method on fasteners
Poor base/foundation designed
Poor alignment or balancing

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Causes of Failures
10-20% of failures are contributed to equipment fabrication
Improper piping practices
Pipe strain on equipment
Torque method on fasteners
Improper welding procedures
Improper fabrication practices
Unlevel base structures
Improper/lack of anchoring points
Inadequate piping support
Improper handling of finished equipment
Pick points/shipping points/tie down points
Improper shipping method
Improper packaging
Tie downs of critical parts

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Causes of Failures
15-25% of failures are due to poor installation practices
Improper handling practices
Pick points, moving practices
Improper anchoring techniques
Improper anchoring bolts and torque
Insufficient anchoring points
Improper alignment and balancing
Poor lubricant selection and control
Incorrect viscosity
Dirty lubrication
Wrong lubrication/grease

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Causes of Failures
10-20% of failures are due to operation issues
Improper starting and operating procedures
Starting equipment under full load
Insufficient monitoring
Thermal condition
Physical vibration
Lubrication condition

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Maintenance cycle of poor practices

10
P-F Curve and Maintenance
Lubrication Mech Heat

excellence Ultrasound
Feel
Precision Vibration
analysis
Smell
Maintenance
RCM Oil Analysis Smoke
Equipment Wear Particle
KPI testing
RCFA/ Thermogrpahy
FMEA MCE
NDT

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Maintenance strategies
evolutions

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Maintenance: Methodologies
There are four universally recognized maintenance

methodologies in use today, they include the
following:
1. Failure-Based or Breakdown Maintenance (CM)
2. Scheduled or Preventive Maintenance (PM)
3. Predictive Maintenance (PdM)
4. Proactive Maintenance (PaM).

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Failure-Based or Breakdown
Maintenance
Breakdown Maintenance is essentially no

maintenance.
Equipment is simply allowed to operate until
complete failure, or where inefficiency or product
quality problems force a shutdown.

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Maintenance
Disadvantages of CM
First, failures can be most untimely. There is
little that can be done beforehand to anticipate
the tools, personnel, and replacement parts
that may be required to repair the equipment
and return it to service.
Secondly, machines allowed to run to failure
generally require more extensive repair than
would have been necessary if the problem had
been detected and corrected earlier.

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Maintenance
Some failures can be catastrophic, requiring

total replacement of the machine or pose a
safety hazard.
It is estimated that on average, it costs about
three times more to repair a machine that has
been allowed to run to total failure compared to
the cost to repair the machine before failure.
And, the added cost of lost production while
the machine is out of service can be
staggering.

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Failure-Based or Breakdown Maintenance
In general, breakdown maintenance should be reserved

for relatively small rotating equipment (less than 5 Hp
motors).
Any machine that has a repair cost as high or
higher than its replacement cost should be allowed
to fail when it represents no risk to safety,
production, or product quality.

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Scheduled or Preventive
Maintenance
Compared to breakdown maintenance, a

program of periodic disassembly, inspection,
and replacement of worn parts has the distinct
advantage of lessening the frequency of
breakdown repairs and also permits scheduled
shutdown.
Under this program of preventive maintenance
(PM), each critical machine is shut down after a
specified period of time or operation and
partially or completely dismantled for a
thorough inspection and replacement of worn
parts if any.

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Goals of PM
Reduce equipment failures

Reduce the magnitude of equipment failure or repair
costs
Reduce the product loss or production downtime
due to equipment failure or repair
Reduce the deterioration in the productive capacity
of equipment

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Maintenance
This approach to maintenance also has disadvantages.

First of all, to periodically disassemble every critical piece
of equipment in the plant can be expensive and time
consuming.
Secondly, the interval between periodic inspections is
difficult to predict. If the program is so successful that no
machinery failures occur, it may be that the interval is too
short and money and production is being wasted. If the
interval is too long, costly failures may still occur.
How to determine interval?
Time based
Condition based
Failure Finding
OEM Directed (Recommended)
Hand me down (Experience)
Regulatory, EPA, OSHA
Risk
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Maintenance
Some PM is absolutely essential.

