MAINTENANCE ENGINEERING(ME1012)

NPR COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT

: MECHANICAL ENGINEERING

SUBJECT CODE

: ME 1012

SUBJECT NAME

: MAINTANENCE ENGINEERING

YEAR

: IV

SEMESTER

: VIII

STAFF INCHARGE: R.KARTHIKEYAN

DESIGN/DEPT

: ASSISTANT PROFESSOR/MECHANICAL ENGG.

NPRCET/MECHANICAL 1

MAINTENANCE ENGINEERING(ME1012)

ME1012 MAINTENANCE ENGINEERING (C !! " # M$%&'"(%') '"* P+ *,%#( "L . T 0 P C 0 . 10

UNIT I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING !'("#$"'"%$ '%#(5(#6 I!0 +#'"%$ '"* 3$"$1(#/

B'/(% 0+("%(0)$/ 1 !'("#$"'"%$ 0)'""("2 O34$%#(5$/ '"* 0+("%(0)$/ 1 0)'""$* 1 / ,"* !'("#$"'"%$ /6/#$!/ 1 R$)('3()(#6 '"* !'%&("$ '5'()'3()(#6 MTBF7 MTTR '"* M8T F'%# +/ '5'()'3()(#6 M'("#$"'"%$ +2'"(9'#( " M'("#$"'"%$ $% " !(%/. UNIT II MAINTENANCE POLICIES PREVENTIVE MAINTENANCE M'("#$"'"%$ %'#$2 +($/ C !0'+'#(5$ !$+(#/ ),3+(%'#( " TPM. UNIT III CONDITION MONITORING : :

1 $'%& %'#$2 +6 P+$5$"#(5$

!'("#$"'"%$7 !'("#$"'"%$ /%&$*,)$/ '"* +$0'(+ %6%)$ P+("%(0)$/ '"* !$#& */ 1

C "*(#( " ! "(# +("2 C /# % !0'+(/ " ;(#& '"* ;(#& ,# CM O"<) '* #$/#("2 '"* 11<) '* #$/#("2 M$#& */ '"* ("/#+,!$"#/ 1 + CM T$!0$+'#,+$ /$"/(#(5$ #'0$/ P(/# ) #&$+! !$#$+/ 8$'+<*$3+(/ '"')6/(/. UNIT IV REPAIR METHODS FOR BASIC MACHINE ELEMENTS 10

R$0'(+ !$#& */ 1 + 3$*/7 /)(*$<;'6/7 /0("*)$/7 2$'+/7 )$'* /%+$;/ '"* 3$'+("2/ F'(),+$ '"')6/(/ F'(),+$/ '"* #&$(+ *$5$) 0!$"# L 2(%') 1',)# ) %'#( " !$#& */ S$=,$"#(') 1',)# ) %'#( ". UNIT V REPAIR METHODS FOR MATERIAL HANDLING E>UIPMENT /6/#$!/ U/$ 1 % !0,#$+/ (" !'("#$"'"%$. T #'): @A ?

R$0'(+ !$#& */ 1 + !'#$+(') &'"*)("2 $=,(0!$"# E=,(0!$"# +$% +*/ J 3 +*$+

NPRCET/MECHANICAL 2

TEBT BOOKS 1. S+(5'/#'5'7 S.K.7 CI"*,/#+(') M'("#$"'"%$ M'"'2$!$"#D7 S. C&'"* '"* C .7 1:?1. 2. B&'##'%&'+6'7 S.N.7 CI"/#'))'#( "7 S$+5(%("2 '"* M'("#$"'"%$D7 S. C&'"* '"* C .7 1::A. REFERENCES 1. G'+27 M.R.7 CI"*,/#+(') M'("#$"'"%$D7 S. C&'"* '"* C .7 1:?E. 2. H(22("/7 L.R.7 CM'("#$"'"%$ E"2("$$+("2 H'"*3 1:??. .. D'5($/7 CH'"*3 F 1 C "*(#( " M "(# +("2D7 C&'0!'" '"* H'))7 1::E. FD7 A#& E*(#( "7 M%G+'; H())7

UNIT I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING !'("#$"'"%$ '%#(5(#6 I!0 +#'"%$ '"* 3$"$1(#/

MAINTENANCE ENGINEERING(ME1012)

