Types of Maintenance

Break-down

Corrective
Maintenance

Cost

Repair it when it fails

Preventive
Maintenance

Cost

Time

Maintenance at regular
intervals
Predictive
Maintenance
Problem detected before
predicted failure.
Maintenance planned ahead

Cost

Time

Time

Corrective Maintenance
- Break-down Maintenance -

Not

recommended
for critical
machines

Corrective Maintenance
leads to:
Secondary damage

Safety risk
Unplanned downtime
Unplanned maintenance

Cost

Product waste
Spares inventory

Time

Preventive Maintenance

- Time-based Maintenance

Not
recommended
for critical
machines

Cost

Time

Time-based Preventive Maintenance involves:

More frequent overhauls
Risk of early failures
Tampering with good machines
Time consuming overhauls
Experts needed for each overhaul

Predictive Maintenance
Break-down

Recommended
for critical

Cost

machines

Time

Monitor the condition of

the machine and predict
when it would fail
Plan maintenance ahead
of time and save money
Repair the machines only
when they need to
Focus overhauls only on
faulty parts

Higher plant availability,

performance and reliability
Greater safety
Better product quality
Attention to environment
Longer equipment life
Greater cost effectiveness

Improves Productivity
Equipment Availability
Equipment Yield
Product quality

Reduces Maintenance Expenses

Spares and Consumables

Repair
Manpower
Rework/Rejection
Capital & Insurance

Condition Monitoring Techniques

VISUAL MONITORING
PERFORMANCE MONITORING
VIBRATION MONITORING
SHOCK PULSE MONITORING

2.5

TEMPERATURE MONITORING

1.5

0.5

WEAR DEBRIS MONITORING

MOTOR CURRENT ANALYSIS
ULTRA SOUND ANALYSIS

0
0

50

100

150

200

250

Classification of
Machines
Driving Machines
Electric Motors
Engines
Diesel
Gas

Turbines
Steam
Gas
Water
Hydraulic
Wind

Intermediate
Couplings
Flexible
Fixed
Cardan

Gears
Helical
Straight
Planetary

Belts

Driven Machines
Pumps

Compressors
Generators
Material Transportation
Paper Machines
Transport Rollers

Other
Steel Roller
Ship Propellers
Vehicles
etc.

Types of Monitoring
Type of monitoring
Fault

Oil anal.

Unbalance
Misalignment
Rolling bearing
Sliding bearing
Gears
Resonance
Cavitation
Bent Shaft
Elect. unbalance
Oil Whirl
Faulty belts
Dirt
Oil contam./wear rate
Lack of lubrication
1 = Well suited
x = Average

x
x
x

Acou.

x
x
x
x
x

1
x

Vibr.
1
1
1
x
1
1
x
1
1
1
x
1

Temp.

0 = Not well suited

= Not possible

Strobo.
x

x
x

Shaft align.
x
x
1

x
x
1

1
x

x
x

What to Measure
Vibration

Gives very early warning

Most faults, Unbalance, Misalignment, Bearing
faults, etc..

Temperature

Inexpensive transducers
Trust bearing problems.

Oil Analysis

Reciprocating machinery
Combined with Vibration

Fluid Pressure

Process monitoring
No early warning

Vibration standards
are guidelines

Just
Tolerable

Allowable

Just Tolerable
Allowable
Allowable
Good
Small
Machines< 15 kW

Group K

Good
15 kW<
Medium Machines
<75kW
<300 kW on special
foundations

Group M

Good
Large Machines
with rigid and heavy
foundations whose
natural speed exceeds
machine speed

Group G

45
28
18
11.2
7.1
4.5
2.8
1.8
1.12
1.71
0.45
0.28
0.18

Velocity mm/s RMS

Just Tolerable

10 times = 20dB

Not
Permissible

= 8dB

Not
Permissible

Not
Permissible

2.5 times

ISO2372 ( BS 4675 , VDI 2056 )

Types of Bearings

Journal Bearings
Stationary Signals
Relative Low Frequency
Displacement transducer

Rolling Element Bearings

Modulated Random Noise
Pulsating signals
High Frequency
Accelerometers

Corrective Maintenance Solutions

Dynamic Balancing
Machine Alignment using Laser technology