Chapter 1 Introduction To Equipment Maintenance Strategy and Types of Maintenance

Chapter 1 Introduction to
Equipment Maintenance Strategy

(EMS) and Types of Maintenance
Dr. Rosmawati Naim & Md Noor Bin Arifin

Faculty of Chemical and Process Engineering
Technology
Universiti Malaysia Pahang
Assessment Policy
Distribution Percentage, %
Quizzes 10
Assignments 20
Test 20
Technical Report 20
Project and Presentation 30

Topic Outcomes
Students should be able:
• To differentiate between different types of
maintenance.
• To apply the knowledge of maintenance on an
equipment
Equipment Maintenance Strategy
(EMS)
• Chapter 1:Intro to Equipment Maintenance Strategy
(EMS) and types of maintenance
• Chapter 2: Maintenance Procedure and Planning
• Chapter 3: Understanding Failure Development
• Chapter 4: Critical Analysis
• Chapter 5: Intro to total productive maintenance
(TPM)
• Chapter 5: Intro to RBI
• Chapter 6: Operation Maintenance Strategy
• Chapter 7:Operation Maintenance – the best
practices
Conten
t
• Definition
• Types of Maintenance
– Preventive Maintenance
– Corrective Maintenance
Definition
• Maintenance can be considered as the
replacement or repair of components and
assemblies (before or after failure), so that the
unit concerned can perform its designated
function over its expected life.
• A maintenance strategy involves the

identification, resourcing and execution of many
thousands of repair, replace and inspect
decisions.
Source: Anthony Kelly, in Plant Maintenance Management Set, 2006
Types of Maintenance
Maintenance
Preventive Corrective
Maintenance Maintenance
Finding Condition
Time based Predictive Risk based Deferred Emergency
Failure based
Types of Maintenance
• There are 9 Types of Maintenance split between Preventive
Maintenance and Corrective Maintenance.
• Preventive Maintenance is done before a failure occurs and
consists of maintenance types like:
o Time Based Maintenance
o Failure Finding Maintenance
o Risk Based Maintenance
o Condition Based Maintenance
o Predictive Maintenance
• Corrective maintenance is done after a failure has occurred
either as:
o Deferred Corrective Maintenance
o Emergency Maintenance
Preventive Maintenance vs.
Corrective Maintenance
• When we do preventive maintenance we are
doing a task before a failure has occurred. That
task can be aimed at preventing a failure,
minimising the consequence of the failure or
assessing the risk of the failure occurring.
• When we are conducting corrective maintenance
the failure has now occurred and we are basically
reinstating equipment functionality. To be clear,
corrective maintenance can be the result of a
deliberate run-to-failure strategy.
Preventive Maintenance vs.
Corrective Maintenance
Preventive Maintenance
• Defined as “an equipment maintenance
strategy based on replacing, or restoring, an
asset at a fixed interval regardless of its
condition.
• 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.e.
every week, every month or every three
months.
• But preventive maintenance can also be based
on usage e.g. every 150 cycles, every
10,000hrs or like your car: service every
10,000km.
Time-based Maintenance (TBM)
• TBM refers to replacing or renewing an item
to restore its reliability at a fixed time, interval
or usage regardless of its condition.
• The purpose of TBM is to protect yourself
against the failure of known wearing parts
which have predictable Mean Time Between
Failure (MTBF) i.e. Time Based Maintenance
assumes that the failure is age related and a
clear service life can be determined.
Failure Finding Maintenance (FFM)
• FFM tasks are aimed at detecting hidden failures typically
associated with protective functions. Think pressure safety valves,
trip transmitters and the like.
• This type of equipment won’t be required to function until
something else has failed. That means that under normal operating
conditions you will not know whether this equipment is still
functional i.e. the failure modes are hidden.
• And since these failures are hidden, you’ll need to find them before
you are relying on that equipment to protect you.
• Once detected you’ll have to repair the failure you found. Failure
Finding Maintenance is conducted at fixed time intervals typically
derived from legislation or risk based approaches
Risk Based Maintenance (RBM)
• RBM is when you use a risk assessment methodology to assign your
scarce maintenance resources to those assets that carry the most risk in
case of a failure
• RISK = LIKELIHOOD X CONSEQUENCE
• As a result, equipment that has a higher risk and a very high consequence
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 RBM process effectively you should have reduced
the total risk of failure across your plant in the most economical way.
• RBM is essentially preventive maintenance where the frequency and
scope of the maintenance activities is continuously optimized based on
the findings from testing or inspection and a thorough risk assessment.
Examples of Risk-Based Maintenance would be Risk-Based Inspection as
applied to static equipment like vessels and piping or even pressure relief
valves.
Condition Based Maintenance (CBM)
• Most failure modes are not age related. However, most
failure modes do give some sort of warning that they are in
the process of occurring or are about to occur.
• If evidence can be found that something is in the early