10

B'/(% 0+("%(0)$/ 1 !'("#$"'"%$ 0)'""("2 O34$%#(5$/ '"* 0+("%(0)$/ 1 0)'""$* 1 / ,"* !'("#$"'"%$ /6/#$!/ 1 R$)('3()(#6 '"* !'%&("$ '5'()'3()(#6 MTBF7 MTTR '"* M8T F'%# +/ '5'()'3()(#6 M'("#$"'"%$ +2'"(9'#( " M'("#$"'"%$ $% " !(%/. Maintenance Engineering is the discipline and profession of applying engineering concepts to the optimization of equipment, procedures, and departmental budgets to achieve better maintainability, reliability, and availability of equipment. Maintenance, and hence maintenance engineering, is increasing in importance due to rising amounts of equipment, systems, machineries and infrastructure. Since the Industrial evolution, devices, equipment, machinery and structures have gro!n increasingly comple", requiring a host of personnel, vocations and related systems needed to maintain them. #rior to 2$$%, the &nited States spent appro"imately &S'($$ billion annually on plant maintenance and operations alone. ) person practicing Maintenance Engineering is *no!n as a Maintenance Engineer. +,-E./I0ES )12 # I1.I#3ES 4 )nalysis of repetitive equipment failures. Estimation of maintenance costs and evaluation of alternatives. 5orecasting of spare parts. )ssessing the needs for equipment replacements and establish replacement programs !hen due application of scheduling and pro6ect management principles to replacement programs. )ssessing required maintenance tools and s*ills required for efficient maintenance of equipment. )ssessing required s*ills required for maintenance personnel. evie!ing personnel transfers to and from maintenance organizations assessing and reporting safety hazards associated !ith maintenance of equipment.

eliability may be defined in several !ays4

MAINTENANCE ENGINEERING(ME1012)

/he idea that an item is fit for a purpose !ith respect to time. In the most discrete and practical sense4 7Items that do not fail in use are reliable7 and 7Items that do fail in use are not reliable7. /he capacity of a designed, produced or maintained item to perform as required over time. /he capacity of a population of designed, produced or maintained items to perform as required over time. /he resistance to failure of an item over time. /he probability of an item to perform a required function under stated conditions for a specified period of time. In line !ith the creation of safety cases for safety, the goal is to provide a robust set of qualitative and quantitative evidence that an item or system !ill not contain unacceptable ris*. /he basic sorts of steps to ta*e are to4 5irst thoroughly identify as many as possible reliability hazards 8e.g. relevant System 5ailure Scenarios item 5ailure modes, the basic 5ailure mechanisms and root causes9 by specific analysis or tests. )ssess the is* associated !ith them by analysis and testing. #ropose mitigations by !hich the ris*s may be lo!ered and controlled to an acceptable level. Select the best mitigations and get agreement on final 8accepted9 3evels, possible based on cost:benefit analysis. is*

AVAILABILITY )

MAINTENANCE ENGINEERING(ME1012)
eliability #rogram #lan may also be used to evaluate and improve

)vailability of a system by the strategy on focusing on increasing testability ; maintainability and not on reliability. Improving maintainability is generally easier than reliability. Maintainability estimates 8 epair rates9 are also generally more accurate. <o!ever, because the uncertainties in the reliability estimates are in most cases very large, it is li*ely to dominate the availability 8prediction uncertainty9 problem= even in the case maintainability levels are very high. >hen reliability is not under control more complicated issues may arise, li*e manpo!er 8maintainers ? customer service capability9 shortage, spare part availability, logistic delays, lac* of repair facilities, e"tensive retro:fit and comple" configuration management costs and others. /he problem of unreliability may be increased also due to the 7D !(" $11$%#7 of maintenance induced failures after repairs. prevented, none of the others are of any importance and therefore reliability is generally regarded as the most important part of availability

+nly focusing on maintainability is therefore not enough. If failures are

A Fault Tree Diagram

MAINTENANCE ENGINEERING(ME1012)
+ne of the most important design techniques is redundancy. RELIABILITY THEORY R$)('3()(#6 is defined as the probability that a device !ill perform its intended function during a specified period of time under stated conditions. Mathematically, this may be e"pressed as,

, !here is the failure probability density function and is the length of the

period of time 8!hich is assumed to start from time zero9.

ACCELERATED TESTING: /he purpose of accelerated life testing is to induce field failure in the laboratory at a much faster rate by providing a harsher, but nonetheless representative, environment. In such a test, the product is e"pected to fail in the lab 6ust as it !ould have failed in the field@but in much less time. /he main ob6ective of an accelerated test is either of the follo!ing4 /o discover failure modes. /o predict the normal field life from the high stress lab life.