Filter changes, periodic tear down of very large
rotating machinery (e.g. turbines and generators),
and valve seat inspections are just a few examples of
necessary PMs.
General PM Activities
Routine functions performed at regular intervals of
time or life cycles of use
Lubricating
Cleaning
Inspection; visual or by measurement
Adjustments to specifications
Replacement of parts due to ordinary wear
Early identification of potential problems
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Preventive Maintenance Dilemma

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Preventive Maintenance for Wearing Parts
Replace Part at
Optimal Risk
NOTE: Looking for the

upturn is not optimal.
When to renew parts to DANGER Zone
Failure Rate minimise total risk is an
economic decision.
Rapid wear-
Random Punctures and Abuse out from use
60,000 km
Usage - Distance
In the random failure period carry spares for the This tell-tale up-turn is what we want
unforeseeable (like a puncture). During this phase to find for our wearing parts. We can
you have total control of how many times you then replace the part as preventive
overload/overstress the part, or whether you let the maintenance before the chance of it
local environment degrade to the point it starts to failing starts to get high with further
fatigue the part. use.

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Preventive Maintenance for Wearing Parts
The blade edge is

renewed at the end
of its usable life
The failure rate of the knife

edge reflects:
Rate of Blunting
Robustness of the Design
Quality (Precision and Accuracy) in
Manufacture
Roughness and Care during Use
The Quality of Maintenance
Care 50 100 150
Times Used
With a failure rate curve of this shape for a part we can see it gradually
degrading with use. That means we can set a usage limit, after which it will need
to be replaced or renewed as preventive maintenance.

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Predictive Maintenance (PdM) involves the trending

and analysis of machinery performance and
operating parameters to detect and identify
developing problems before failure and extensive
damage can occur.
On-line detection and diagnosis of problems is
obviously the most desirable way to maintain
machinery.

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Reduce consequence of failure

More time for planning the repair work
More efficient use of maintenance time
Less emergency downtime
Safer (and less stress!) work condition

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If problems can be detected early:

Shutdown for repairs can be scheduled for a
convenient time.
A work schedule, together with the requirements for
personnel, tools, and replacement parts can be
prepared before the shutdown.
Extensive damage resulting from forced failure can
be avoided.
Repair time can be kept to a minimum, resulting in
reduced machinery downtime.
Costly trial and error approaches to solve a problem
can be avoided since analysis identifies the nature of
the problem.

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Selecting PdM Frequency

(How often to monitor equipment condition?)
Do Maintenance
Repair or Replace Equipment Airline 7 - 11%
& Condition
Unusable Airline 3 - 4%
Performance
Monitor Naval 6 - 9%
Operating
Naval 2 - 3%
Smooth Change in
Running Performance is Airline 1 - 2% Airline 14 - 15%
Detectable Impending Naval 10 - 17% Naval 42 -56%
Failure
Failed
Time (Depending on the situation

Airline 4 - 5% Airline 66 - 68%
this can be from hours to months.)
Naval 3 - 17% Naval 6 - 29%
The Failure Degradation Sequence
The Six Failure Curves and the Percentage

Of Equipment Types They Apply Too.
for random failure zone
When parts fail randomly you cannot predict which part will fail, or when it will fail. Unlike parts with wear-
out failure, which can be observed and replaced, the random failure part can only be observed at defined
intervals and monitored for evidence of developing, or impending, failure.
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Predictive Technologies
Oil Analysis
Wear Particle Analysis
Vibration Analysis
Thermography
Mechanical Ultrasound
Motor Circuit Evaluation (MCE)
Non Destructive Testing (NDT)

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Predictive Technologies
When selecting the correct predictive technology

you must understand what specific failure mode you
are trying to find.
The cost of the technology can not be more
than the cost of the potential true downtime or
failure.
Predictive Technology tools allow for the detection
and correction of deteriorating conditions in assets
before they lead to failure.

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Oil Analysis
Important oil characteristic

Moisture
Oxidation
Additive Depletion
Particle Counts
Viscosity
Acid or base number

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Oil Analysis-Moisture
The number one destroyer of lubricating oil.

Tests:
Crackle 1000 ppm (0.1%) A good field indicator, easy
to perform qualitative only, not suitable for trending
FT-IR water 1000 ppm (0.1%) quantitative, good for
trends, easy to perform. other liquid contaminants
(glycol) present can confuse the spectrometer.
Karl Fischer 10 ppm (0.001%) low The best test for low
moisture levels. Very accurate. Required for turbine
systems & transformers Unless lab has a nitrogen
spurge, lubricant additives may cause interference.
Need some lab expertise to run correctly.

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Oil Analysis-Oxidation
We can not stop oxidation, we can only delay it

with additives and control of conditions.
Increased oxidation occurs from high temperature,
moisture, and contaminants.

