Module V

(8 hours)

Periodic and preventive maintenance: Periodic inspection-concept and need, degreasing,

cleaning and repairing schemes, overhauling of mechanical components, overhauling of
electrical motor, common troubles and remedies of electric motor, repair complexities and
its use, definition, need, steps and advantages of preventive maintenance. Steps/procedure
for periodic and preventive maintenance of: I. Machine tools, ii. Pumps, iii. Air compressors,
iv. Diesel generating (DG) sets, Program and schedule of preventive maintenance of
mechanical and electrical equipment, advantages of preventive maintenance. Repair cycle
concept and importance

Periodic maintenance:

 Periodic maintenance is a process that ensures company assets remain in good condition
throughout their useful life.
 It is based on the fixed maintenance schedule for assets like equipment, machinery, and
vehicles.
Periodic inspection-concept and need

Periodic inspection means examining equipment at fixed time intervals to:

 Detect early signs of wear, damage, or malfunction.

 Maintain consistent performance.
 Prevent sudden breakdowns during operation.
 Increase the lifetime of components.
 Ensure safety of workers and equipment.

Inspections may include visual checks, vibration analysis, temperature monitoring,

lubrication checks, etc.

Degreasing

Degreasing is the process of removing oil, grease, dust, and sludge from machine surfaces
using:

 Solvents
 Alkaline cleaners
 Steam or pressure washing

 It helps improve heat dissipation and prevents corrosion.

  Degreasing cleans almost all electronic assemblies, electrical components and almost
all metals, and nearlyany size or shape part can be cleaned.
 Degreasing is an essential part of the production process, particularly in industries
fabricating or assembling metal parts, such as aircraft, appliances, automotive,
electronics and railroad.
 Common chemicals used in degreasers include:

 Solvents like acetone or isopropyl alcohol

 Alkaline cleaners like sodium hydroxide

 Surfactants like detergents

Cleaning and repairing schemes

Cleaning and repairing schemes are important maintenance practices carried out to keep machines
and equipment in proper working condition. They involve systematic procedures to remove
contaminants, identify faulty components, and restore equipment performance to the desired level.
These schemes help avoid breakdowns, improve efficiency, and increase service life of machinery.

Cleaning and repairing schemes are preventive maintenance activities carried out to remove
dirt, grease, dust, rust, and foreign particles from machine components and to restore damaged
parts for proper functioning. Cleaning improves heat dissipation, reduces wear, prevents
corrosion, and maintains efficiency. Cleaning methods include manual cleaning, chemical
cleaning, steam cleaning, abrasive cleaning, and ultrasonic cleaning depending on the level of
contamination.

After cleaning, components are inspected for wear, cracks, misalignment, and corrosion. Minor
repairs such as tightening bolts, replacing gaskets, adjusting belts, and lubrication are
performed, while major repairs may involve bearing replacement, welding cracks, re-
machining parts, or component replacement. Proper reassembly, alignment, lubrication, and
performance testing ensure safe and efficient machine operation. These schemes reduce
breakdowns, increase machine life, and improve operational reliability.

Meaning and Purpose

Cleaning and repairing schemes refer to all planned activities involving:

 Cleaning of machine parts

  Removal of dirt, dust, grease, rust, sludge, and carbon deposits
 Detection of wear, corrosion, cracks, and misalignment
 Repair or replacement of damaged parts

Their main objective is to ensure operational reliability and maintain optimum working
conditions.

Importance in Industrial Maintenance

These schemes are essential because:

 Machines operate continuously under harsh conditions.

 Accumulated dirt reduces heat transfer and efficiency.
 Grease and oil deposits may cause fire hazards.
 Dust can block ventilation, leading to overheating.
 Rust weakens structural components.

Therefore, regular cleaning prevents premature failures and costly downtime.

Overhauling of mechanical components

Overhauling involves complete dismantling, inspection, servicing, and rebuilding of

mechanical components such as:

 Pumps
 Compressors
 Gearboxes
 Bearings
 Valves

Worn parts are repaired or replaced to restore the machine to its original condition

Overhauling of Machine

 Overhauling of a machine is defined as a process of general maintenance performed on a

machine or other industrial equipment.
 The goal of overhauling is to keep the system in serviceable condition.
 Regular checks can prevent all kinds of critical damage.
 Machinery overhaul is usually performed by companies offering maintenance services.
  The frequency of overhauling can be agreed upon, routine maintenance is usually scheduled
for once a year.
 A more frequent equipment check is recommended for older machines and especially larger
machines involving complex mechanisms.
Benefits
 Cost-effective
 Extended life length
 Increased performance
 Reduced labor costs
Overhauling of a Machine in Stages
Overhauling usually involves the following stages:
Inspection
1. First of all, the machine will be thoroughly inspected.
2. Experienced maintenance crews perform an inspection on the overhauled machine under
production conditions.
3. It means, the machine’s performance is monitored while the machine is in use.
4. Such a procedure allows to allocate any issues and perform the troubleshooting more
effectively.
 Disassembly
1. After the initial inspection, the piece of equipment should be taken apart.
2. Disassembly is crucial for further check and the next steps of the overhauling process, such
as repair. 3. A skilled maintenance worker is capable of putting the machine down efficiently,
indicating which parts of the equipment need to be replaced or repaired.
 Repair
1. Depending on the issue, the machine is either repaired or certain damaged parts are
replaced.
2. This step once again proves how effective overhauling is as opposed to replacing the whole
piece of equipment at once. 3. Replacement of parts might take longer than a simple repair,
as the spare parts might need to be ordered from a manufacturer.
 Reassembly
1. Following the successful replacement of spare parts, reassembly of the whole mechanism
is performed.
2. Being one of the final steps, the reassembly is crucial for the functioning of the equipment.
3. Certain skill is surely needed to perform reassembly, so it’s best handled by professionals.
 Testing
1. The final step that concludes the overhauling process.