)n )ccelerated testing program can be bro*en do!n into the follo!ing steps4 Soft!are reliability is a special aspect of reliability engineering. System reliability, by definition, includes all parts of the system, including hard!are, soft!are, supporting infrastructure 8including critical e"ternal interfaces9, operators and procedures. /raditionally, reliability engineering focuses on critical hard!are parts of the system. Since the !idespread use of digital integrated circuit technology, soft!are has become an increasingly critical part of most electronics and, hence, nearly all present day systems. 2espite this difference in the source of failure bet!een soft!are and hard!are, several soft!are reliability models based on statistics have been proposed to quantify !hat !e e"perience !ith soft!are4 the longer soft!are is run, the higher the probability that it !ill eventually be used in an untested manner and e"hibit a latent defect that results in a failure 8Shooman 1ABC9, 8Musa 2$$D9, 82enney 2$$D9. )s !ith hard!are, soft!are reliability depends on good requirements, design and implementation. Soft!are reliability engineering relies heavily on a disciplined soft!are engineering process to anticipate and design against unintended consequences. /here is more overlap bet!een soft!are quality engineering and soft!are reliability engineering than bet!een hard!are quality and reliability. ) good soft!are development plan is a *ey aspect of the soft!are reliability program. /he soft!are development plan describes the design and coding standards, peer revie!s, unit tests, configuration management, soft!are metrics and soft!are models to be used during soft!are development. 2efine ob6ective and scope of the test .ollect required information about the product Identify the stress8es9 2etermine level of stress8es9 .onduct the accelerated test and analyze the collected data.

MAINTENANCE ENGINEERING(ME1012)

MEAN TIME BETWEEN FAILURES

MAINTENANCE ENGINEERING(ME1012)

Mean time bet!een failures 8M/,59 is the predicted elapsed time bet!een inherent failures of a system during operation.
E1F

M/,5 can be calculated as the arithmetic mean

8average9 time bet!een failures of a system. FORMAL DEFINITION OF MTBF ,y referring to the figure above, the M/,5 is the sum of the operational periods divided by the number of observed failures. If the 72o!n time7 8!ith space9 refers to the start of 7do!ntime7 8!ithout space9 and 7up time7 8!ith space9 refers to the start of 7uptime7 8!ithout spMean time betMean time bet!een failures!een failuresace9, the formula !ill be4

/he M/,5 is often denoted by the Gree* letter H, or

/he M/,5 can be defined in terms of the e"pected value of the density function I8t9

!here I is the density function of time until failure J satisfying the standard requirement of density functions J

/he +vervie! 5or each observation, do!ntime is the instantaneous time it !ent do!n, !hich is after 8i.e. greater than9 the moment it !ent up, uptime. /he difference 8do!ntime minus uptime9 is the amount of time it !as operating bet!een these t!o events.

M/,5 value prediction is an important element in the development of products. eliability engineers ? design engineers, often utilize eliability Soft!are to calculate productsK M/,5 according to various methods?standards 8MI3:<2,L:21C5, /elcordia S ((2, Siemens 1orm, 5I2ES,&/E B$:B1$ 8 252$$$9, etc.9. <o!ever, these 7prediction7 methods are not intended to reflect fielded M/,5 as is commonly believed. /he intent of these tools is to focus design efforts on the !ea* lin*s in the design

MAINTENANCE ENGINEERING(ME1012)

MTTR M// is an abbreviation that has several different e"pansions, !ith greatly differing meanings. It is !ise to spell out e"actly !hat is meant by the use of this abbreviation, rather than assuming the reader !ill *no! !hich is being assumed. /he M can stand for any of minimum, mean or ma"imum, and the recovery, repair, respond, or restore. can stand for any of

/he most common, mean, is also sub6ect to interpretation, as there are many different !ays in !hich a mean can be calculated. Mean time to repair Mean time to recovery?Mean time to restore Mean time to respond Mean time to replace In an engineering conte"t !ith no e"plicit definition, the engineering figure of merit, mean time to repair !ould be the most probable intent by virtue of seniority of usage. It is also similar in meaning to the others above 8more in the case of recovery, less in the case of respond, the latter being more properly styled mean 7response time79.

