preventive maintenance and condition monitoring standards pdf

Preventive Maintenance And Condition Monitoring Standards Pdf

On Saturday, April 17, 2021 9:34:45 AM

File Name: preventive maintenance and condition monitoring standards .zip
Size: 23955Kb
Published: 17.04.2021

Across industry, many definitions are used when it comes to the different types of maintenance. As far as I am concerned terminology is not important.

Preventive maintenance or preventative maintenance is maintenance that is regularly performed on a piece of equipment to lessen the likelihood of it failing. It is performed while the equipment is still working so that it does not break down unexpectedly. In terms of the complexity of this maintenance strategy, it falls between reactive or run-to-failure maintenance and predictive maintenance. Preventive maintenance can be scheduled on a time or usage based trigger.

Preventive Maintenance Essential Care and Condition Monitoring Book

Across industry, many definitions are used when it comes to the different types of maintenance. As far as I am concerned terminology is not important. Other than making sure we are talking about the same thing. As long as we can sensibly talk about the underlying principles. At least, the way I see it:. Corrective maintenance is done after a failure has occurred either as Deferred Corrective Maintenance or as Emergency Maintenance. In the rest of this article, I will discuss each of these different types of maintenance I detail:.

Scheduled restoration tasks and replacement tasks are examples of preventive maintenance tasks. Preventive maintenance or preventative maintenance is basically a type of maintenance that is done at a regular interval while the equipment is still functioning with the objective of preventing failure or reducing the likelihood of failure.

Preventive maintenance can be time based i. But preventive maintenance can also be based on usage e. Apart from the regular interval approach time based maintenance there are also other types of maintenance that fall within the category of preventive maintenance:. In the following paragraphs, I will explore each of these types of maintenance in more detail including when you should consider using them.

Time-Based Maintenance refers to replacing or renewing an item to restore its reliability at a fixed time, interval or usage regardless of its condition. I limit the use of that phrase as for some reason people then jump to the conclusion that another maintenance is not scheduled. When in fact, of course, all maintenance should be scheduled through our Weekly Schedule.

The only exception would be Emergency Maintenance, which due to its very nature of requiring immediate attention cannot be scheduled. Time Based Maintenance assumes that the failure is age related and a clear service life can be determined.

It is important to realise that in many industries companies do have to complete certain tasks to meet regulatory compliance requirements and these would typically be executed on a fixed time interval i. Time Based Maintenance. But even with compliance related maintenance, there are often opportunities to engage a regulator and look at moving to for example risk-based approaches. Failure Finding Maintenance tasks are aimed at detecting hidden failures typically associated with protective functions.

Think pressure safety valves, trip transmitters and the like. That means that under normal operating conditions you will not know whether this equipment is still functional i. Failure Finding Maintenance is conducted at fixed time intervals typically derived from legislation or risk based approaches. As a result, equipment that has a higher risk and a very high conseauence of failure would be subject to more frequent maintenance and inspection.

Low risk equipment may be maintained at a much lower frequency and possibly with a much smaller scope of work. When you implement a Risk Based Maintenance process effectively you should have reduced the total risk of failure across your plant in the most economical way.

Risk-Based Maintenance is essentially preventive maintenance where the frequency and scope of the maintenance activities is continuously optimised based on the findings from testing or inspection and a thorough risk assessment. However, most failure modes do give some sort of warning that they are in the process of occurring or are about to occur. Condition Based Maintenance as a strategy therefore looks for physical evidence that a failure is occurring or is about to occur.

Thinking of CBM in this way shows its broader applications outside condition monitoring techniques often only associated with rotating equipment. The time range between P and F, commonly called the P-F interval, is the window of opportunity during which an inspection can possibly detect the imminent failure and give you time to address it.

It is important to realise that CBM as a maintenance strategy does not reduce the likelihood of a failure occurring through life-renewal, but instead is aimed at intervening before the failure occurs, on the premise that this is more economical and should have less of an impact on availability.

In other words: condition monitoring does not fix machines and condition monitoring does not stop failures. Condition monitoring only lets you find problems before they become a failure. A common rule of thumb is that the interval between CBM tasks should be one-half or one-third of the P-F interval.

With plenty of warning the rectification can be planned, materials and resources can be mobilised and breakdown prevented though production is still stopped for the maintenance duration. When the P-F interval is only a few days the resulting organisational and workplace actions are much like a breakdown and the value of CBM is largely lost.

For CBM to be effective as a strategy, early intervention is essential. This requires an efficient and effective process for data gathering, data analysis, decision making and finally intervention. I see Predictive Maintenance as an extension, a more advanced approach to CBM where we use potentially many process parameters gained from online sensors to determine if our equipment is moving away from stable operating conditions and is heading towards failure. A Run to Failure or Corrective Maintenance strategy only restores the function of an item after it has been allowed to fail.

