Chemical Industries
Chemical Industries
Chemical Industries
explosion was felt 10 miles away. This resulted in many injuries and
equipment damage. The above incidents confirm that the accident happened
due to mechanical failures coupled with operational errors so there is a need
for maintenance of unit operations.
IMPORTANCE OF MAINTENANCE
Prevents interruption of production.
Prevents producing or rendering low quality services.
Saves energy, manpower and cost in the long run.
Prevents unscheduled downtime, shut downs.
Increases efficiency and prolongs the life span of equipments and
process lines.
Creates a safe working environment.
Equipment failure
Speed loss
Energy loss
Yield loss
Unscheduled downtime
Start-up time
Financial loss.
CLASSES OF MAINTENANCE
Maintenance can be classified as follows:
Planned maintenance
Steps involved in planned maintenance are:
Step 1: evaluate equipment and understand current conditions by preparing
equipment ledgers, evaluate standards from manuals, define failure ranks
and understand the process meticulously.
Step 2: restore deterioration and correct weaknesses by preventing identical
or similar major failures. Abolish environment which causes deterioration.
Step 3: build up an information management system which consists of failure
database, equipment budget and systems for controlling spares and standby
unit.
Step 4: build a periodic maintenance system by preparing maintenance
worksheets, equipment and components, periodic maintenance and improve
shutdown maintenance.
Autonomous maintenance
Steps involved in autonomous maintenance are:
Step 1: Perform initial cleaning and inspection of all equipment.
Step 2: Establish counter measures for the causes and effects of dirt and
dust.
Step 3: Create cleaning and lubrication standards for activities.
Step 4: Conduct general inspection training for all equipment.
Step 5: Carry out equipment inspection checks on a frequent basis.
Step 6: Workplace management and control needed to ensure success.
Step 7: Continuous improvement never ends. (www. Enna.com)
MAINTENANCE STRATEGIES
Maintenance can be defined as an activity carried out for any equipment to ensure
its reliability to perform its functions.
The main purpose for maintenance strategies is to ensure the plant and associated
services are in safe condition fit for use and comply with the law and all statutory
requirements. Maintenance strategy is adopted in order to extend the life cycle of
plants and its services. Maintenance personnel choose different strategies
depending on allocation and resources
Corrective maintenance:
Maintenance is carried out based on the detection of an anomaly, like a breakdown
of the system. It is aimed at restoring normal operating conditions. This strategy
may be cost effective until catastrophic faults occur.
Preventive maintenance:
Maintenance carried out at predetermined intervals or according to prescribed
criteria, aimed at reducing the failure risk or performance degradation of the
equipment. The maintenance cycles are planned according to the need to take the
device out of service. The incidence of operating faults is reduced.
Risk-based maintenance:
MAINTENANCE COST
In recent years, there is a growing concern on the subject of higher
maintenance cost and maintenance productivity. According to some
company, maintenance is the largest single manageable expenditure in the
plant: in many companies, surpass their annual net profit. Although many
agrees that maintenance strategies such as preventative and predictive
maintenance program has been shown to produce saving of up to 25%,
study have shown that still 1/3 of these maintenance cost can be saved.
Typically, maintenance cost can be divided into two main groups namely:
1) Direct costs are easy to justify and to report. They consist of items such as labor,
materials, services, and maintenance overhead cost are the cost tabulated and shown as
maintenance costs.
2) Hidden or indirect costs which are harder to measure. These hidden cost of maintenance
are classified as the six big losses: Breakdowns and unplanned plant shutdown losses,
Excessive set-up, changeovers and adjustments losses,
Idling and minor stoppages,
Running at reduced speed,
Startup losses and
Quality defects.
Therefore, it is very important for companies to maximize their maintenance
effectiveness and equipment uptime. According to a study on maintenance
productivity, most maintenance department is only around 25% to 35%
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TYPES OF MAINTENANCE
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Diagnosis of the problem: The maintenance technician must take time to locate the
failed parts or otherwise satisfactorily assess the cause of the system failure.
Repair and/or replacement of faulty components(s):Once the cause of the failure has
been determined, action must be taken to address the cause, usually by replacing or
repairing the component that caused the system to fail.
Verification of the repair action: once the component(s) in question have been repaired
or replaced, the maintenance technician must verify that the system is again successfully
operating.
PREVENTIVE MAINTENANCE:
Disadvantages
Labor intensive.
Includes performance of unnecessary maintenance.
May not reduce the likelihood of catastrophic failure.
Incidental damages might occur during maintenance.
Predictive Maintenance
This is a method in which the service life of important part is predicted based on inspection
or diagnosis. Predictive maintenance is condition-based maintenance. The approach is
based on measuring of the equipment condition in order to assess
whether equipment will fail during some future period, and then taking
action to avoid the consequences of that failures. This is where predictive
technologies (i.e. vibration analysis, infrared thermographs, ultrasonic
detection, etc.) are utilized to determine the condition of equipment, and
to decide on any necessary repairs. Apart from the predictive
technologies, statistical process control techniques, equipment
performance monitoring or human senses are also adapted to monitor the
equipment condition. It involves measuring and analyzing data about deterioration and
Product cost: Labour cost per unit increases as the idle labour time
increases
when improper functioning of machines takes place, material scrap, unit labour and
material costs increases.
cannot
Customer satisfaction:
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Organisation losses:
EFFECTS OF MAINTENANCE
EFFECTIVE MAINTENANCE
NON-EFFECTIVE MAINTENANCE
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