MAINTENANCE ENGINEERING(ME1012)
UNIT< I PRINCIPLES AND PRACTICES OF MAINTENANCE PLANNING PART<A (2 M'+F/$1. 2efine maintenance. $2. 2efine reliability. $(. State the benefits of reliability analysis in industries. $M. 2efine failure rate. $D. >hat is Mean 5ailure ateN $%. 2efine Mean /ime to 5ailure. $C. >hat is Mean /ime ,et!een 5ailures 8M/,59N $B. 2efine Mean /ime to epair 8M// 9. $A. 2efine Maintenance )ction ate. 1$. 2efine 5ailure 2ensity. PART<B (1E M'+F/1. >hat do you mean by maintenance 6ob planningN 2iscuss various steps of maintenance 6ob planning. 81%9 2. >hat is long term planN 2iscuss fe! long term planningN 81%9 (. >hat are the ob6ectives of maintenance organization and !hat different types of organizations are in use in Indian industriesN 81%9 M. >hat is equipment availability and !hat are the three basic approaches to define and quantity availability. 81%9 D. E"plain M/,S, M/,5, M//5, M// and failure rateN 81%9 %. E"plain briefly different types and classes of maintenance cost. 81%9

UNIT II MAINTENANCE POLICIES PREVENTIVE MAINTENANCE M'("#$"'"%$ %'#$2 +($/ C !0'+'#(5$ !$+(#/ ),3+(%'#( " TPM. 3&, I.)/I+1 3ubrication is the process, or technique employed to reduce !ear of one or both surfaces in close pro"imity, and moving relative to each other, by interposing a substance called lubricant bet!een the surfaces to carry or to help carry the load 8pressure generated9 bet!een the opposing surfaces. /he interposed lubricant film can be a solid, 8e.g. graphite, MoS29 a solid?liquid dispersion, a liquid, a liquid:liquid dispersion 8a grease9 or, e"ceptionally, a gas. In the most common case the applied load is carried by pressure generated !ithin the fluid due to the frictional viscous resistance to motion of the lubricating fluid bet!een the surfaces. 3ubrication can also describe the phenomenon such reduction of !ear occurs !ithout human intervention 8hydroplaning on a road9. /he science of friction, lubrication and !ear is called tribology. 1 $'%& %'#$2 +6 P+$5$"#(5$ !'("#$"'"%$7 !'("#$"'"%$ /%&$*,)$/ '"* +$0'(+ %6%)$ P+("%(0)$/ '"* !$#& */ 1

MAINTENANCE ENGINEERING(ME1012)

/he regimes of lubrication

MAINTENANCE ENGINEERING(ME1012)

)s the load increases on the contacting surfaces three distinct situations can be observed !ith respect to the mode of lubrication, !hich are called regimes of lubrication4 5luid film lubrication is the lubrication regime in !hich through viscous forces the load is fully supported by the lubricant !ithin the space or gap bet!een the parts in motion relative to one another 8the lubricated con6unction9 and solidJsolid contact is avoided.
o
E2F

<ydrostatic lubrication is !hen an e"ternal pressure is applied to the lubricant in the bearing, to maintain the fluid lubricant film !here it !ould other!ise be squeezed out.

<ydrodynamic lubrication is !here the motion of the contacting surfaces, and the e"act design of the bearing is used to pump lubricant around the bearing to maintain the lubricating film. /his design of bearing may !ear !hen started, stopped or reversed, as the lubricant film brea*s do!n.

Elastohydrodynamic lubrication4 /he opposing surfaces are separated, but there occurs some interaction bet!een the raised solid features called asperities, and there is an elastic deformation on the contacting surface enlarging the load: bearing area !hereby the viscous resistance of the lubricant becomes capable of supporting the load. ,oundary lubrication 8also called boundary film lubrication94 /he bodies come into closer contact at their asperities= the heat developed by the local pressures causes a condition !hich is called stic*:slip and some asperities brea* off. )t the elevated temperature and pressure conditions chemically reactive constituents of the lubricant react !ith the contact surface forming a highly resistant tenacious layer, or film on the moving solid surfaces 8boundary film9 !hich is capable of supporting the load and ma6or !ear or brea*do!n is avoided. ,oundary lubrication is also defined as that regime in !hich the load is carried by the surface asperities rather than by the lubricant.
E(F