It is based on the assumption that the failure is acceptable i. A run to failure strategy can effectively be used for general area lighting, smart process instrumentation without trip functionality etc.

When opting for corrective maintenance as a strategy it is essential to ensure that the failure modes under consideration do not have the potential to become Emergency Maintenance.

You see, if you adopt run-to-failure for equipment that once it has failed must be restored immediately to have doomed your organisation to a reactive maintenance environment. A reactive maintenance environment is not where you want to be. It is more expensive, less efficient, and less safe. And that was very deliberate because it is so essential that we absolutely minimize the amount of Emergency Maintenance we allow into our organisations.

Emergency Maintenance typically leads to longer equipment outages and more production impact. And it is less safe. So when a corrective maintenance work request is raised it is essential that you prioritise it properly to make sure that where possible you defer the work request and give your team the time to properly plan and schedule the work.

So Emergency Maintenance is the one and only maintenance type that we really want to avoid as much as possible. An efficient and effective Preventive Maintenance Program will have a mix of all these different types of maintenance.

The most expensive type of maintenance is Emergency Maintenance because this is the type of maintenance that is so urgent that you drop everything to run off and fix the problem.

That means that Emergency Maintenance is usually not well planned prepared and therefore is highly inefficiency and expensive typically at least 3 — 5 times as expensive as well planned preventive maintenance. As far as I am concerned, breakdown maintenance is simply corrective maintenance and not another type of maintenance in itself.

And depending on the risk associated with that breakdown it could be urgent or less urgent. Emergency Maintenance. In my view, they are not the same. So in my view, Planned Maintenance is maintenance that has been through the planning process and is properly prepared with all job steps, labour, parts, and tools identified and organised. The opposite of Planned Maintenance is Unplanned Maintenance which has not properly been prepared and is planned on the plan as the job is done.

This is highly inefficient and something you should avoid at all cost. I refer to this as Emergency Maintenance. The above table of types of maintenance does not include Autonomous Maintenance or Autonomous Care also referred to as Front Line Maintenance in other organisations. This an interesting question and generally speaking unplanned corrective maintenance i.

Emergency Maintenance is the most expensive to conduct. That means when you execute Emergency Maintenance you typically have very low efficiency with additional time wasted looking for materials, organising access to the equipment, waiting on other trades etc.

Another common issue with Emergency Maintenance is that often parts and services are expedited to arrive faster and increased costs are incurred to make that happen. In general, prevention of a failure is simply a lot cheaper and safer than letting equipment fail. Plus, preventive maintenance would have much less impact on production than breakdown maintenance i.

A good example would be something like general area lighting in an industrial plant where you will simply wait till you have a number of lights that have ailed and then you replace them.

Trying to replace these lights before they fail would be a waste of money because we cannot accurately predict when lightbulbs will fail. And because the consequence is low we can simply accept that general lighting is run to failure. Predictive Maintenance really is a type of Preventive Maintenance as they both see you conducting maintenance before the failure has occurred. The issue is though that most people think of the traditional Time-Based Maintenance when they talk about Preventive Maintenance.

So from that perspective which is better? If you have a failure mode that is random in nature you would want to opt for a condition-based or predictive maintenance task so that you can see the potential failure coming closer and take action before the failure occurs.

But, if you have a failure mode that is very clearly age-related or where a condition based task is simply not economical then you would use a time-based maintenance task. Lube oil change out on a turbine with thousands of litres of oil is often best done on condition to ensure you get maximum life out of the oil.

Leave a comment below telling us what types of maintenance you use and why. Have you had great results with one specific type of maintenance let us know:. Erik Thank you for a lot of detailed information concerning the different types of maintenances. Erik, This is all good reading and mixed feedback which shows that different strategies are used across different sites.

For a developing department to move from Reactive to Proactive to Strategic is a long and hard journey and to get there we have to have buy in from all stake holders because if this does not occur we will find it hard to progress. Regardless of how it happened and any witch hunt that may ensue, we have to fix it. Thank you for the articulated and well thought through and simplified process to achieve achieve high safety standard and cost saving.

I would like to know how does one choose the right maintenance after considering the availability of resources to carry them out? What is the minimum resources to carry them out?

You first determine what maintenance needs to be done i. Now of course, in the real world we are all constrained with the resources we have, but you first want to determine the maintenance you really need to do and from there determine the required resources manpower, parts, budget etc.

Hi Fethi, that depends on the type of maintenance that is actually contained within the procedure. If you are testing e. Hi Erik, most of key maintenance KPIs are lagging and most of them rotate on down time; which leading maintenance measures can I use and be able to control the outcomes of the maintenance process in a manufacturing industry?

Hi Moses, there are many KPIs or performance metrics that you can use to manage and improve maintenance.

