Introduction to Maintenance and

Installation of Machinery
MEng5251

By yared zewde
 CHAPTER OBJECTIVES
• At the end of this chapter students will be able
to:
– Define maintenance.
– Explain the needs of maintenance.
– Explain the main objectives of maintenance.
– General Procedure of Machine Installation
– Identify types of maintenance.
 What is Maintenance?
 Maintenance can be considered as a combination of activities
directed towards preservation and restoration of the
performance of a facility, machine or equipment.
 All actions appropriate for retaining a part/equipment in, or
restoring it to a given condition
 Maintenance include:
 servicing
 repair
 modification
 overhaul
 inspection and condition verification
 Maintenance Terms and Definitions

• Maintenance engineering:
– The activity of equipment/item maintenance that develops
concepts, criteria, and technical requirements in
conception and acquisition phases to be used and
maintained in a current status during the operating phase
to assure effective maintenance support of equipment.
– Maintenance Engineering is the discipline and profession of
applying engineering concepts for the optimization of
equipment, procedures, and departmental budgets to
achieve better maintainability, reliability, and availability of
equipment.
– is an analytical function as well as it is deliberate and
methodical
 Maintenance Terms and Definitions

• Preventive maintenance:
– All actions carried out on a planned, periodic, and
specific schedule to keep an item/equipment in stated
working condition through the process of checking
and reconditioning to forestall or lower the
probability of failures or an unacceptable level of
degradation
• Corrective maintenance:
– The unscheduled maintenance or repair to return
items/equipment to a defined state and carried out
because maintenance persons or users perceived
deficiencies or failures.
 Maintenance Terms and Definitions

• Predictive maintenance:
– The use of modern measurement and signal processing
methods to accurately diagnose item/equipment
condition during operation.
• Maintenance concept:
– A statement of the overall concept of the item/product
specification or policy that controls the type of
maintenance action to be employed for the item under
consideration.
• Maintenance plan:
– A document that outlines the management and technical
procedure to be employed to maintain an item; usually describes:
• facilities, tools, schedules, and resources.
 Maintenance Terms and Definitions

• Reliability:
– The probability that an item will perform its stated
function satisfactorily for the desired period when
used per the specified conditions.
• Maintainability:
– The probability that a failed item will be restored
to adequately working condition.
• Active repair time:
– The component of downtime when repair persons
are active to effect a repair.
 Maintenance Terms and Definitions

• Mean time to repair (MTTR):

– A figure of merit depending on item maintainability equal to the
mean item repair time.
• Overhaul:
– A comprehensive inspection and restoration of an item or a piece
of equipment to an acceptable level at a durability time or usage
limit.
• Quality:
– The degree to which an item, function, or process satisfies
requirements of customer and user.
• Inspection:
– The qualitative observation of an item’s performance or
condition.
 Failure
Failure – inability to produce work in appropriate
manner
• Equipment / machine failure on production floor –
worn out bearing, pump, pressure leaks, broken
shaft, overheated machine etc.
• Equipment failure in office – failure of power supply,
air-conditioning system, computer network,
photocopy machine
• Vehicle failure – brake, transmission, engine, cooling
system
 Types of failures
• (a) Gradual Failure: In this, the failure mechanism
is progressive. As the age of an item increases, its
performance deteriorates. This results in:
– Increased operating cost
– Decreased productivity of the item
– Decrease in resale value of item
 (b) Sudden Failure
 This type of failure can be observed in the items that
do not deteriorate gradually with age but which fail
suddenly after some period of service.

Equipments failure pattern will follow certain frequency

distribution that may be:
– progressive,
– retrogressive or
– random in nature.
• Progressive failure: It is said to be progressive failure,
when probability of failure increases with the age of an
item. Ex: light bulbs, tyres etc.
• Retrogressive failure: Certain items will have more
probability of failure in the initial years of their life and
with the increase in the life of an item the chances of
failure become less Ex: aircraft engines
• Random failure: It is said to be random failure, when
constant probability of failure is associated with
equipment that fails because random causes such as
physical shocks that are independent of age.
 Maintenance verses Repair

• Repairs are restoration work for when something

gets broken, damaged or stops working.
• Maintenance are routine activities meant to
prevent damage and prolong the life of
appliances, fixtures, and the property itself.
• Maintenance is a total approach aimed at
reducing downtime.
• Repair is one of the steps in this total approach.
 Areas of Maintenance:
1. Civil maintenance- Building construction
maintenance, maintaining service facilities
2. Mechanical Maintenance- Maintaining
machines and equipments, transport vehicles,
compressors and furnaces…
3. Electrical Maintenance- Maintaining electrical
equipments such as generators, transformer,
motors, telephone systems, lighting, fans, etc.
 What is the place of Maintenance
Professionals in Industry?
 Maintenance Planner
 Sales Engineer
 Maintenance Engineer
Technique Manager