stages of failure, it may be possible to take action to
prevent it from failing completely and/or to avoid the
consequences of failure.
• CBM 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.
• An important concept within Condition Based Maintenance is
the P-F curve shown in the figure below:
• The curve shows that as a failure starts manifesting, the equipment
deteriorates to the point at which it can possibly be detected (point
“P”).
• If the failure is not detected and mitigated, it continues until a
functional failure occurs (point “F”). 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.
• How much more effective CBM is above breakdown maintenance
depends on how long the P-F interval is.
• 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.
• For failure modes where the P-F interval shows a large variability,
condition monitoring is not an effective strategy.
Predictive Maintenance (PDM)
• Up until recently when people spoke about PDM this was
essentially as a synonym for CBM. But in my view with the
advent of Artificial Intelligence, much lower costs of
equipment sensors (IIoT) and machine learning there is
clearly a difference appearing between Predictive
Maintenance (PDM) and Condition Based Maintenance
(CBM), at least in my view.
• 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.
Predictive Maintenance (PDM)
• There are a lot of (very large) companies
actively moving into this space and it is
certainly a fast-moving and exciting part of our
discipline as Maintenance & Reliability
professionals. However, I do still believe that
even the most advanced Predictive
Maintenance approaches need to be
underpinned by sound reliability principles
and understanding.
Corrective Maintenance (CM)
• 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.e. no significant impact on safety
or the environment) and preventing failure is either not
economical or not possible.
• Apart from being the outcome of a deliberate Run to

Failure strategy Corrective Maintenance is also the
result of unplanned failures which were not avoided
through preventive maintenance.
Corrective Maintenance (CM)
• A run to failure strategy can effectively be used for general area
lighting, smart process instrumentation (without trip functionality)
etc. where the consequence of failure is limited and would not
necessitate a need for an urgent repair.
• 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.
• So although a run-to-failure strategy can be a good option, make

sure you decide wisely.
Deferred Corrective Maintenance
• Corrective maintenance can be broken down into two sub-types:
– Deferred Corrective Maintenance
– Emergency Maintenance (EM)
• EM is expensive, various sources have suggested that Emergency
Maintenance is 3 to 5 times as expensive as ‘normal’ preventive
maintenance.
• EM 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 we prioritize
it properly to make sure that where possible we defer the work
request and give your team the time to properly plan and schedule
the work.
Emergency Maintenance (EM)
• Emergency Maintenance is corrective maintenance that is so urgent
that it breaks into your Frozen Weekly Schedule (you do have one
don’t you?).
• It upsets your plans and schedules and typically throws everything
into disarray.
• Some people thrive in this type of environment and often get
heralded as heroes when they’ve worked 16hrs non-stop to get
production back online. But when it comes to the Road to Reliability
it is a dead end.
• So Emergency Maintenance is the one and only maintenance type
that we really want to avoid as much as possible. In fact, World
Class organisations ensure that less than 2% of their total
maintenance is Emergency Maintenance.
Comparison of Maintenance Types
Which Type of Maintenance is Most
Expensive?
• 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).
Thank You

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Chapter 1 Introduction to

Equipment Maintenance Strategy

Dr. Rosmawati Naim & Md Noor Bin Arifin

Project and Presentation 30

• A maintenance strategy involves the

• If evidence can be found that something is in the early

• Predictive Maintenance as an extension, a more advanced

• Apart from being the outcome of a deliberate Run to

• So although a run-to-failure strategy can be a good option, make

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