Developing a Maintenance Plan

Developing a Maintenance Plan

ACKNOWLEDGEMENT

To carry out this project “Developing a Maintenance Plan” was big challenge for us

since, it required technical and management knowledge in detail to build up a

Maintenance plan in a hospital. Actually, we were not able to face this challenge and

prepare this report successfully if we did not receive such a guidance and encouragement

from the persons stated below.

At first, our sincere gratitude goes to Mr. IndradevaMendis and Ms. Gayani Konara who

are our lecturers of Maintenance Management. It with particular pleasure that we grateful

to them for the constant support, guidance and for the encouragement, which was

provided for us.

Then my heartiest appreciation goes to Mr. L.P.J De Silva Group Maintenance Engineer,

Mr. DeepthiWijerathne Maintenance engineer and all other managers, department heads

and all other staff members of central hospitals for providing facilities and guidance to

complete this project successfully.

We are particularly grateful to the staff of the Campus Library and computer lab for their

help. We also fondly remind all the kind hearts & helping hands were together with us in

making this project a success.

Department of Building Economics Page 1


TABLE OF CONTENTS

ACKNOWLEDGEMENT...................................................................................................1

TABLE OF CONTENTS.....................................................................................................2

LIST OF FIGURES.............................................................................................................4

LIST OF TABLES...............................................................................................................5

1.0 INTRODUCTION.........................................................................................................6

2.0 INTRODUCTION TO THE VISITED SITE................................................................7

2.1 Current Maintenance Practices at GSK......................................................................7

3.0 MAINTENANCE MANAGEMENT............................................................................8

3.1 Elements of effective maintenance management.......................................................8

3.2 Maintenance strategies or options..............................................................................9

3.3 Preventive maintenance............................................................................................10

3.3.1 Preventive maintenance helps to:......................................................................11

3.3.2 Long-term benefits of preventive maintenance;................................................11

4.0 STEPS TO START A MAINTENANCE PROGRAM TO GSK................................12

4.0 ASSETS REGISTRY...................................................................................................13

4.1 Assets registry for manufacturing equipments........................................................13

4.2 Assets Registry for Manufacturing Equipment........................................................15

5.0 PRIORITIZATION OF EQUIPMENTS.....................................................................18

5.1 Preventive maintenance evaluation criteria..............................................................19

5.2 Preventive maintenance prioritization assessment sheet..........................................20

6.0 MAINTENANCE SCHEDULE..................................................................................21

6.1 Preventive maintenance schedule for chiller............................................................21

6.2 Preventive maintenance schedule for condenser water pump..................................22

6.3 Preventive maintenance schedule for chilled water pump.......................................23

6.4 Preventive maintenance schedule for Cooling Tower..............................................23

6.5 Preventive maintenance schedule for AHU.............................................................25

6.6 Preventive maintenance schedule for Package Unit................................................25

6.7 Preventive maintenance schedule for Split Unit......................................................26

6.8 Preventive Maintenance schedule for Cool Room...................................................27

6.9 Preventive maintenance schedule for Exhaust Fan..................................................28

6.10 Preventive maintenance schedule for Air compressor...........................................28

6.11 Preventive maintenance schedule for Transformers..............................................29



6.12 Preventive maintenance schedule for Capacitor Bank...........................................30

6.13 Preventive maintenance schedule for High Tension Panel....................................30

6.14 Preventive maintenance schedule for Illumination System...................................32

6.15 Preventive maintenance schedule for Generators..................................................32

6.16 preventive maintenance schedule for Boilers.........................................................34

6.17 Preventive maintenance schedule for Water Tanks...............................................35

6.18 Preventive maintenance schedule for Pumps.........................................................36

6.19 Preventive maintenance schedule for Sprinkler System........................................37

6.20 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells.....37

6.21 Preventive maintenance schedule for Fire Extinguishers......................................38

6.22 Preventive maintenance schedule for Fire Control Panel......................................38

6.23 Preventive maintenance schedule for Elevators.....................................................38

6.24 Preventive maintenance schedule for RO Plant.....................................................40

6.25 Preventive maintenance schedule for Doors and Windows...................................41

6.26 Preventive maintenance schedule for Painting.......................................................41

7.0 WORK INSTRUCTIONS FOR MAINTENANCE ACTIVITIES.............................42

7.1 General instructions..................................................................................................42

7.2 Civil Maintenance working Instruction....................................................................43

7.2.1 Cleaning.............................................................................................................43

8.0 PREDICTIVE MAINTENANCE................................................................................46

8.1 The characteristics of predictive maintenance are the following:............................47

8.2 Advantages of predictive maintenance....................................................................47

8.3 Thermography..........................................................................................................47

8.4 lubricating oil analysis.............................................................................................48

8.5 Utrasonic Monitoring...............................................................................................48

8.6 Vibration monitoring................................................................................................49

8.7 Motor Analysis.........................................................................................................49

8.7.1 Megger Testing..................................................................................................49

8.7.2 Resistance Testing.............................................................................................50

8.7.3 Impedance Testing.............................................................................................50

9.0 PREDICTIVE MAINTENANCE APPLICATIONS..................................................51

9.1 PREDICTIVE MAINTENACE STRATEGY.........................................................54

10.0 HUMAN RESOURCE ALLOCATION PLAN........................................................55

11.0 CONCLUSIONS........................................................................................................56



12.0 REFERENCES..........................................................................................................57

LIST OF FIGURES

Figure 1 Signs....................................................................................................................37

Figure 2 Infrared camera....................................................................................................43

Figure 3 Thermal Imaging Camera....................................................................................43

Figure 4 Vibration Analyzer..............................................................................................44



LIST OF TABLES

Table 1 Assets registry for manufacturing equipments.......................................................9

Table 2 Assets Registry for Manufacturing Equipment....................................................12

Table 3 Preventive maintenance evaluation criteria..........................................................15

Table 4 Preventive maintenance prioritization assessment sheet......................................15

Table 5 Preventive maintenance schedule for chiller........................................................17

Table 6 Preventive maintenance schedule for condenser water pump..............................17

Table 7 Preventive maintenance schedule for chilled water pump....................................18

Table 8 Preventive maintenance schedule for Cooling Tower..........................................19

Table 9 Preventive maintenance schedule for AHU..........................................................20

Table 10 Preventive maintenance schedule for Package Unit...........................................21

Table 11 Preventive maintenance schedule for Split Unit.................................................21

Table 12 Preventive Maintenance schedule for Cool Room.............................................22

Table 13 Preventive maintenance schedule for Exhaust Fan.............................................23

Table 14 Preventive maintenance schedule for Air compressor........................................24

Table 15 Preventive maintenance schedule for transformers............................................25

Table 16 Preventive maintenance schedule for Capacitor Bank.......................................25

Table 17 Preventive maintenance schedule for High Tension Panel.................................26

Table 18 Preventive maintenance schedule for illumination system.................................27

Table 19 Preventive maintenance schedule for Generators...............................................29

Table 20 Preventive maintenance schedule for Boilers.....................................................30

Table 21 Preventive maintenance schedule for Water Tanks............................................30

Table 22 Preventive maintenance schedule for Pumps......................................................31

Table 23 Preventive maintenance schedule for Sprinkler System.....................................32

Table 24 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells..33

Table 25 Preventive maintenance schedule for Fire Extinguishers...................................33

Table 26 Preventive maintenance schedule for Fire Control Panel...................................33

Table 27 Preventive maintenance schedule for Elevators.................................................34

Table 28 Preventive maintenance schedule for RO Plant..................................................35

Table 29 Preventive maintenance schedule for Doors and Windows................................36

Table 30 Preventive maintenance schedule for Painting...................................................36

Table 31 Predictive Maintenance Applications.................................................................48

Table 32 Predictive Maintenace Strategy..........................................................................49



1.0 INTRODUCTION

Today, because of the competitive business environment, organizations tend to minimize

the cost on every angel of expenditures occurred. Considering the expenditure of an

organization, operations and maintenance consumes a large proportion out of total.