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Oil Analysis-Acid/Base
Number
This test will determine the pH of the lubricant.
Establish this number when the oil is new and when
you see a change the lubricant is changing for some
reason.
These tests show up as TAN or TBN. They represent
Total Acid Number or Total Base number..
The acidity level will influence the corrosion risk to
the components (ie bearing)
The base level will determine the ability of the
lubricant to neutralize acidity due to oxidation, heat

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Mechanical Ultrasonic
Inspection
Ultrasonic inspection unit on all motor bearings and
bearings on attached equipment. Able to reduce
unplanned downtime by 60% just using this
technology.
This worked by setting a base line for failure action.

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Inspection
Use it to check individual bearings
Use it to listen to gearbox internals
Use for lubrication
Listen as you pump in grease, stops over greasing
Use it to know when to grease
Use to determine how bad is the component

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Inspection
Good Valve Bad Valve
Time series view of a Good Time series view of a Leaking

Compressor Valve. Note the short Compressor Valve. Note the
open moment. prolonged open moment

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Thermography
The second most popular use is in the electrical area.
These cameras have the capability to detect hot electrical
connections. These connections are hot due to poor contact or
overloading of that point in the connection.
These hot connections dont go away and usually lead to
downtime or possible fires.
The cameras are non contact making them safe to use around
rotating equipment.

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Thermography-Example

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Vibration Analysis
All items in a process have a natural frequency.

In vibration it is key to baseline machinery
frequencies and amplitudes to determine machinery
health and to recognize if something is changing.
Baselines should always be gathered on new
equipment after a short run-in period.

40
Vibration Analysis
Vibration Analysis can detect:

Coupling wear
Bearing wear
Structural looseness
Gear wear

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Non Destructive Testing
Non Destructive Testing is a Predictive technology

that is used to find problems with equipment from
wear, corrosion, and erosion
NDT looks for defects that would cause the part to
fail while in service. It makes sure the part is within
its specification tolerance. These checks let you
know well ahead of time of a potential failure.
This equipment is used mainly on stationary
equipment such as tanks, pipes, boiler tubes, etc. It
can be used on many different materials, Steel,
Copper, Plastics, and other composite materials.

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Visual
Liquid Dye Penetrant
Magnetic Particle
Ultrasonic
Eddy Current
Radiography
Modified Pulse Echo (Shear Wave Analysis) (Shafts)
Hydrostatic Testing

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What can N.D.T. methods tells us?

Cracks in vessels
Erosion or corrosion of tanks/piping
Weld Integrity
Stress cracks
Reductions in material thickness
Boiler tube wall thickness
Shaft material defects

44
Reliability Centered
Maintenance (RCM)
A process that was designed in the early 70s by
United Airlines. The process later became the
standard by which all commercial aircraft are
maintained.

45
Key Performance Indicator-
OEE

46

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Moving Practices

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Maintenance category
Maintenance
Preventive Maintenance Corrective Maintenance

(also called scheduled (also called unscheduled
maintenance) maintenance)
TYPICAL
TASK
Time Inspections Access Maintenance
replacement
Remove and
Repair
Calibration and Cleaning and Replace
Adjustment Lubrication
Confirm Fault Close Up and
Corrected Secure
REQUIRED BY REQUIRED BY
Safety Failures
On-condition monitoring - confirmed
Servicing - unconfirmed

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Maximize Precision work techniques

Minimum spare part required
Maximum runtime, minimal downtime
Reduction of predictive maintenance cost
Elimination of equipment failure modes

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7-51
Generic Maintenance policies

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Proactive Maintenance (PaM) practices focus on

circumventing the failure modes of machinery and
minimizing the costs to maintain equipment.
There are two general areas of proactive
maintenance.
The first is the area of proactive skills or proactive
technologies.
The second is proactivity from a programmatic
perspective.

53
Philosophy of Maintenance
The three strategic maintenance philosophies to be
discussed include:
1. Condition-Based Maintenance (CBM)
2. Reliability-Centered Maintenance (RCM)
3. Total Productive Maintenance (TPM).

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Condition-Based Maintenance
(CBM)
The philosophy of Condition-Based Maintenance is
a practical maintenance strategy which seeks to
optimize the mix of failure-based, preventive,
predictive, and proactive maintenance practices.
The strategy is typically implemented by first
identifying a Reliability Team that performs a
qualitative assessment of plant processes and
machinery to determine criticality of the assets.

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(CBM)
Second, the team studies the equipment to identify
which types of maintenance practices will be
applied to each asset. Fractional horsepower
motors, for instance, might simply be allowed to
run to failure.
Conversely, a critical machining tool or large
turbine/generator set will have a full complement of
PM, PdM and PaM techniques applied.