2. Without testing it is naturally impossible to identify if the performed repair was effective.
3. During testing the retrofit is either proclaimed successful or – less frequently – the process
goes back to the starting point (inspection).

Overhauling an electric motor

Overhauling an electric motor consists of:

 Cleaning stator, rotor, and ventilation passage

 Checking shaft alignment and bearing condition
 Testing insulation resistance
 Re-winding if insulation is damaged
 Checking brushes and commutators (in DC motors)
 Lubricating bearings

A sample motor overhaul work scope includes

 Collection from site

 Inspect and record all relevant data from the nameplate

 Carry out electrical and mechanical check tests to verify motor condition and any
reported faults, where possible

 Dismantle motor

 Clean and inspect all component parts

 Datum checks, including bearing journals and seatings, shaft extensions, shaft
extension run out, shaft seal fits, commutator diameter, and brush surface length

 Repair or replacement of defect components and parts

 Steam cleaning, stove drying and varnishing of stator and rotor windings as specified
in IEEE 1068

 Rotating parts dynamically balanced to ISO grade 2.5 or better

 Up to date motor plate fitted before dispatch

  Delivery service to customer site and recommissioning. Common Troubles and
Remedies of Electric Motor.

 Electric motors play a central role in machinery in every industry.

 A failure in this critical piece of machinery could be catastrophic to the business, with
the potential for high costs and a long period of downtime.

 Understanding the common problems that can occur with electric motors can allow
you to put measures in place to avoid failure and give your electric motor the best
possible chance of achieving its maximum possible service life.

1. Low Resistance

 Low resistance is the most common cause of failure in electric motors. It is also often
the most difficult to overcome.

 Under conditions such as overheating, corrosion or physical damage, degradation of

the insulation of the internal windings of the motor may occur.

 This then causes insufficient isolation between the motor windings or conductors,
leading to short circuits, leakages and eventually motor failure.

 Regularly inspect the insulation of the windings for signs of wear and replace before
low resistance leads to failure. If you are unsure, consult an expert.

2. Overheating

 Overheating is generally caused by either a high temperature in the operating

environment or poor power quality.

 It is responsible for around 55% of insulating failures in electric motors. For every 10
degrees Celsius that the temperature of a motor rises, the insulation life is reduced by
half.

 To avoid overheating, ensure that electric motors are kept as cool as possible.

 This can be done by maintaining as cool an operating environment as possible and

regularly checking the temperature of the motor.

3. Electrical Overload

 Electrical overload is also commonly referred to as over current.

  It is caused by an excessive flow of current within the windings of the motor, which
exceeds the design current that the motor is able to carry efficiently and safely.

 Over current is often the result of a low supply voltage, which results in the motor
drawing in more current in an attempt to maintain torque.

 Electrical overload can also be caused by short-circuited conductors, or an excessive

voltage supply.

 It is important to install effective over current protection which is able to detect

overcurrent and interrupt supply to protect the motor.

4. Vibration

 Vibration can be extremely damaging to electric motors, frequently causing premature

failure. It is often caused by the motor being positioned on an uneven or unstable
surface.

 However, vibration can also be a result of an underlying issue with the motor, such
as misalignment or corrosion.

 Electric motors should be regularly inspected for vibration using a motor analyzing
tool.

 Ensure that electric motors are positioned on a flat and stable surface.

 If vibration still occurs, check for signs of wear, as well as misalignment or loose
bearings.  Consider contacting a specialist if the source of vibration cannot be easily
identified.

5. Contamination

 Electric motors frequently operate in environments where dust, dirt and chemicals are
present, which may find their way inside the motor, leading to contamination and motor
failure.

 These contaminants can dent bearing raceways and balls, leading to high levels of
vibration and wear.

 They may also block the cooling fan, limiting the motor’s ability to regulate its
temperature and increasing the chances of overheating.

 As contamination is one of the leading causes of failure in electric motors, it is

essential to prevent it from entering the motor. Luckily, this is relatively easy.
  Ensure that work areas, tools and fixtures are kept as clean as possible at all times to
help eliminate the chances of contamination entering the motor.

 When laying out the workspace, try to position motors away from applications such
as grinding machines which product large quantities of harmful contamination.