As Facilities Managers, it is possible to contribute to reduce cost by introducing novel

concepts regarding maintenance of organization. In that account, predictive maintenance

strategies can be use as an excellent option with preventive strategies to improve the

reliability of machines and to develop a reliability cantered maintenance plan.

Developing maintenance plan is a huge task when considering the scale of the

organization. Even though it is a huge task, preparing it is very pleasure task. Detail

investigation must be carried out to do that well. There are various steps to follow to

develop a better maintenance plan each step has to be followed very carefully.

The main purpose on this report is to improve the reliability of equipment by introducing

some predictive maintenance strategies in a particular building. In order to achieve that

purpose we selected the most sophisticated factory in Sri Lanka named Glaxo Smith

Kline (GSK).

This report consists of four chapters and first chapter provides an introduction to

predictive maintenance and highlighting its importance and includes includes the existing

maintenance strategies of the GSK. The second chapter provides details about the Asset

registry and the details of how it has been categorised based on its criticality. the third

chapter, proposed preventive maintenance programme is mentioned along with

maintenance schedule, check lists work instructions and human resource allocation plan.

Appropriate predictive maintenance technologies are illustrated in fourth chapter. The last

chapter is the conclusion to the report that depicts the findings and issues of our survey

effort.



2.0 INTRODUCTION TO THE VISITED SITE

Glaxo Smith Kline (GSK) is one of the world’s largest research-based pharmaceutical

Companies that discovers, develops, manufactures and markets human health Products.

The company has two main divisions, pharmaceuticals and consumer healthcare. The

Consumer healthcare businesses of GSK consist of over-the-counter (OTC) medicines,

oral care products, such as the toothpaste brands Aquafresh, Macleans and Sensodyne,

and Nutritional healthcare drinks. The pharmaceuticals division is the largest part of

GSK’s Businesses and can be divided into prescription drugs and vaccines.

Mission Statement of GSK

“Improve the quality of human life by enabling people to do more, feel better and live

longer”

GSK premises is spread over 118500 ft2, and located in Ratmalana. This factory consist

of only one storey, which has incorporated all kind of services like Mechanical

Ventilation Air Conditioning (MVAC), Electricity (Raw power, Generator), Boiler,

Reverse Osmoss (RO) plant, and Public Health and safety Engineering services. GSK

also consist of primary manufacturing site and secondary manufacturing site

2.1 Current Maintenance Practices at GSK

The maintenance division of the GSK is responsible for all the maintenance. This is the

main important department to contribute for the quality and the health and safety of the

factory. There is a good coordination among the Premises and Engineering and

Maintenance Division. Below mentioned figure illustrates the arrangement of

maintenance division.



3.0 MAINTENANCE MANAGEMENT

The term ‘maintenance’ means to keep the equipment in operational condition or repair it

to its operational mode. Main objective of the maintenance is to have increased

availability of production systems, with increased safety and optimized cost. Maintenance

management involves managing the functions of maintenance. Maintaining equipment in

the field has been a challenging task since the beginning of industrial revolution. Since

then, a significant of progress has been made to maintain equipment effectively in the

field. As the engineering equipment becomes sophisticated and expensive to produce and

maintain, maintenance management has to face even more challenging situations to

maintain effectively such equipment in industrial environment.

A good maintenance management system coupled with knowledgeable and capable

maintenance staff can prevent health and safety problems and environmental damage;

yield longer asset life with fewer breakdowns; and result in lower operating costs and a

higher quality of life. The objectives of the maintenance management system;

Optimize the use of available funds, personnel, and facilities and equipment

through effective maintenance management methods.

Provide accurate data for maintenance and construction program decision making.

Systematically identify maintenance needs and deficiencies and capital

improvement needs at all field stations.

Determine the unfunded maintenance backlog for the Service.

Enable preparation of Service maintenance and construction budget requests using

systematic, standardized procedures.

Monitor and document corrective actions, project expenditures, and

accomplishments.

3.1 Elements of effective maintenance management

An effective maintenance system includes the following elements.

Maintenance Policy

Control of materials

Preventive Maintenance

Condition Monitoring



Work Order

Job planning

Priority and backlog control

Data recording system

Performance measurement measures or indices

Maintenance performance for an organization or plant can be assessed through analysis of

Reliability, Availability and Maintainability. Relevant parameters, measures or indices

for specific plants/equipments can be identified .The performance over a period of time

will show if it is improving, going down or being sustained. This will also help in

knowing how well the objectives are being met. In addition, it will guide the areas which

are strong and which need to be strengthened.

3.2 Maintenance strategies or options

A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and

systematic plan of maintenance action. Following are the maintenance strategies that are

commonly applied

Breakdown Maintenance or Operate to Failure or Unplanned Maintenance

The equipment under breakdown maintenance is allowed to run until it breaks down and

then repairing it and putting back to operation. This strategy is suitable for equipments

that are not critical and have spare capacity or redundancy available.

Preventive or Scheduled Maintenance

Preventative experience is a very valuable teacher. There is nothing wrong in seeking

expert advice, from whatever source, to prevent problems occurring. It is carried out at

pre-determined intervals, or corresponding to prescribed criteria, and intended to reduce

the probability of failure, or the performance degradation of an item.

Predictive or Condition Based Maintenance

Condition monitoring detects and diagnoses faults and it helps in planned maintenance

based on equipment condition. This condition based maintenance strategy or predictive

maintenance is preferred for critical systems and for such systems breakdown

maintenance is to be avoided. A number of Condition monitoring techniques such as



vibration, temperature, oil analysis, etc. have been developed, which guide the users in

planned maintenance

Opportunity Maintenance

In opportunity maintenance, timing of maintenance is determined by the procedure

adopted for some other item in the same unit or plant.

Design out Maintenance

In design out maintenance, the aim is to minimize the effect of failures and in fact

eliminates the cause of maintenance. Although it is an engineering design problem, yet it

is often a responsibility of maintenance department. This is opted for items of high

maintenance cost that are due to poor maintenance, poor design or poor design outside

design specifications. It may be mentioned that a best maintenance strategy for each item

should be selected by considering its maintenance characteristics, cost and safety.

3.3 Preventive maintenance

Preventive maintenance is regular, repetitive work done to keep equipment in good

working order and to optimize its efficiency and accuracy. The preventive maintenance is

the prevention of equipment breakdowns before them happen. It provides the prevention

of equipment breakdowns before them happen. It is designed to preserve and enhance

equipment reliability by replacing worn components before they actually fail. This

activity involves regular, routine cleaning, lubricating, testing, calibrating and adjusting,

checking for wear and tear and eventually replacing components to avoid breakdown.

Preventive activities are primarily condition based. The condition of a component,

measured when the equipment is operating, governs planned/scheduled maintenance.

Typical preventive maintenance activities include periodic inspections, condition

monitoring, critical item replacements, and calibrations. In order to accomplish this,

blocks of time are incorporated into the operations schedule. One can easily see that this

is the beginning of a proactive mode rather than a reactive one.

Preventive maintenance encompasses activities, including adjustments, replacement, and

basic cleanliness, that forestall machine breakdowns. The purpose of preventive

maintenance is to ensure that production quality is maintained and that delivery schedules

are met.



