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PLANT MAINTENANCE WORK AND SERVICE - PRACTICE March 6, 2021

TYPES OF PLANT MAINTENANCE

The technical meaning of maintenance involves functional checks, servicing, repairing or replacing of
necessary devices, equipment, and machinery, building infrastructure, and supporting utilities in
industrial, business, and residential installations

What is MAINTENANCE?

I. Cost-effective practices to keep equipment operational; these activities occur either before or
after a failure.
II. Maintenance is any activity that is carried out on any facility either to restore to or to retain the
III. facility in a good and acceptable working conditions
IV. 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.
V. Industrial maintenance is a process of maintaining machines and equipment in a factory. With
the development of special-purpose machine and equipment, it cost a lot more money so their
idle time and downtime becoming a lot more expensive day by day. Therefore, it is important
that plant machinery and equipment should be properly maintained.
VI. Any activity such as tests, measurements, replacements, adjustments, and repairs—intended to
retain or restore a functional unit in or to a specified state in which the unit can perform its
required functions.
VII. All action taken to retain material in a serviceable condition or to restore it to serviceability. It
includes inspections, testing, servicing, and classification as to serviceability, repair, rebuilding,
and reclamation.
VIII. A repair action taken to keep a force in condition to carry out its mission.
IX. The routine recurring work required to keep a facility (plant, building, structure, ground facility,
utility system, or other real property) in such condition that it may be continuously used, at its
original or designed capacity and efficiency for its intended purpose.
X. Maintenance, in general, can be defined as efforts taken to keep the condition and performance
of a machine always like the condition and performance of the machine when it is still new.
XI. Maintenance is the function whose objective is to ensure the fullest availability of production
equipment, utilities and related facilities at optimal cost and under satisfactory conditions of
quality, safety and protection of the environment.

OBJECTIVES OF PLANT MAINTENANCE

i. To optimize the reliability of equipment and infrastructure.

ii. To ensure that equipment and infrastructure are always in good condition.
iii. To carry out prompt emergency repair of equipment and infrastructure so as to secure the best
possible availability for production.
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PLANT MAINTENANCE WORK AND SERVICE - PRACTICE March 6, 2021

iv. To ensure the operation of equipment for production and for the distribution of energy and
fluids;
v. To improve operational safety;
vi. To train personnel in specific maintenance skills;
vii. To advise on the acquisition, installation and operation of machinery;
viii. To contribute to finished product quality;
ix. To ensure environmental protection.
x. Minimizing energy usage
xi. Improving equipment efficiency and reducing scrap rate.
xii. Optimising the useful life of equipment.
xiii. Providing reliable cost and budgetary control.
xiv. Identifying and implementing cost reductions.

Maintenance activities can basically be divided into two parts:

Planned maintenance activities and unplanned maintenance activities.

Planned maintenance is maintenance that is organized and carried out with thought to the future,
control and recording in accordance with the plans that have been determined previously.
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PLANT MAINTENANCE WORK AND SERVICE - PRACTICE March 6, 2021

TYPES OF PLANT MAINTENANCE

Planned maintenance

Maintenance which is known to be necessary sufficiently in advance for normal planning and
preparation procedures to be followed.

Unplanned maintenance

This is maintenance which is not carried out regularly as the need for it is not predictable; it is
sometimes called unscheduled maintenance.

Preventive maintenance

The principle of preventive maintenance is anticipation. It is put into practice in two forms: systematic
(periodic) maintenance and condition-based maintenance.

Corrective maintenance

Also called breakdown maintenance, palliative or curative maintenance. This form of maintenance
consists of: troubleshooting on machines whose poor condition results in stoppage, or in operation
under intolerable conditions.

Corrective or Breakdown maintenance

In Corrective or Breakdown maintenance repairs are made after the equipment is out of order and it
cannot perform its normal function.

In that case, the maintenance department comes into action and makes necessary repairs after
checking. They do not attend the equipment until another breakdown occurs. Breakdown leads to poor
maintenance, excessive delays in production, more spoilt material, and profit loss.

This type of maintenance is justified for small plants, where they do not feel financial justification for
scheduled techniques Corrective or Breakdown maintenance needs few records and a small staff.