,esides supporting the load the lubricant may have to perform other functions as !ell, for instance it may cool the contact areas and remove !ear products. >hile carrying out these functions the lubricant is constantly replaced from the contact areas either by the relative movement 8hydrodynamics9 or by e"ternally induced forces. 3ubrication is required for correct operation of mechanical systems pistons, pumps, cams, bearings, turbines, cutting tools etc. !here !ithout lubrication the pressure bet!een the surfaces in close pro"imity !ould generate enough heat for rapid surface damage !hich in a coarsened condition may literally !eld the surfaces together, causing seizure. In some applications, such as piston engines, the film bet!een the piston and the cylinder !all also seals the combustion chamber, preventing combustion gases from escaping into the cran*case .TOTAL PRODUCTIVE MAINTENANCE /#M is a maintenance process developed for improving productivity by ma*ing processes more reliable and less !asteful. /#M is an e"tension of /OM8/otal Ouality Management9. /he ob6ective of /#M is to maintain the plant or equipment in good condition !ithout interfering !ith the daily process. /o achieve this ob6ective, preventive and predictive maintenance is required. ,y follo!ing the philosophy of /#M !e can minimize the une"pected failure of the equipment. /o implement /#M the production unit and maintenance unit should !or* 6ointly.

MAINTENANCE ENGINEERING(ME1012)

MAINTENANCE ENGINEERING(ME1012)
+riginal goal of total productive management4 P.ontinuously improve all operational conditions, !ithin a production system= by stimulating the daily a!areness of all employees 8by Seiichi 1a*a6ima, -apan, -I#M9 /#M focuses primarily on manufacturing 8although its benefits are applicable to virtually any 7process79 and is the first methodology /oyota used to improve its global position 81AD$s9. )fter /#M, the focus !as stretched, and also suppliers and customers !ere involved 8Supply .hain9, this ne"t methodology !as called lean manufacturing. /his sheet gives an overvie! of /#M in its original form. )n accurate and practical implementation of /#M, !ill increase productivity !ithin the total organization, !here4 819 ) clear business culture is designed to continuously improve the efficiency of the total production system. 829 ) standardized and systematic approach is used, !here all losses are prevented and?or *no!n all departments, influencing productivity, !ill be involved to move from a reactive to a predictive mindset. 8M9 ) transparent multidisciplinary organization in reaching zero losses. 8D9 Steps are ta*en as a 6ourney, not as a quic* menu. 5inally /#M !ill provide practical and transparent ingredients to reach operational e"cellence.

MAINTENANCE ENGINEERING(ME1012)
IMPLEMENTATION /#M has basically ( goals : Qero #roduct 2efects, Qero Equipment &nplanned 5ailures and Qero )ccidents. It sets out to achieve these goals by Gap )nalysis of previous historical records of #roduct 2efects, Equipment 5ailures and )ccidents. /hen through a clear understanding of this Gap )nalysis 85ishbone .ause:Effect )nalysis, >hy:>hy .ause:Effect )nalysis, and #:M )nalysis9 plan a physical investigation to discover ne! latent fuguai 8slight deterioration9 during the first step in /#M )utonomous Maintenance called 7I"(#(') C)$'"("27. /#M identifies the C losses 8types of !aste9 8muda9, namely set:up and initial ad6ustment time, equipment brea*do!n time, idling and minor losses, speed 8cycle time9 losses, start:up quality losses, and in process quality losses, and then !or*s systematically to eliminate them by ma*ing improvements 8*aizen9. /#M has B pillars of activity, each being set to achieve a Pzero target. /hese B pillars are the follo!ing4 focussed improvement 8Lobetsu Laizen9= autonomous maintenance 8-ishu <ozen9= planned maintenance= training and education= early:phase management= quality maintenance 8<inshitsu <ozen9= office /#M= and safety, health, and environment. 5e! organisation also add #illars according to their >or* #lace li*e4 /ools Management= Information /echnology ; more. /he ,ase for the /#M )ctivity is ASG S$(+( 8Sorting out the required or not required items9= S$(#( " 8Systematic )rrangement of the required items9= S$(/ S$(F$#/, 8Standardisation9= S&(#/,F$ 8Self 2iscipline9. /he #illars ; their details a9 Efficient Equipment &tilisation b9 Efficient >or*er &tilisation c9 Efficient Material ; Energy &tilisation 8.leaniness9=