3.3.1 Preventive maintenance helps to:

Improve production by reducing machines down time

Is cost effective in many capital intensive processes and equipment

Provides flexibility for the adjustment of maintenance periodicity

Increases component life cycle and efficiency

Generates energy savings

Avoid unexpected equipment or process failures that cause to product loss.

Results in an estimated 12% to 18% cost savings over that found in a reactive

maintenance program

It also helps to avoid the replacing of the parts of the equipment before the

scheduled time.

It also ensures the safety of the person who is working with the machine since if

the machine is not in a proper condition it might also lead to a major accident

which is not desirable at all.

3.3.2 Long-term benefits of preventive maintenance;

Improve system reliability.

Decrease cost of replacement.

Decrease system downtime.

Better spares inventory management



4.0 STEPS TO START A MAINTENANCE PROGRAM TO GSK

The maintenance plan should consist of a schedule of preventive maintenance work and

guidelines for the implementation of corrective maintenance work. It should ensure that

resources are directed in the best way to achieve the planned output. Even if the

maintenance activities of a organization are always consider as a cost component, a

proper maintenance plan leads the company to reach its profit margin through minimizing

the maintenance expenses. Even though the maintenance schedule exists, implementation

of such schedules has to be rigorously carried out.

this project focus on starting a maintenance program to GSK. To accomplish this task

group followed some methodology and steps. As the first step; identified the systems of

GSK- Rathmlna, System operations, current maintenance activities of the maintenance

procedure were found and prepared an Assets Registry. Secondly focused on,

Prioritization of equipments according to their criticality for the reliable operation of

building.

The next step taken was, Studying the system component, maintenance procedures and

instructions by referring the Manufacture’s Manuals. It helps to identify the maintenance

activities for particular equipment and prepare a maintenance schedule for each

equipment using the knowledge on systems and information getting through the manuals.

Thereafter, clearly classified the maintenance works periodically (Daily, weekly,

Monthly, Quarterly, Bi – annually and annually). Then prepared the General Maintenance

Instructions for maintenance works to be followed by the work force to carry out the

maintenance work without any injury.

Finally to carry out the maintenance programme prepared the human power was allocated

for each equipment separately. Because the organization must provide enough qualified

personal resources to perform maintenance tasks.



4.0 ASSETS REGISTRY

4.1 Assets registry for manufacturing equipments

Category Description NoSerial

NoLocation

Liquid Manufacturing Vessel 8

Liquid Manufacturing Area

Silversion Mixer2


Pilot Mixer2


Drum Lifter1


New Mono Pump1


Small Silversion Mixer1


Drum Pump1


Filter Press1


Liquid Filling Suger Syrup Pump2


Instant Water Heater 2 Liquid Filling Area

Hand Dryer 5 Liquid Filling Area

Water Geezer 1 Liquid Filling Area

Bottie Dryer 2 Liquid Filling Area

Bottle Washing Machine 1 Liquid Filling Area

Liquid Filling Machine 2 Liquid Filling Area

Liquid Packing Belt Conveyer 1 Liquid Packing Area

Labelling Machine 1 Liquid Packing Area

Gumming Machine 1 Liquid Packing Area

Oueter Sealing M/C 1 Liquid Packing Area

Gum Tape Machine 1 Liquid Packing Area

Auto Cartonner Machine 1 Liquid Packing Area

Shirink Sleving Machine 1 Liquid Packing Area

Glucolin Form,Fill Sealing M/C 1 Glucolin Production



Production Area

Mater Burt Filling M/C2

Glucolin Production Area

Belt Conveyer1


Spiral Flow Conveyer1


Band Heat Sealer1

Gluolin Production Area

Dust Collector(Glucolin)1


TEW Heat Sealer1


Y Con Blender1


Printing Equipments

Rejafix Printer1 Ground Floor

Leaflet Folder 1 Ground Floor

Coding Machine 1 Ground Floor

Leaflet Folder (New) 1 Ground FloorOTC Equipments

Rejafix Printer 1 OTC Section

Atles Copco Airdryer 1 OTC Section

Storcklin Stacker 1 OTC Section

Dust Collector(Panadol) 1 OTC Section

Drum Lifter 2 OTC Section

Drum Lifter 2 OTC Section

De-Blisterin MC 1 OTC Section


Table 1 Assets registry for manufacturing equipments


4.2 Assets Registry for Manufacturing Equipment

Category Description No Serial

No LocationAir Conditioning/

Ventilation Chiller (York) 3 Ground Floor Cooling Tower 3 Ground Floor

Condenser Water Pump 6 Ground Floor Chilled Water Pump 6 Ground Floor

Air Handling Unit 6 Ground Floor

Condenser Water Pump Panel 1 Ground Floor

Chilled Water Pump Panel 1 Ground Floor Air Handling Unit Panel 6 Ground Floor

Cooling Tower Panel 6 Ground Floor

Split Air Conditioner Unit 16 Cloak Rooms

Package Unit 3 Production Areas

VAV 8 Liquid Manufacturing Area

Condensation Tank 1 Ground Floor Cooling Tower Fans 6 Ac Plant Room Air Curtain 4 Production Areas Air Compressor 2 Compressor Room Toilet Extractor Fan 20 Roof Top Turbine Ventilator 50 Roof Top

Fresh Air Fan Ground FloorElectrical Transformers 2 Transformer Room Capacitor Banks 1 Electrical Room Main Distribution Boards 2 Electrical Room LT Switch Gear Panel 1 Electrical Room HT Switch Gear Panel 1 Electrical Room Main Breakers 2 Electrical Room Bus Riser And Tap Off Point Electrical Room Automatic Transfer Switch 2 Electrical Room Electrical Grounding Ground Floor Distribution System All Areas Power Outlets All Areas Emergency Exit Lamps 50 All Areas Fluorescent Fittings All Areas Switches All Areas Emergency Backup System Generators 2 Generator RoomWater Treatment Activated Carbon Filter 1 Ro Plant Ultra Violent Lamp 1 Ro Plant



Membranes 4 Ro Plant Sand Filter 2 Ro Plant Treated Water Tank 1 Ro PlantHeating Boiler 1 Boiler Room Solar Water Heater 2 Roof TopFire Protection Heat Detectors All Areas Smoke Detectors All Areas Fire Panel 2 Panel Room Fire Alarm System All Areas

Fire Hydrants 5 Ground Floor Fire Hose Reel 2 All Areas Fire Extinguishes 177 All Areas Diesel Engine Pump 1 Pump Room Fire Pump 2 Pump Room Fire Doors 2 Office Water Supply Storage 1 Pump Room Emergency Lighting 50 All Areas Building Transportation Lift Cars(Goods) 1


Lift Motors 2 Lift Motor Room Lift Cables 2 Lift Motor Room Lift Control Panel (Goods) 1 Lift Motor RoomInstruments/Tools Volt Meter 5 Electrical Room Ohm Meter 5 Electrical Room Tachometer 5 Electrical Room Flame Guard Tester 1 Welding Room

Air Sampling Pump 1 Electrical Room Light Meter 1 Manufacturing Area Sound Level Meter 1 Manufacturing Area Air Sampling Meter 1 Manufacturing Area Enviro Meter 1 Manufacturing Area Personal Dose Meter 1 Manufacturing AreaStructural Door Closers All Areas Automatic Doors 4 Office Entrance Claddings Building Exterior Dock Leveler All Areas

Roofing Roof Roof Penetrations Roof Roof Drains Roof Roof Flashing Roof Gutters/Downspouts Building ExteriorAdministrative Fax Office Security Alarms Security Room



Telephone 30 OfficeComputers 50 Office

Conveyors Office Photo Copy And Scanning 1 OfficeLaboratory Steam Sterilizers 2 Chemical Laboratory De-Ionized Water 1 Chemical Laboratory Bottle Washer 2 Chemical Laboratory ETO Sterilizers 2 Chemical Laboratory Fume Cupboard 2 Chemical Laboratory

Oven 4 Biological Lab Heater 4 Chemical Laboratory Kheldal Apparatus 1 Chemical Laboratory Burner 3 Biological Laboratory Gas Chromatogram 1 Biological Lab


Table 2 Assets Registry for Manufacturing Equipment


5.0 PRIORITIZATION OF EQUIPMENTS

When consider the preventive maintenance program; after prepared the Assets Registry

(listing all the assets or equipments); need to do the Prioritization of equipments

according to their criticality for the reliable operation of building. Because if a preventive

maintenance program is to succeed manager must learn to use economic decisions. It

must be dynamic and flexible when describing what and how often to perform

maintenance functions. To accomplish this task Prioritization of assets is become crucial.