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(CBM)
Third, a review of PM tasks should be
conducted to see which activities must be
conducted, which may be deferred based on
machine condition, and which activities may be
eliminated altogether.
Fourth, an evaluation must be performed to
decide which predictive and proactive
techniques to implement in-house, which to
out-source, and identify those that are not
applicable.
Evaluations must be carried out to identify the
appropriate equipment (hardware and software) and
vendors, and those tools must be procured.

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(CBM)
Finally, the Reliability Team implements the
program on a building block basis introducing
new technologies and new tools as the program
matures.
Importantly, the team must espouse Continuous
Improvement and re-evaluate the program on a
semiannual or annual basis.

58
Reliability-Centered Maintenance
(RCM)
Very similar to CBM, Reliability-Centered
Maintenance is a technical maintenance strategy
that strives to identify the appropriate methodology
based on the maintenance requirements for each
asset.
The major difference between RCM and CBM lies in
the fact that RCM employs a rigorous quantitative
evaluation of equipment criticality based on
identified failure modes and effects.

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Reliability-Centered Maintenance (RCM)
Once these failure modes are identified, the

maintenance requirements are specified for
each piece of equipment.
This approach goes on to develop procedures
for the conduct of PM.
The RCM approach was first developed in the 1970s
for application in the aircraft and nuclear power
industries.
The approach is well proven to develop outstanding
PM procedures and achieve high reliability. In the
classical RCM approach, predictive and proactive
maintenance requirements are not addressed.

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61

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Total Productive Maintenance (TPM)
Total Productive Maintenance may be thought of as

a management strategy for reliability.
TPM deals with the resource side of maintenance
including personnel, materials, financial, and
scheduling. It is a manufacturing led approach to
maintenance that is typically based on the use of
cross-skilled teams.

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TPM seeks to improve operational efficiencies

and often is measured in terms of overall
equipment effectiveness (OEE).
OEE is the valuable operating time of an asset
or process net of downtime, speed losses and
quality losses as depicted in Figure 1-1.
TPM uses a continuous improvement approach
to preventive and predictive maintenance and
also focuses on maintenance prevention.

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Computerized Maintenance Management Systems (CMMS)
The CMMS system is the main reliability

management system.
The CMMS is capable of tracking people (skills,
schedules, and cost) and equipment (tools,
spares, and stores).
The system facilitates planning of maintenance
through work request and work order
management.
Good CMMS practices may also lead to the
equipment histories so necessary to achieve
root cause failure analysis.

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The CMMS system can be an invaluable source

of information for financial data, equipment
activity history, and metrics.
A constraint to establishing a good CBM
Program is often the lack of detailed equipment
history.
A machinery history guideline should be
developed and implemented through the correct
utilization of the CMMS.
Storing basic information such as symptom,
problem, corrective action and unusual
conditions provides important historical data for
future troubleshooting efforts.

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The machinery history must be part of the CMMS as

shown in Figure 1-2 and should be integrated with
the maintenance department database to ensure all
pertinent information is available to the Reliability
Team so they can make the best decision.

69

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Maintenance

Philosophy and Methodologies

MCB4633 Plant Equipment Maintenance and Reliability

January 2015 Semester

Understand the various maintenance methodologies

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Failed to perform the function that the equipment is

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Why does system fail?

Equipment replaced here Few Problems! Time/Load Cycles

Equipment replaced here Lots of Problems!

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Maintenance cycle of poor practices

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

P-F Curve and Maintenance

Lubrication Mech Heat

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

There are four universally recognized maintenance

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Breakdown Maintenance is essentially no

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Some failures can be catastrophic, requiring

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Failure-Based or Breakdown Maintenance

In general, breakdown maintenance should be reserved

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Compared to breakdown maintenance, a

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Reduce equipment failures

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

This approach to maintenance also has disadvantages.

Some PM is absolutely essential.

Preventive Maintenance Dilemma

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Preventive Maintenance for Wearing Parts

NOTE: Looking for the

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Preventive Maintenance for Wearing Parts

The blade edge is

The failure rate of the knife

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Predictive Maintenance (PdM) involves the trending

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Reduce consequence of failure

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

If problems can be detected early:

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Selecting PdM Frequency

Time (Depending on the situation

The Six Failure Curves and the Percentage

for random failure zone

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

When selecting the correct predictive technology

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

Important oil characteristic

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester

The number one destroyer of lubricating oil.

MCB4633 Plant Equipment Maintenance and Reliability January 2015 Semester