Quite a few will be lagging but there are plenty of leading indicators, it all depends on your goals and objectives. Thanks Erik for this clarification. I know the benchmark targets for availability and OEE, if I were to look at reliability, what measure and target would I look at?

Preventive maintenance

The document will be available in your library until the end of your session. To save permanently, please create an account. Reduced Maintenance Cost : Early identification of potential problems allows companies to schedule full spectrum vibration analysis and other service before equipment fails or is seriously damaged. Increased Uptime : Collected data can be used to create more reliable service schedules and reduce unplanned shut-downs caused by machine failures. Ease of Use : Wireless system enables communication with remote and hard-to-access equipment without the hassle or expense of running wire to each device.


Keywords: Inspection, prediction condition monitoring, scheduling, Condition monitoring is important to the maintenance manager as it allows it plan preventive in the system was done using CBM reference standards.


Improving Periodic Preventive Maintenance Strategies Using Condition Monitoring Data

To browse Academia. Skip to main content. By using our site, you agree to our collection of information through the use of cookies. To learn more, view our Privacy Policy.

Due to reduction in petroleum production and aging production facilities, the Norwegian oil and gas industry is interested in optimization maintenance strategies and reducing costs. One possibility currently being explored is to use condition monitoring data available in the process monitoring system, to update and improve the predetermined periodic preventive maintenance strategies. Furthermore, we discuss some issues and challenges of the integration of available condition monitoring data in the planning and optimization of predetermined preventive maintenance strategies. Skip to main content Skip to sections.

Preventive maintenance

Condition monitoring and predictive maintenance

Condition-based Monitoring CbM and Predictive Maintenance PM are two maintenance strategies which aim at optimizing equipment efficiency and reducing service timing and costs during equipment lifecycle. Condition Monitoring CM is the monitoring of several parameters such as equipment vibration and temperature to identify potential issues such as misalignments or bearing failures. Condition monitoring tools can for instance map equipment degradation when a vibration analysis shows a change in the harmonic frequency of rotating equipment components.

Predictive maintenance techniques are designed to help determine the condition of in-service equipment in order to estimate when maintenance should be performed. This approach promises cost savings over routine or time-based preventive maintenance , because tasks are performed only when warranted. Thus, it is regarded as condition-based maintenance carried out as suggested by estimations of the degradation state of an item. The main promise of predictive maintenance is to allow convenient scheduling of corrective maintenance , and to prevent unexpected equipment failures. The key is "the right infor equipment lifetime, increased plant safety, fewer accidents with negative impact on environment, and optimized spare parts handling.

The Condition Monitoring Standards Books describes How and Why condition monitoring tasks are done for common components found in all industry. The books are frequently used by operators and craftspeople. Thank you for taking the time to view Condition Monitoring Standards Volume 1. IDCON INC is a management consulting company specializing in reliabilty and maintenance for the manufactuing and processing industries maximize profits through the improvement of reliability and maintenance practices. Click this link to read reliability articles and maintenance tips or to join our newsletter group.

Preventive Maintenance Essential Care and Condition Monitoring Book

It is a unique resource for improving maintenance management processes and learning smart preventive maintenance PM , condition monitoring, inspection and troubleshooting techniques on a wide variety of components including pumps, motors, gears, bearings, chain, pipes and valves, couplings, seals, fans, lubrications, lifting equipment, hydraulics, pneumatics, compressors, steam, electrical systems, etc. The condition monitoring and PM techniques are presented in the book together with inspection tools and examples of how to inspect and prevent failures for a number of standard components. The maintenance book carefully explains how to set up and improve a preventive maintenance program in any industry. The reliability book teaches the reader how to organize condition monitoring, lubrication, alignment, cleaning, and other preventive maintenance systems into one orchestrated process. Preview this book.

The future holds great promise for condition monitoring as more sensors are developed that can be mounted on equipment. Also, more equipment is being built to Internet of Things IoT standards. Data analyzed for condition monitoring serves as the basis for predictive maintenance.

Across industry, many definitions are used when it comes to the different types of maintenance. As far as I am concerned terminology is not important. Other than making sure we are talking about the same thing. As long as we can sensibly talk about the underlying principles. At least, the way I see it:.

Predictive Maintenance techniques detect anomalies in equipment before those turn into system-critical failures, allowing maintenance to be scheduled before the equipment actually breaks down. After having proven its benefits in the context of Industry 4.

management pdf pdf

1 Comments

  1. Ligia R.

    overtime cost, limited or misused preventive maintenance, and so on. Keywords: Condition based maintenance, condition monitoring, production systems, What are the functions and associated performance standards of the asset in its.

    22.04.2021 at 03:21 Reply

Leave your comment

Subscribe

Subscribe Now To Get Daily Updates