To develop the Maintenance program for the factory building the following issues should

be the main considerations.

(1) How critical is the equipment?

(2) Does the normal size of the equipment without preventive maintenance exceed

operating needs?

(3) Is standby equipment available in case of failure?

(4) Does the cost of preventive maintenance exceed the cost of repair or replacement?

(5) Will failure to maintain equipment harm peoples, staff or visitors?

The GSK is consist lot of equipment use for the medicine manufacturing. According to

our assets registry we mentioned that the equipments categorized into two types such as

manufacturing equipments and non manufacturing equipments therefore the proper

management of this equipment is a complex and costly task that can be accomplished

through careful and systematic risk assessment regarding various types of equipment. to

this assessment we mainly concern about the non manufacturing equipments. The

identified risks can then be used as a basis for structuring and operating an equipment

management program. Once the initial assessment is made, an organization can develop

programs of preventive maintenance based on the risk involved.

Investigations have been carried out to identify the maintenance requirements of the

building and identified some risk levels for the equipment. This risk levels are base for

the identification of the maintenance requirement of equipment. Following describe about

the risk levels. Those risk levels have some sub categories



Risk level I

Equipment Functional Areas - Various environmental areas in which equipment is used

Risk level II

Impact of Failure or Malfunction - Defines potential impact scenarios that may result due

to failure or malfunction of the equipment.

Risk level III

Preventive Maintenance Frequency - Defines the level and frequency of preventive

maintenance required.

Assets are described under above risk level clarifications and it receives some points.

Then according to the total value of points we can decide the Maintenance Priority for the

equipments.

5.1 Preventive maintenance evaluation criteria

Risk Category Description Points

Risk Category I

Equipment Functional

Area

Medicine manufacturing area 10

Laboratory areas, purifying plant (RO) 9

Manufacturing store 8

Primary and secondary packing area 7

Over Printing, labelling areas 6

Plant Room 5

All over the building structure (other) 4

Administrative Areas 3

Employee Quarters 2

Outside of the factory 1

Risk Category II

Impact Of Failure Or

Malfunction

Potential peoples death 5

Potential peoples or staff injury 4

Potential peoples or staff health problem 3

Discomfort or Inconvenience 2

No significant risk 1



Risk Category III

Preventive

Maintenance

Frequency

Monthly 5

Quarterly 4

Semi-annually 3

Annually 2

Not Required 1

Table 3 Preventive maintenance evaluation criteria

5.2 Preventive maintenance prioritization assessment sheet

Facility Name

Risk

Category

I

Risk

Categor

y II

Risk

Category

III

Total

Points

Maintenance

Priority

Air

Conditioning/Ventilation 5 4 5 14 3rd

building Transportation 5 2 5 12 4th

Potable Water/Plumbing 5 4 5 14 3rd

Fire Protection 10 5 5 20 1st

Electrical 5 5 4 14 3rd

Structural 4 2 2 8 4rd

Administrative 3 2 2 7 5th

Laboratory 9 4 5 18 2nd

Instruments/Tools 3 2 5 10 5th

Heating 5 3 4 12 4th

Emergency Backup power 5 5 4 14 3rd

Water treatment (RO) 9 4 5 18 2nd

6.0 MAINTENANCE SCHEDULE

A maintenance schedule is a plan or schedules those details when works, either major or

minor, will be completed. The following mention schedule can be used for the preventive

maintenance works, it includes all the services and maintenance works relates to the each

system is illustrated by giving some specific date to complete them with the suitable

frequencies.


Table 4 Preventive maintenance prioritization assessment sheet


6.1 Preventive maintenance schedule for chiller

ActivityDuration

D W M Q BA A

Overall visual inspection √

Check set points √

Checking refrigerant level √

Check oil heaters

√

Clean strainers

√

Dust clean electrical panels

√

Compare design parameters against present values √

Check measuring equipments √

Clean litter, dirt, or debris in the panels √

Check all wiring connections are tight. √

Check all contacts for pitting and corrosion √

Check crankcase heaters are working properly √

Check and clean electrical control panel √

Check Flow rates √

Check chilled water reset settings and function √

Compressor motor and assembly √

Verify motor amperage load limit √

Check refrigerant condition √

Clean evaporator and condenser tubes √



Compressor oil system √

Check chiller lockout set point √

Compressor motor and assembly √

Clean condenser tubes √

Clean evaporator tubes √

Table 5 Preventive maintenance schedule for chiller

6.2 Preventive maintenance schedule for condenser water pump

ActivityDuration

D W M Q BA A

Check inlet pressure

√

Check outlet pressure

√

Check water leak

√

Clean pump and motor

√

Check visual inspection/abnormal noise

√

Check water pump bearing

√

Check flexible coupling bush

√

Check electrical system

√

Check alignment/levelling

√

Clean strainer

√

Check gate valve



√

Table 6 Preventive maintenance schedule for condenser water pump

6.3 Preventive maintenance schedule for chilled water pump

Activity Duration

D W M Q BA A

Check inlet pressure

√

Check outlet pressure

√

Check water leak

√

Clean pump and motor

√

Check visual inspection/abnormal noise

√

Check water pump bearing

√

Check flexible coupling bush

√

Check electrical system

√

Check alignment/levelling

√

Clean strainer

√

Check gate valve

√

Table 7 Preventive maintenance schedule for chilled water pump

6.4 Preventive maintenance schedule for Cooling Tower

Activity Duration



D W M Q BA A

Check motor supports and alignment

√

Clean fan blades

√

Check lubrication

√

Check fan motor condition and belts and pulleys

√

Operate makeup water float switch manually

√

Clean suction screen

√

Check drift eliminators, louvers, and fill

√

Test water samples

√

Strainer cleaning

√


√

Clean fan blades

√

Check lubrication

√

Check water distribution and sprinkler operation

√


√


√




√


√

Test water samples

√

Check tower structure

√

Clean tower

√

Strainer cleaning

√


√

Clean fan blades

√

Check lubrication

√


√


√


√


√

Test water samples

√

Check tower structure

√

Check bearings

√

Clean tower

√



Paint tower

√

Table 8 Preventive maintenance schedule for Cooling Tower



6.5 Preventive maintenance schedule for AHU

Activity Duration

D W M Q BA A

Cleaning the return air inlet

√

Cleaning the drain line

√

Tightness of the belt

√

Cleaning the machine room

√

Cleaning the plant surface

√

Filter cleaning √

Wash coil with pressure gun √

Clean exterior of the unit √

Check belts/bearings and pulleys √

Blower inspection

√

Diffuser Cleaning

√

Repairing copper tubes for leakages

√

Motor inspection- Abnormal Sound

√

ducts Cleaning and Repairing the damages

√

Change bag filters

√

Paint rusted surfaces

√

Check valve operation



√

Paint AHU room

√

Table 9 Preventive maintenance schedule for AHU

6.6 Preventive maintenance schedule for Package Unit

Activity Duration

D W M Q BA A

Check the condition of the air filter

Clean the cooling coil

Clean air filter

Check the system pressures (Suction & discharge)