REPAIRABLE

MAINTENANCE ENGINEERING(ME1012)

epairable parts are parts that are deemed !orthy of repair, usually by virtue of economic consideration of their repair cost. ather than bear the cost of completely replacing a finished product, repairables typically are designed to enable more affordable maintenance by being more modular. /his allo!s components to be more easily removed, repaired, and replaced, enabling cheaper replacement. Spare parts that are needed to support condemnation of repairable parts are *no!n as replenishment spares. ) rotable pool is a pool of repairable spare parts inventory set aside to allo! for multiple repairs to be accomplished simultaneously. /his can be used to minimize stoc*out conditions for repairable items. REPAIR CYCLE 5rom the perspective of logistics, a model of the life cycle of parts in a supply chain can be developed. /his model, called the repair cycle, consists of functioning parts in use by equipment operators, and the entire sequence of suppliers or repair providers that replenish functional part inventories, either by production or repair, !hen they have failed. &ltimately, this sequence ends !ith the manufacturer. /his type of model allo!s demands on a supply system to ultimately be traced to their operational reliability, allo!ing for analysis of the dynamics of the supply system, in particular, spare parts.

MAINTENANCE ENGINEERING(ME1012)
UNIT<II MAINTENANCE POLICIES PREVENTIVE MAINTENANCE PART<A (2 M'+F/$1. >hat is meant by ,rea*do!n maintenance approachN $2. .lassify various planned maintenance approach. $(. 2efine .orrective maintenance approach. $M. >hat is meant by preventive maintenance approachN $D. 3ist out the ob6ectives of .orrective maintenance. $%. >hat is meant by #redictive MaintenanceN $C. 3ist out some condition based monitoring techniques and briefly discuss on them. $B. >hat is meant by eliability .entered Maintenance 8 .M9N $A. >hat is /otal #roductive Maintenance 8/#M9 and discuss itKs similarities !ith /OMN 1$. >hat is, meant by eliability .entered Maintenance 8 .M9N 11. >hat does Safety, <ealth and Environment pillar of /#M aims atN PART<B (1E M'+F/1. >hat do you understand by maintenance categoriesN E"plain common types and e"plain the basis of their selection. .81%9 2. >hat are all the steps involved in preventive maintenance !hy preventive maintenance is better than reactive maintenance. . 81%9 (. 2istinguish bet!een fi"ed time maintenance and connect based maintenance. Give the merits and demerits. . 81%9 M. ,riefly e"plain the procedure for /#M. .81%9 D. E"plain the repair cycle of metallic materials. . 81%9 %. >hat are the functions of lubrication and gives the tips on lubrication. 81%9

UNIT III CONDITION MONITORING

MAINTENANCE ENGINEERING(ME1012)

C "*(#( " ! "(# +("2 C /# % !0'+(/ " ;(#& '"* ;(#& ,# CM O"<) '* #$/#("2 '"* 11<) '* #$/#("2 M$#& */ '"* ("/#+,!$"#/ 1 + CM T$!0$+'#,+$ /$"/(#(5$ #'0$/ P(/# ) #&$+! !$#$+/ 8$'+<*$3+(/ '"')6/(/. CONDITION MONITORING .ondition monitoring is the process of monitoring a parameter of condition in machinery, such that a significant change is indicative of a developing failure. It is a ma6or component of predictive maintenance. /he use of conditional monitoring allo!s maintenance to be scheduled, or other actions to be ta*en to avoid the consequences of failure, before the failure occurs. 1evertheless, a deviation from a reference value 8e.g. temperature or vibration behavior9 must occur to identify impeding damages #redictive Maintenance does not predict failure. Machines !ith defects are more at ris* of failure than defect free machines. +nce a defect has been identified, the failure process has already commenced and .M systems can only measure the deterioration of the condition. Intervention in the early stages of deterioration is usually much more cost effective than allo!ing the machinery to fail. .ondition monitoring has a unique benefit in that the actual load, and subsequent heat dissipation that represents normal service can be seen and conditions that !ould shorten normal lifespan can be addressed before repeated failures occur. Serviceable machinery includes rotating equipment and stationary plant such as boilers and heat e"changers.

METHODS OF CM
1.

MAINTENANCE ENGINEERING(ME1012)

Screen monitoring records video or static images detailing the contents, or screen capture, of the entire Evideo displayF or the content of the screen activity !ithin a particular program or computer application. Monitoring tools may collect real time video, accelerated or Etime:lapseF video or screen shots, or may ta*e video or still image captures at regular intervals 8e.g., once every M minutes9. /hey may collect images constantly or only collect information !hile the user is interacting !ith the equipment 8e.g., capturing screens !hen the mouse or *eyboard is active9. 2ata monitoring trac*s the content of and changes to files stored on the local Ehard driveF or in the userKs 7private7 net!or* share. Leystro*e monitoring 8e.g., number of *eystro*es per minute9 may trac* the performance of *eyboard:intensive !or* such as !ord processing or data entry. Leystro*e logging captures all *eyboard input to enable the employer to monitor anything typed into the monitored machine.