Preventive maintenance:

In preventive maintenance locates weak spots like bearing, part under excessive vibration, pressure
vessel, etc which needs regular inspection and minimal repair thereby reducing the danger of
breakdown.

Preventive maintenance

Involves periodic inspection of components and corrects them in such conditions while they are still in
the minor stage. To make plant equipment always ready for use and achieve maximum production.
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PLANT MAINTENANCE WORK AND SERVICE - PRACTICE March 6, 2021

Predictive maintenance :

It is newer maintenance technique uses human senses or sensing instrument such as Audio gauge to
sense machine sound, Vibration analyzer for checking vibration, Amplitude meter, thermometer,
pressure gauge, etc, to predict trouble before breakdown.

In predictive maintenance, equipment conditions are measured periodically to take timely action such as
equipment adjustment, repair, or overhaul.

Predictive maintenance increases the lifetime of the equipment.

Preventive maintenance

Is defined as taking precautionary steps or actions to prevent equipment failures before they actually
occur. Preventive maintenance typically involves routine inspections, upgrades, proper lubrication
(where applicable), adjustments, and replacement of outdated equipment or parts.

Preventive maintenance can be implemented in many areas of your business, and includes any
preventive action, such as changing water filters, regularly cleaning essential equipment (such as
refrigerator condenser coils), inspecting business vehicles (i.e. delivery vans), and checking grout and
caulking to protect a property against water damage.

Predictive maintenance tracks the normal operation of an appliance or machine to detect possible
defects before they pose a problem. This type of maintenance uses condition-monitoring technology to
measure the performance of equipment.

Emergency maintenance is similar to reactive maintenance—both processes require a last-minute

response to the abrupt breakdown of equipment. However, emergency maintenance entails some type
of threat to health and safety (e.g. a sudden chemical spillage in a manufacturing plant may require total
evacuation of the premises, as well as alert the appropriate authorities).

Corrective maintenance is best described as any action that targets and fixes a system malfunction so
that the equipment can be restored to proper working order. Unlike reactive maintenance, it is not a
strategy; rather, it is an action that targets a specific piece of equipment. Additionally, the defect may be
caught or noticed before it causes a significant problem, or total equipment breakdown.

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.

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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.

Preventive Maintenance:

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.

Routine maintenance which includes those maintenance activities that are repetitive and periodic in
nature such as lubrication, cleaning, and small adjustment.

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

Corrective Maintenance

• 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.

Shutdown corrective maintenance, which is a set of corrective maintenance activities that are
performed when the production line is in total stoppage situation.

Predictive Maintenance

• 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 maximising the service life
of equipment without increasing the risk of failure.

The following types of maintenance methods are commonly used in several industries.

1. Preventive Maintenance
2. Predictive Maintenance
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3. Corrective Maintenance
4. Breakdown Maintenance

Preventive Maintenance:

It is a method for preventing damage to equipment by periodically replacing parts based on time of use
and carrying out minor maintenance and inspections to find out the current state of the equipment /
machinery.

Example: Cleaning, checking, lubricating, bolt tightening Periodic inspection Periodic and small over haul
restorations

Predictive Maintenance:

Predictive maintenance is a method for doing maintenance by replacing parts based on predictions
using a tool. The point is if the preventive method is only based on the schedule, then the predictive
method is based on the results of the measurement.

Corrective Maintenance:

It is a method intended to improve the reliability of equipment/machines by improvising. In addition to

equipment, it is also intended for parts that have a short life cycle (reduce the frequency of damage) and
speed up repair time.

In other words, this method is to extend MTBF (Mean Time Between Failure) and accelerate MTTR
(Mean Time To Repair) because of its reliability (activity to prevent recurrence of damage) and
maintainability (activity to speed up repair time).

Example: The operator has difficulty checking the oil volume of the generator engine, so improvisation is
done by making a measuring cup equipped with a scale.

Breakdown Maintenance

It is a method where inspection and replacement of parts are not carried out, so with this method we
leave the equipment damaged and then we fix it or replace it

Total productive maintenance (TPM):

Total productive maintenance is a maintenance activity that involves production operators in

maintaining equipment / machinery in addition to activities carried out by maintenance operators.

Examples are cleaning, lubricating, tightening nuts & bolts, dailly checking (checking equipment /
machine state), simple repairs (replacing leaking hoses, welding tips) etc.
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