Inspect Duct Work& piping arrangement

Purge the refrigeration system

Clean the condenser

Check the refrigerant leaks

Check the belt tension of the blower fan

Lubricate the blower fan motor

Check safety devices

Check wires for loose connection

Check the compressor current

Check the outdoor unit for corrosion

Table 10 Preventive maintenance schedule for Package Unit

6.7 Preventive maintenance schedule for Split Unit

Activity Duration

D W M Q BA A

Check gas pressure and current

Check wire connections

Compare performance before and after



Check blower condition

Indoor and outdoor coil, filter chemical service

Check gas pressure and current

Check wire connections

Comb cooling fins

Compare performance before and after

Check blower condition

Check blower bearings

Paint brackets

Table 11 Preventive maintenance schedule for Split Unit

6.8 Preventive Maintenance schedule for Cool Room

Activity Duration

D W M Q BA A

Clean drain and drain pan.

Clean door gasket.

Check and clean condenser fan.

Check door micro switch.

Clean condenser

Clean drain and drain pan

Clean door gasket

Check and clean condenser fan

Check door micro switch

Check evaporator blower

Check thermostat operation

Check electrical connections

Check drain pan heaters

Clean condenser.

Clean drain and drain pan.

Clean door gasket.

Check and clean condenser fan.



Check door micro switch.

Check evaporator blower.

Check thermostat operation.

Check electrical connections.

Check refrigerant charge.

Check for corrosion and repaint with

anticorrosion.

Check door hinges for wear.

Check drain pan and defrost heaters if fitted.

Table 12 Preventive Maintenance schedule for Cool Room

6.9 Preventive maintenance schedule for Exhaust Fan

Activity Duration

D W M Q BA A

Dust cleans the unit.

.Check bearings.

.Check and clean cooling fan.

Check electrical connection.

Get clip on reading.

Dust cleans the unit.

Check bearings.

Check and clean cooling fan.

Check electrical connection.

Table 13 Preventive maintenance schedule for Exhaust Fan

6.10 Preventive maintenance schedule for Air compressor

Activity Duration

D W M Q BA A

check for Pressure drop

Check air filter

Check for oil and leaks.



Check safety circuit switches.

Drain water from compressor oil

Change compressor oil and oil filter.

Check compressor shaft seal for leakage.

Check air filter piping, fitting, and clamps.

Check compressor supports.

Install new air filter element.

Check sump safety valve.

Check belt tension.

Change coalescing element

Table 14 Preventive maintenance schedule for Air compressor

6.11 Preventive maintenance schedule for Transformers

Activity Duration

D W M Q BA A

Sound of Transformer

Clean the insulation members

Check loading & compare with nameplate rating

Circuit Breakers are inspected for material

integrity.

Circuit Breakers are reconditioned. Components

showing signs of wear are replaced with new

Functionally test fans & controls for proper

Functionally test temperature alarms &

announciator points

Check area around transformer clear of debris &

parts storage

Check the transformer room for proper ventilation

De-energize & remove panels for internal

inspection

Use vacuum to clean as much dust as possible



After vacuuming use low pressure dry air (20 to 25

psi) to blow off remaining dirt.

Check for discoloured copper & discoloured

insulation

Check for corroded & loose connections

Check for carbon tracking for insulation &

insulators

Check for cracked, chipped & loose insulators

If winders are found dirty, add filter material to air

intake ports

Check fan blades for cleanliness; remove dirt &

dust

Check fans, controls, alarms & anounciator points

Table 15 Preventive maintenance schedule for transformers

6.12 Preventive maintenance schedule for Capacitor Bank

Activity Duration

D W M Q BA A

status of cables, cable terminals, lugs and cable

insulations

Visually inspect the capacitors for abnormal

conditions

Clean inside and outside of the panel using a soft

pad

Clean power control cables. Wax polished exterior

of capacitor banks

Check the earth connection, condition of the

moving and fix contact points of the contactors.

Measure the line voltages of all steps

Check the functionality of the Power Factor relay.

Check the condition of the control fuse and fuse

base of the relay.

Check the condition of the relay cover.



Check CT terminals at the capacitor bank

Table 16 Preventive maintenance schedule for Capacitor Bank

6.13 Preventive maintenance schedule for High Tension Panel

Activity Duration

D W M Q BA A

Check all indicators

Dust clean the enclosure

Check all indicators

Check cable termination

Clean and vacuum all dust and dirt. Check for loose

connections.

Audibly check motor bearings. Check for excessive

vibration tighten loose mounting bolts or report

where necessary.

Check generators R. P. M. and the frequency and

battery charger and the D. C. voltage.

Visually check wiring insulation. Check for

tightness of all nuts and bolts screws wires etc. of

the breaker and the panel.

Clean and remove loose external and internal dirt

and dust.

Visual checking of MCCBs door handles, settings

for thermal and magnetic tripping, time delay,

discolouring, check the circuit breaker trip function

using test button.

Measure the current.

Check all Panel meters and indicator lamps of the

electrical distribution panels and distribution board.

Visual check for any discolouring or burning marks.

Check and correct the earth fault settings. Test the



function of relay and shunt trip of circuit breaker.

Clean inside and outside of the panel using a soft

pad or cotton waste applying an evaporative liquid,

bus bars and bus bar insulators.

Clean power control cables. Wax polished exterior

of capacitor banks.

Check the earth connection, condition of the

moving and fix contact points of the contactors.

6.14 Preventive maintenance schedule for Illumination System

ActivityDuration

D W M Q BA A

Check the electronic ballast function in regulate

√

Ensure the power sources of that fittings

√

Ensure the Efficacy and efficiency

√

Check the light colour

√

Ensure the starting time of the lamps and fittings

√

Check the colour temperature

√

Check the fluorescent tube

√

Ensure the all fittings function in accurately

√

Table 18 Preventive maintenance schedule for illumination system


Table 17 Preventive maintenance schedule for High Tension Panel


6.15 Preventive maintenance schedule for Generators

ActivityDuration

D W M Q BA A

Before starting the engine, check oil level

Check fuel level in the tank

Before starting the engine, check coolant level in

radiator

Check all instruments are functioning

Check for leakages of coolant, fuel and lube oil

Check the engine protection system daily for fault

lamps

Whenever the generator is operating ensure the space

heaters are disconnected

Check for loose electrical connections in the battery

chargers and tighten as required

Check the batteries. Clean the top of the batteries with

a clean cloth.

Clean all cable clamps and battery terminals using a

bristle brush. Check the battery charger

Check the operation of the supply air fan/fans

Clean and remove loose external and internal dirt and

dust.

Check the bearing bracket temperature.

Check the wires and connection on the voltage

regulator assembly

Repeat all A checks

Change oil in sump, drain off while still hot

Clean magnetic drain plug

Lubricate the FIP linkage by using oil can

Clean the area around the fuel filter head and filter.

Change the lubricating oil and filters at the specified



oil change interval.

Clean radiator core with compressed air

Check connections of starter motor & alternator and

tighten

Check coolant concentration

Clean and check the oil drain plug threads and the seal

surface.

The tube is to be removed and check and internally for

obstructions or sludge build-up.

Inspect the bypass oil filter and cooling system hoses

and connections for leaks

Remove and clean air ducting hoses

Adjust both the intake and exhaust crossheads.