Which industries require the service of

maintenance professionals?
 Maintenance in Service Industry
• Hospital
• Transport companies
• Banks
• Hotels and resorts
• Restaurants
• Shopping malls / retail
• Gas station
 Maintenance in Manufacturing
Companies
 Metal industries  Textile and Garment
 Plastic factories Factories
• Electronic  Breweries
• Automotive  Soft drink factories
• Petrochemicals • Furniture
• Refinery • Ceramics
 Questions?
• Why do we need maintenance?
• What are the costs of doing maintenance?
• What are the costs of not doing maintenance?
• What are the benefits of maintenance?
• How can maintenance increase profitability of
company?
 The main purposes of maintenance:
 to eliminate system failures and hazards.
 to ensure that equipment continues to work with in
the design tolerances and specifications.
 Attempt to maximize performance of production
equipment efficiently and regularly
 Minimize production loss from failures
 Increase reliability of the operating systems
 to ensure equipment are capable of being performed
for the required period.
 Principal Objectives in Maintenance

• To achieve product quality and customer satisfaction

through adjusted and serviced equipment
• Maximize useful life of equipment
• Keep equipment safe and prevent safety hazards
• Minimize frequency and severity of interruptions
• Maximize production capacity – through high
utilization of facility
 Maintenance Objectives
• Must be consistent with the goals of
production (cost, quality, delivery, safety)
• Must be comprehensive and include
specific responsibilities
 Problems in Maintenance
• Lack of management attention to maintenance
• Difficulties in applying quantitative analysis
• Difficulties in obtaining time and cost
estimates for maintenance works
• Difficulties in measuring performance
 Problems exists due to:
• Failure to develop written objectives and policy
• Inadequate control procedures for work order,
service requests etc.
• Infrequent use of standards
• Absence of cost reports to aid maintenance planning
and control system
 Effect of Poor Maintenance

Inadequate or lack of effective and efficient maintenance

system especially in a manufacturing enterprise gives
rise to several undesirable consequences. These
consequences include:
(i) Excessive machine breakdown
(ii) Frequent emergency maintenance work
(iii) Shortened life-span of the facility
(iv) Poor use of maintenance staff
(v) Loss in production output
(vi) Inability to meet delivery dates
(vii) Excessive overtime
Maintenance Costs
 Cost to replace or repair
 Losses of output
 Delayed shipment
 Scrap and rework
General Procedure of Machine Installation
Installation procedure of a machine involves a
series of activities like:
a) Location and layout;
b) Positioning of machines;
c) Foundation;
d) Leveling and alignment;
e) Grouting;
f) Fitting of other parts, accessories, piping etc.;
g) Final leveling and test runs
a) Location and Layout
 The location of a machine depends on its purpose of
installation, definite types and sizes and other special
requirements, if any.
For example:
 a centrifugal pump location should be as close to the
source of water as possible when suction lift is present
 a compressor location may be selected near the
particular shop where maximum air will be consumed
and at the same time a clear intake air will be
available.
Location and Layout

 Once the location is finalized, the work of laying out

the foundation plan is to be undertaken.
 Laying out means marking of the foundation plan. It
may be done with the help of chalk on a concrete floor
and by a string with a number of pegs.
 The general procedure is to indicate the outlines as
per specification of the machine.
 The axis lines are to be drawn both longitudinally and
crosswise to locate the center of foundation.
 b) Foundation
 The shapes and sizes of the foundation differ
according to the type and size of the machines.
 Designs of machine foundations involves
consideration of static load and kinetic forces
 The load of the machine is static load which is of minor
importance in the design of machine foundation. The
moving parts of the machine develop inertia forces
which are the major forces to be considered in its
design
 Foundations should be isolated from the adjoining
parts of the building by leaving the gap around it to
avoid the transmission of vibrations
 The machine foundation should be safe from a bearing
capacity failure under static and dynamic loads.
c) Positioning of Machines
 Positioning of the machine at the location is an
important job, which deserves care, skill and
efficient teamwork.
 An equipment may have the weight of a few tons. But
it is to be loaded or unloaded, to be moved vertically
or horizontally to bring it at the site and to place it
on the foundation as well.
 Different types of lifting devices like pulley blocks,
chain hoists, overhead cranes etc. may be used as
per the availability and requirement.
 When the load is light, rope pulley blocks are widely
used and chain pulley blocks may be useful, but for
a very heavy load, electric cranes are generally
employed.
d) Leveling and Alignment
 After having the machine on the foundation, the
important job is to level and align it with other
accessories.
 The leveling is performed with leveling wedges, shoes
etc.
 The horizontal and slight vertical movements of the
heavy mass of machine is performed by pipes, rollers
as shown in Fig. 9a or using pinch bars (Fig. 9b).
 Straight edge, spiral level, dial indicator etc., are
generally useful instruments to level the machine.
 The leveling is to be checked in the both, longitudinal
and transverse direction.
Leveling and Alignment cont..