2.

(.

M.

Idle time monitoring *eeps trac* of time !hen the employee is a!ay from the computer or the computer is not being actively used.

BENEFITS

MAINTENANCE ENGINEERING(ME1012)

o Screen monitoring records video or static images detailing the contents, or screen capture, of the entire Evideo displayF or the content of the screen activity !ithin a particular program or computer application. o Monitoring tools may collect real time video, accelerated or Etime:lapseF video or screen shots, or may ta*e video or still image captures at regular intervals 8e.g., once every M minutes9. o /hey may collect images constantly or only collect information !hile the user is interacting !ith the equipment 8e.g., capturing screens !hen the mouse or *eyboard is active9. o 2ata monitoring trac*s the content of and changes to files stored on the local Ehard driveF or in the userKs 7private7 net!or* share. o Leystro*e monitoring 8e.g., number of *eystro*es per minute9 may trac* the performance of *eyboard:intensive !or* such as !ord processing or data entry. Leystro*e logging captures all *eyboard input to enable the employer to monitor anything typed into the monitored machine. o Idle time monitoring *eeps trac* of time !hen the employee is a!ay from the computer or the computer is not being actively used.

LOAD TESTING

MAINTENANCE ENGINEERING(ME1012)
o 3oad testing is the process of putting demand on a system or device and measuring its response. o 3oad testing is performed to determine a systemRs behavior under both normal and anticipated pea* load conditions. o It helps to identify the ma"imum operating capacity of an application as !ell as any bottlenec*s and determine !hich element is causing degradation. o >hen the load placed on the system is raised beyond normal usage patterns, in order to test the systemKs response at unusually high or pea* loads, it is *no!n as stress testing. o /he load is usually so great that error conditions are the e"pected result, although no clear boundary e"ists !hen an activity ceases to be a load test and becomes a stress test. o /here is little agreement on !hat the specific goals of load testing are. o /he term is often used synonymously !ith concurrency testing, soft!are performance testing, reliability testing, and volume testing. o 3oad testing is a type of non:functional testing.

8EAR DEBRIS ANALYSIS

MAINTENANCE ENGINEERING(ME1012)

&sing a Scanning Electron Microscope of a carefully ta*en sample of debris suspended in lubricating oil 8ta*en from filters or magnetic chip detectors9. Instruments then reveal the elements contained, their proportions, size and morphology. &sing this method, the site, the mechanical failure mechanism and the time to eventual failure may be determined. /his is called >2) : >ear 2ebris )nalysis

MAINTENANCE ENGINEERING(ME1012)
M'+F/1. >hat is equipment health monitoringN

UNIT<III CONDITION

MONOTORING PART<A (2

2. 3ist do!n the factors for increasing the demand condition monitoring. (. 3ist do!n the *ey features of condition monitoring. M. >rite do!n the basic steps in condition monitoring. D. >hat are three types of condition monitoringN %. State the advantages and disadvantages of condition monitoring. C. Mention the various costs involved in costing of condition monitoring mainly. B. State the methods of measuring vibration. A. 2escribe briefly pistol thermometer. 1$. 1ame the types of pyrometers. 11. Mention title applications of bimetallic strip. 12. 3ist do!n the features of /2. 1(. State the applications and limitations of thermisters. PART<B (1E M'+F/1. >hat is condition monitoring and e"plain condition monitoring >hat type of condition monitoring are normally used in industry. 81%9 2. >hat is lea*age monitoringN E"plain some of the lea*age mediums used for condition monitoring. 81%9 (. >hat is !ear debris analysis !hat are the three !ear debris analysis techniques commonly used and compare their performance and usesN . 81%9 M. ,riefly e"plain the cost comparison !ith and !ithout condition monitoring. 81%9 D. >hat is thermal monitoring and !hat thermal monitoring are used in industries e"plain principle and uses of thermograph .81%9 %. ,riefly e"plain various methods and instruments for condition monitoring. 81%9

MAINTENANCE ENGINEERING(ME1012)