Lean each battery cell with distilled water.

Remove & clean the engine breather cap in kerosene

oil

Blow air in reverse direction & refit, replace rubber

gasket in the breather

Check valve clearance

Lubricate water pump with bearing grease

Check the thermostat for proper functioning and

operating temperature

Check the engine oil heaters and coolant heaters for

proper operation.

Check the torque on the nuts and bolts

Check tightening of oil pan mounting cap screw

Check tightening of oil pan mounting cap screw

Apply grease to fan hub & belt tension

Clean the fuel tank for the dirt and the sediment

Table 19 Preventive maintenance schedule for Generators



6.16 preventive maintenance schedule for Boilers

ActivityDuration

D W M Q BA A

Ensure that feed water meets the boiler requirement √

Check burner operation √

Clean Blow Down Valve √ Check blow down and water treatment procedures √ Check the low water cutoff √ Remove and clean the gauge glass

√Examine water level of the boiler. √ Check Pressure of Diesel √ Clean the Eye Glass √ Check damper seals for leaks

√

Check air inlet

√

Measure the co2 level

√

Check Air Pressure √ Check oil Pressure √ Check oil pump suction condition. √ Check Leakages in Oil Pumps √ Check Flame Condition √ Clean burner nozzle

√

Replace the burner

√Inspect burner components √ Check clean the Photo cell

√

Clean flame sensor

√

Open and clean, out doors of Boiler and lubricate

√

Check the Condition of Door Seal

√

Ensure Proper Lubrication of all moving Parts

√

Check feed water pump

√

Clean Water Filter in Feed Water Pump

√

Check water sample

√

Check and clean/replace oil filters and strainers.

√

Remove Water Level Controller and floaters, clean

the scale and sediment materials

√

Check water level control

√

Clean Electrical Contacts and relays

√

Check all valves and joints for leaks

√

Clean Water Pump Seal and Non-Return Valve

√

Lubricate the modulation motor linkages

√



Inspect the combustion air louvers and or ventilation

screens

√

Inspect and clean the cover of the boiler

√

Inspect boiler insulation

√

Test safety relief valve

√

Check steam control valves

√

Clean Blower Fan blades

√

Clean Fuel Filter

√

Fix the new manhole and hand hole gaskets

√Check for leaks.

√

Clean return tank and strainer.

√

Prevent any sediments

√

Control temperature & Safety check

√Table 20 Preventive maintenance schedule for Boilers

6.17 Preventive maintenance schedule for Water Tanks

Activity Duration

D W M Q BA A

Check the seal of the access panel

Drain and clean the tank

Table 21 Preventive maintenance schedule for Water Tanks

6.18 Preventive maintenance schedule for Pumps

Activity Duration

W M Q A

Priming Speed

Capacity and output

Check the Gaskets and O-rings

Shaft seal leakage

Temperature of bearings and windings

Check the oil level

Check oil leak and grease leak

Clean inner and outer surface of the starter panel

Check the control circuit

Check undue noise and vibration of the starter panel and



pump

Lubrication

Oil pressure

Check the starter panel for overheating & ventilation

Check electrical terminal connections at motor

Check tension of all mounting and securing and blots

Check indicator lights

Remove dust and dirt from the motor terminals at the

terminal box using a compressed air (blower).

Vacuum clean the terminal box

Check that motor air vents are free of dust build up

Check and record the phase current and line voltage when

the motor is running.

Table 22 Preventive maintenance schedule for Pumps

6.19 Preventive maintenance schedule for Sprinkler System

Activity Duration

W M Q A d d

Check sprinkler heads and control valves for

position and condition

check reserve supply of sprinkler heads

Inspect visible piping, hangers, drain valves and

gauges

Check sprinkler system control valves are open &

properly supervised dry pipe sprinkler system air

pressure is being maintained

Inspect exposed sprinkler system pipe hangers,

sprinkler heads, dry pipe auxiliary drains, dry pipe

valve water priming level.

Test water flow on wet sprinkler system using most

hydraulically remove test connection and



Test Sprinkler system water supply pressure using

main drain valve.

Table 23 Preventive maintenance schedule for Sprinkler System

6.20 Preventive maintenance schedule for Smoke, Heat detectors and

Alarm bells

ActivityDuration

D W M Q A

tight the communication terminals

Clean and remove dust and dirt from the top part

of the detector

Clean and remove dust and dirt from the alarm

bells.

Clean and tight communication terminals.

Paint the bell housing if necessary

kkkk

Table 24 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells

6.21 Preventive maintenance schedule for Fire Extinguishers

ActivityDuration

D W M Q A

Inspect maintenance and testing of all fire

extinguishers

Refill the fire Extinguishers

Table 25 Preventive maintenance schedule for Fire Extinguishers

6.22 Preventive maintenance schedule for Fire Control Panel

Activity Duration

D W M Q A

Clean the communication ports of the control card



Check the card for deteriorated points

Check the output voltage of the battery chargers

Clean the terminals and surfaces of batteries

Check security of electrical connections

Table 26 Preventive maintenance schedule for Fire Control Panel

6.23 Preventive maintenance schedule for Elevators

ActivityDuration

D W M Q A

Check and lubricate brake parts

Check and lubricate selector parts

Check lighting in cabin

Check emergency light

Check emergency bell

Check interphone

Check indicators in cabin

Check interlock system, contacts, rollers and door

guide shoes

Check condition of guide shoes of car & cwt

Check hall calls, indicators in corridors

Machine room, shaft & pit cleaning

Check riding comfort of car and stop level

Check safety ray and door safety edge

Cleaning o car and false ceiling

Check & clean door tracks

Check & clean door / gate contacts

Check & clean headers & sills



Check operation of car fan

Table 27 Preventive maintenance schedule for Elevators



6.24 Preventive maintenance schedule for RO Plant

Activity Duration

D W M Q A

Check the RO membrane

Check the NaCl dosing system

Check the Drain Line

Check the UV unit

Check the sand filter

Check the carbon filter

Check the softner

Check the status of the mixed box

Check the O3 adding unit

Check the raw water pumps

Clean the treated water storage

Table 28 Preventive maintenance schedule for RO Plant



CIVIL WORKS SCHUDLE

6.25 Preventive maintenance schedule for Doors and Windows

Activity Duration

D W M Q A

check the All door hinges and screws √

check All doors smooth function √

check the Handles and knobs √

Check the Windows guides √

Check the Window stoppers √

Check the Window Window shutters √

Check the Window frames and glass √

Check the Window Window seal √

Doors lubrications √

Table 29 Preventive maintenance schedule for Doors and Windows

6.26 Preventive maintenance schedule for Painting

Activity Duration

D W M Q A

Staircase Steps Painting √

Pipe Painting √

Corridor Painting √

Skirting Painting √

Door Frame Painting √

Arrow Painting √

Windows Painting √

Table 30 Preventive maintenance schedule for Painting



7.0 WORK INSTRUCTIONS FOR MAINTENANCE ACTIVITIES

Assumption

The working instructions in this report have been considered as a common element for all

tasks to be followed by the work force. These general instructions should be followed by

all work force of maintenance department to prevent and reduce hazards and accidents or

incidents in order to increase the safety of the workforce.

The special work instructions to be performed in each maintenance activity should be

referred to the manual.

7.1 General instructions

All safety measures should be taken according to the event.

All professionals should be in an appropriate mental and physical condition and

should perform with appropriate clothing.

The professional should perform with appropriate tools according to the sort of

task.

When maintenance acidities take place the above shown signs should be taken in

to consideration by the work force.

Make sure to cut the electrical supply for an equipment before starting to clean or

to do any maintenance activity.