Figure 9: (a) Rolling of Load, (b) Lifting of Load.

 Leveling and Alignment cont..

 The parallelism, perpendicularity of different faces, axes

should be leveled and aligned, as are required.
 When leveling is completed, the foundation bolt cavity
along with the bolt may be made concreted. Pouring of
cement concrete is generally made through the gap
provided at the top of the foundation, as shown in Fig. 10.
 This concreting will provide a bondage of the foundation
bolts with the foundation block while performing grouting,
Figure 10: Pouring concrete in bolt cavity.
 d) Grouting
 Grout is used to secure the base plates of heavy
machinery to the foundation which allows the machinery
to function properly
 Additionally, grout reduces operational vibrations that can
cause structural damages and machinery malfunctions
 Epoxy grout made from epoxy resins and an aggregate
which makes excellent durability, hardness and water
resistance properties.
 Cement grout is made with water, cement and sand.
 Once started, the pouring should be completed
continuously and the machine must be felt undisturbed
for a few days after grouting to provide it time to set.
e) Fitting of other parts

 When the machine is erected, the other accessories

may be joined accordingly.
 But, while laying out the foundation plan, the overall
requirement should be kept in mind.
 The auxiliary structures e.g. in case of a heavy-duty
diesel engine foundation, the structures for outer
bearing pedestal, water pump blocks etc. should be
planned at a time.
f) Final leveling and test runs
 Accurate leveling can be carried out only when the
grouting has set in after a few days.
 The machine is to be made cleaned and leveled then.
Such leveling involves minor adjustments.
 Everything should now be made ready to carry the test
run.
 Introduction for Maintenance
strategies
 Maintenance may be classified into four categories:
– (some authors prefer three categories- scheduled and
preventive maintenances are merged)
 Corrective or Breakdown maintenance
 Scheduled maintenance
 Preventive maintenance
 Predictive (Condition-based) maintenance
 Corrective or Breakdown Maintenance
• Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and
can not perform its normal function anymore
• No actions or efforts are taken to maintain the
equipment as the designer originally intended to
ensure design life is reached.
Advantages
• Low cost (but, shortening the life of the equipment
resulting in more frequent replacement)
• Less staff
 Disadvantages of Corrective Maintenance

• Breakdown generally occurs inappropriate times leading to

poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety for both workers
and machines
• More spoilt materials
• increased cost due to unplanned downtime of equipment
• Direct loss of profit
 Preventive Maintenance (PM)
• Principle – “Prevention is better than cure”
• Actions performed on a time- or machine-run-based
schedule that detect, preclude, or mitigate
degradation of a component or system
• locates weak spots of machinery and equipments
• periodic/scheduled inspections and minor repairs to
reduce the danger of unanticipated breakdowns
 Advantages of PM

• Advantages:
–Reduces break down and there by down time
–Cost effective in many capital-intensive processes
–Greater safety of workers
–Reduced equipment or process failure
–Lower maintenance and repair costs
–Less stand-by equipments and spare parts
–Better product quality and fewer reworks and scraps
–Increases plant life
Predictive (Condition-based) Maintenance

• In predictive maintenance, machinery conditions are

periodically monitored and this enables the
maintenance crews to take timely actions, such as
machine adjustment, repair or overhaul

• It makes use of human sense and other sensitive

instruments, such as
–audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain gauges
etc.
 Predictive Maintenance (Contd.)

• Unusual sounds coming out of a rotating equipment

predicts a trouble
• An excessively hot electric cable predicts a trouble
• Simple hand touch can point out many unusual
equipment conditions and thus predicts a trouble
Predictive Maintenance:

Vibration
Visual analysis Oil
Inspection analysis

Efficiency Condition based Temperature

analysis management analysis

Pressure
Wear
analysis
analysis Ultrasonic
Advantages

• Increased component operational life/availability.

• Allows for preemptive corrective actions.
• Decrease in equipment or process downtime.
• Decrease in costs for parts and labor.
• Better product quality.
• Improved worker and environmental safety.
• Improved worker morale.
• Energy savings.
• Estimated 8% to 12% cost savings over preventive
maintenance program
Disadvantages

• Increased investment in diagnostic equipment.

• Increased investment in staff training.
• Savings potential not readily seen by
management.
Questions?