Figure 1 Signs


Proper PPE should be worn by the work force.

Make sure there’s no litter, dirt, or debris in the panels. If there is anything

unusual should be removed quickly.

Updating daily log for all equipments is a major requirement, since it is the most

important tool contributing for the overall efficiency.

The supervisors should ensure that all componants of equipments are in safe

condition.

Confirmation of no smell of gas or evidence of fuel leaks exists in the working

area need to be informed to the department.

7.2 Civil Maintenance working Instruction

7.2.1 Cleaning

Floor cleaning

Floors of office area should be cleaned after 5.15 p.m. previous day.

Floors of production area should be cleaned before 7.30 a.m. of the particular day.

Wash marble surfaces with lukewarm water or with a mild detergent solution and

wipe dry with a mop.

Discard any leftover and used cleaning solution promptly and properly

Toilets/ wash rooms

All toilets i.e. male toilets, female toilets, executive toilets must be cleaned thrice

a day.

Mild detergents should be used for cleaning purposes.

Using of abrasive cleaner should be avoided.

Hard disinfectants and the cleaning products in aerosol cans should also be not

used.

Always close cleaning agent securely to prevent fumes from escaping or spills.

Always toilets should be dry to prevent slippery.

Always put cleaning supplies away when finished the cleaning tasks.

Cleaning should not be a disturbance to the users.

Window Cleaning



Use a solution of mild detergent and water, or a mild commercial cleaner whose

label says it is safe for painted surfaces.

Always rinse off the cleaning solution. Wipe off excess water with a dry cloth.

Do not use strong cleaners or scouring powder as these can damage the paint.

Clean window frames before cleaning window glass to avoid solution spot on

glass panes.

Use hand vipers to remove the water droplets.

Use soft detergent such as ‘t-pole’ to clean the glass of the window.

Clean the glasses occasionally (normally, once in 18 / 24months)to remove rust

by applying cleaning agent such as ‘renotec’ and cutting it using buffer pad.

Gardening

Watering plants should be done before 8.30 a.m. in the morning and after 5.30

p.m.

Tools and equipment should be replaced to their allocated location

After finishing the task all the leftovers should be discarded properly.

Painting

Good surface preparation is the key to a long-lasting and great-looking paint job.

Repair cracks or chips, sand and smooth rough edges, and clean chalky surfaces.

Give the walls 24 hours to dry after wiping them down.

Assemble all painting tools and cleanup supplies before starting.

Protect floors and furniture with a drop cloth or sheet.

Remove loose fibers from roller covers with painter's tape or a lint roller before

using.

Spray or roll from top to bottom, left to right to cover neatly and evenly. Lighter,

multiple coats will cover better than one heavy layer of paint.

Sprayers offer the best and most efficient coverage when painting large areas or

exteriors. After spraying, back roll to ensure even coverage.

Use a quality brush or roller.



Place a garbage bag over your paint tray, brush or roller to prevent the paint from

drying. This will keep the paint for 24 hours - and let you take a break without

worrying that your paint will dry out.

For water-based paints, rinse brushes, rollers and tools with water. For oil-based

paints, use paint thinner.

Use bristle protectors that fit over brushes and protect them when not in use. They

are available at most hardware stores.



8.0 PREDICTIVE MAINTENANCE

Predictive Maintenance can be defined as measurements that detect the onset of a

degradation mechanism, thereby allowing casual stressors to be eliminated or controlled

prior to any significant deterioration in the component physical state. Predictive

maintenance is used to define needed maintenance task based on quantified

material/equipment condition. Predictive maintenance is unscheduled maintenance based

on data collected from the actual plant. It also falls under the proactive maintenance

category. From the data collected during routine maintenance we can see the condition of

the equipment and plant and base our maintenance procedure upon this condition. This

provides us with information so that we can conduct our maintenance accordingly and

greatly reduce our maintenance and downtime costs. Recommendations provided from

the results of data collected must be followed to increase the efficiency of the plant and

preclude future emergencies.

Predictive maintenance involves performing maintenance on a machine in advance of the

time a failure would occur if the maintenance were not performed. Of course, this means

that one must calculate when a machine is predicted to fail. In order to do this, the firm

must collect data on variables that can be used to indicate an impending failure (vibration,

temperature, sound, colour, etc.). This data is then analyzed to approximate when a

failure will occur and maintenance is then scheduled to take place prior to this time. By

seeking the correct level of maintenance required, unplanned downtime is minimized.

Inspection

This can be done by the five senses of a person to determine the condition of the

equipment or component.

Condition Monitoring

Some parameters can be monitored; using sophisticated measuring equipment, to detect

signs of imminent failure. Examples of these are Vibration, Shock Pulse, Oil condition,

Acoustic emissions, Equipment Performance, Thermography, and Non-destructive

Testing. These techniques are discussed in detail in the following section.



8.1 The characteristics of predictive maintenance are the following:

It uses feedback and communications to ensure that changes in procedures are

promptly made available to managers. list item

It employs a life-cycle view of maintenance and supporting functions.

It ensures that nothing affecting maintenance occurs in isolation.

It employs a continuous process of improvement.

It optimizes and tailors maintenance techniques and technologies to each

application.

It integrates functions that support maintenance into maintenance program

planning.

It uses root-cause failure analysis and predictive analysis to maximize

maintenance effectiveness.

It periodically evaluates the technical content and performance interval of

maintenance tasks (PM and PTI)

8.2 Advantages of predictive maintenance

Increased component operational life/availability

Allows for pre-emptive corrective action

Decrease in equipment or process downtime

Better product quality

Improved worker and environmental safety

Improved worker moral

Energy saving

8.3 Thermography

Thermographic testing is a technique that uses the latest infrared imaging technology to

detect problems that can’t always be seen by the human eye. Using a thermal image

camera, abnormal heat generation caused by loose connections or other sources in

electrical panels, compressors, pumps, switchgears, motors and motor control centres can

be easily identified. The images taken during these tests can be used to quickly identify

problem areas so preventive maintenance measures can be taken to correct the problems

before equipment is damaged. This predictive maintenance technique reduces costly

downtime by identifying faulty equipment before it becomes a problem and helps to



reduce hazardous fires or other life threatening malfunctions. Types of Thermographic

tools are mentioned below.

Spot radiometer (Infrared thermometer)

Cooled infrared detectors

Fully automated sensors

Infrared cameras

Un cooled infrared detectors

Thermal imaging camera & screen

8.4 lubricating oil analysis

This is an analysis technique, which determines the condition of lubricatin goils used in

mechanical and electrical equipment. However, it is nota tool for determining the

operating condition of machinery. Some forms of lubricating oil analysis will provide an

accurate quantitative breakdown of individual chemical elements, both oil additive and

contaminates, contained in the oil. As a predictive maintenance tool, lubricating oil and

spectrographic analysis can be used to schedule oil change intervals based on the actual

condition of the oil.

8.5 Utrasonic Monitoring

This predictive maintenance technique monitors the noise generated by plant machinery

or systems to determine their actual operating condition and ultrasonic monitors the

higher frequencies (i.e., ultrasound) produced by unique dynamics in process systems or

machines. As part of a predictive maintenance program, ultrasonic instruments are used

for three primary applications: airborne noise analysis, leak detection, or material testing.

The principal application for ultrasonic monitoring is in leak detection. Two types of

ultrasonic systems are available that can be used for predictive maintenance: structural

and airborne. Types of ultrasonic tools are mentioned below.

Hand held scanner

Ultrasonic detector


Figure 2 Infrared camera

Figure 3 Thermal Imaging Camera

http://www.professionalequipment.com/enlargeproduct.asp?productid=5561


8.6 Vibration monitoring

This technique uses the noise or vibration created by mechanical equipment and in some

cases by plant systems to determine their actual condition. Any degradation of the

mechanical condition within plant machinery can be detected using vibration-monitoring

techniques. Used properly, vibration analysis can identify specific degrading machine

components or the failure mode of plant machinery before serious damage occurs. Most

vibration-based predictive maintenance programs rely on one or more monitoring

techniques. These techniques include broadband trending, narrowband trending, or

signature analysis. Types of Vibration Monitoring tools are mentioned below.

Transducers

Vibration analyzer

8.7 Motor Analysis

When it comes to motor condition analysis, infrared (IR) and vibration will not provide

all the answers required to properly characterize motor condition. Traditional electrical

testing methods must be used in conjunction with vibration analysis to prevent premature

failure of electric motors. These tests should include:

8.7.1 Megger Testing

In order to measure high resistances, a device known as a mega-ohmmeter can beused.

This instrument differs from a normal ohmmeter in that instead of measuring current to

determine resistance, it measures voltage. This mode of testing involve sapplying

relatively high voltage (500 to 2,500 volts, depending on the unit) to thecircuit and

verifying that no breakdown is present. Generally, this is considered as non-destructive

test, depending on the applied voltage and the rating of the insulation. This method of

testing is used primarily to test the integrity of insulation. It will not detect shorts between

windings, but it can detect higher-voltage–related problems with respect to ground.


Figure 4 Vibration Analyzer


8.7.2 Resistance Testing

Resistance is measured by using an ohmmeter. In reality, an ohmmeter does not directly

measure resistance; it measures current instead. The scale of the meter is calibrated in

ohms, but the meter movement responds to current. The amount of current supplied by

the meter is very low, typically in the rage of 20 to 50 microamperes. The meter functions

by applying its terminal voltage to the test subject and measuring the current in the

circuit.

8.7.3 Impedance Testing

Impedance has two components: a real (or resistive) component and a reactive (inductive

or capacitive) component. This method of testing is useful because it can detect

significant shorting in coils, either between turns or to ground. Other non-intrusive

methods are not existed to detect a coil that is shorted between turns. Types of impedance

testing tools are mentioned below.

Eddy current tester

Ohmmeter

Mega-ohmmeter



9.0 PREDICTIVE MAINTENANCE APPLICATIONS




Table 31 Predictive Maintenance Applications

Plant Types of Tests Description Frequency

Air

Conditionin

g and Air

Distribution

System

Oil AnalysisThis test would show indicators of wear metals,

contaminants, viscosities and inhibitor levelAnnually

Lithium bromide

Analysis

This analysis shows what the chemical balance

is of the solutions in the absorber, inhibitor

levels are, whether ammonia is present,

solutions percentage, octyl alcohol content,

alkalinity, copper and foreign contaminants

Annually

Vibration Analysis

This test indicates an imbalance, misalignment,

bearing defects, open rotor bar conditions, gear

wear, harmonics and excessive shaft run-out

Annually

Eddy Current

Testing

This is a non - destructive test of the heat

exchangers within chiller. It can detect inside

diameter and outside diameter defects. This test

also determines the severity of the defect and

whether immediate action should be taken.

Every 3 to 5

years

Motor Current

Analysis

Motor amperage should not exceed

manufacturer's specificationAnnually

Shock Pulse

Measurement

(SPM)

Accurately forecast future equipment downtime

by detecting non-visible bearing and shaft

surface race damage. SPM audits are vital to

diagnose bearing conditions for electric motors

and pump system assemblies.

Annually

Computerized/laser

alignment

Bearing wear and fatigue can cause high

vibration levels that lead to early equipment

failure. It can correct the misalignment of fan

motors, couplers, pumps, V-belts, and drive

sheaves, helping to increase the overall life of

the equipment

Annually

Visual Inspection

Inspect the unit to ensure it is operating in a

“normal” condition for vibration, noise, and

odors. Verify gauges and thermometers are

reading within range. Inspect for leakage due to

access doors not being properly closed. Verify

that any internal lighting is off. Verify all

safety guards are in place.

Daily

Inspect belt tension and alignment. Look for


Service Category Equipment Name ThermographyOil

AnalysisUltrasonic Analysis

Vibration Analysis

Mortor Analysis Chemical Attack Test

Megger Testing

Ressistance Testing

Impedence Testing

Electrical System

HT Breakers √ √ Transformer √ √ Generator System √ √ √ √ √ Main Distribution Boards √ √ √ √ LT Panel √ √ √ √ Central Ups System √ Capacitor Bank System √ √

Air-Conditioning System

Chiller √ √ √ Cooling Tower √Condenser Water Pump √ √ √ AHU √ Supply Exhaust Fans √ √

Water/Drainage And Fire Pump System

Water Pump √ √ √ √ Dosing Pump √ √ √ Main Receiver Tank √

Fire Protection SystemSmoke Extraction Fan √ √ Staircase Pressurization Fan √ √

Lift & EscalatorsLift Motors √ √ √ Escalators √ √ √ √

Water Purificators Water Purifier √

9.1 PREDICTIVE MAINTENACE STRATEGY


Table 32 Predictive Maintenace Strategy


10.0 HUMAN RESOURCE ALLOCATION PLAN



11.0 CONCLUSIONS

The ultimate goal of any maintenance plan is to identify the imminent failures and make a

prognosis of the remaining useful life of analysed component regardless of which

technique is used. Predictive maintenance is not just acting according to a prescheduled

operational programmed but predicting the likely defect of the equipment and its

affection to overall reliability of the facility.

The maintenance environment of tomorrow will exist mostly for those who are highly

skilled in maintenance. Therefore, careful study to improve methods and reduce

maintenance costs is imperative. Achieving these initiatives will help potentially save

millions in maintenance-related expenditure over time. Analysis of the various elements

of strategic maintenance management indicates that it is a comprehensive and composite

system of integrated processes, but not necessarily a complex one.

This process, as depicted within this project, will achieve an orderly flow of work when

each element is appreciated and properly placed in relation to the other, thus allowing

mission, vision and goals/ objectives of any pharmaceutical facility maintenance strategic

plan to develop and experience success.

Continues monitoring through some specified selected instruments to identify the

different parameters of each equipment is the key operational difference in predictive

maintenance. Strategic decision making is also another key characteristic feature of the

procedure which make possible the predetermining the problem occurrence time frames

and provisions to be made and relative time constrains too. Cost effectiveness and

reliability are correlated features in predictive management where according to the

monitoring frequency demanded cost parameters and reliable operations can be achieved

with less and motivated work force.

Since this is not highly practiced within Sri Lanka assuming and analyzing accuracy can

be deviated from the actual provisions. But this synergic effect is a highly economic

feature to present economic circumstances where moving towards reliability centred

operations of the facilities. Even though this predictive maintenance strategy is an

improved worker and environmental safety feature this will be a new bench mark for

green concept for the buildings.



12.0 REFERENCES

Dodson, Bryan (1994). Reliability Engineering, Quality Publishing, Tucson,

Arizona.

Dodson, Bryan (1994). "Determining the Optimum Schedule for Predictive

Maintenance," Quality Engineering, Vol. 6, No. 4, pp. 667 - 679.

MOBLEY, K.K.,2002. An Introduction to Preventive Maintenance,2nd ed.USA:

Butter north-Heinemann.

POLMER, D., 1999. Maintenance Planning & Scheduling Handbook,USA:

McGraw Hill.

SMITH, A. M.,1993.Reliability Centered Maintenance,USA: McGraw Hill.


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Developing a Maintenance Plan

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