 Electric motors are the driving component of a vast range of applications across every
industry, and regular inspection is essential to reduce the risk of premature failure.

 If you are in doubt about the condition of your motor, it is always advised to contact
a specialist for further investigation.

Repair Complexities

 Refers to the level of difficulty involved in repairing machines or components.

 Influenced by design, accessibility, spare parts availability, and precision required.
 May require specialized tools, trained technicians, and advanced diagnostic methods.
 Involves dismantling of interconnected assemblies and careful reassembly.
 Requires accurate alignment, calibration, and safety precautions.
 Higher complexity increases repair time, cost, and downtime.

Uses / Importance

 Helps maintenance engineers plan repair activities effectively.

 Assists in estimating downtime and resource requirements.
 Aids decision-making between repairing and replacing components.
 Prevents repeated failures and enhances overall machine reliability.
 Reduces maintenance cost through efficient planning.
 Improves safety and performance after restoration.
 Supports preventive and predictive maintenance scheduling.

PREVENTIVE MAINTENANCE

DEFINITION

Preventive maintenance is an undeniably critical competent to any maintenance strategy. It’s

key to lowering maintenance costs, reducing equipment downtime, improving asset lifespan
and efficiency, and increasing workplace safety.
Need of Preventive maintenance

 Preventive Maintenance is very much needed by decrease business downtime and closure
due to unexpected equipment failure.
 Preventive Maintenance is to increase equipment life expectancy.
 Preventive Maintenance will ensure all equipment and employees work is in safe by
eliminating the unexpected machinery breakdowns, etc.
 Preventive maintenance will significantly reduce safety risks for employees.

Steps for preventive maintenance

1. Create an Asset List.

2. Identify the Priorities.
3. Identify Critical Tasks for the Preventive Maintenance.
4. Determine Maintenance Frequency.
5. Create a Preventive Maintenance Checklist & Schedule.
6. Work with the Asset Maintenance Team.

Advantages Disadvantages
1. Less equipment downtime Upfront costs-keeping equipment well-
maintained requires investment
2. Longer asset life More labour-intensive, so you'll need more
staff on hand
3. Fewer interruptions to critical operations Potential for over-maintenance
4. Increased workplace safety and improved
compliance with OSHA (Occupational
Safety and Health Administration)
5. Improved efficiency (assets in good
condition perform better)

Steps and procedure for periodic& preventive maintenance of machine tool,

pump, air compressor and diesel generator.

Procedure for Periodic& Preventive Maintenance

1. Machine Tools

 Preventive maintenance of machine tools can be easily performed with a few basic tips,
including the need to keep these tools:
 Dry by storing them in non-moisturized locations and safeguarding them from industrial rust
and pollutants.

 Lubricated including the moving parts, internal, and fixed components without which, your
machine tools are likely to break down due to wear and tear.

 Sharpened, particularly those tools that are used for cutting, sharpening, or slicing without
which, these machine tools are likely to have a shorter operating life due to constant wear and
tear.

 Clean to get rid of industrial hazard materials and grime that can prevent your tools from
working at optimum efficiency.

 In good shape by performing maintenance on smaller machine accessories such as the tool
screws and bolts.

 With a digitized Front Line Worker Platform, manufacturers can optimize the preventive
maintenance work of their machines and equipment. Let’s look at how this can be
accomplished.

 How Front Line Worker Platforms Improve Preventive Maintenance of Tools & Equipment

 For effective preventive maintenance of tools and equipment in your manufacturing facility,
front line operators must incorporate several actions as part of their daily tasks, including the
following:

 Regular inspection of machine tools for any defects or wear or tear

 Complete cleaning of manufacturing assets including the factory premise and ventilation

 Periodic lubrication of all moving parts in machinery to prevent damage

 Repair or replacement of defective machine tools and equipment

 A Connected Worker Platform improves preventive maintenance operations by empowering

front line workers to:

 Automate repetitive task assignment such as tool cleaning

 Integrate the maintenance-related tips into their daily workflows and check off if they have
been followed at the end of every working day.
 Improve the quality of their maintenance work by streamlining best practices through an
integrated platform and removing any redundant or inefficient steps from the process of
cleaning their tools and equipment.

 Implement daily inspection routines using a guided maintenance workflow as part of the PM
guidelines.

 Have procedures in place to make sure tools are properly collected at the end of jobs and that
any issues without equipment is reported.

2. Pumps

 The strength and effectiveness of your pump preventive maintenance plan depending on how
robust your checklist is.

 While you would want to include all possible checks in the plan, it is impractical and
inadvisable for all routine checks.

 Therefore the checklist is divided based on the frequency of checks making it more
sustainable and effective: Daily Check:

 Check pump exterior for any leaks

 Clean pump and nearby region to remove any debris

 Check for excessive pump vibration or unusual noises

 Check for foaming or oil discoloration

 Check bearing temperature for overheating

 Inspect all gaskets to ensure there are no oil leaks

 Inspect self flush pumps is applicable

 Clean bearing covers if needed

 Check pump cooling system Monthly Check:

 Top up oil to bearing reservoirs if needed

 Clean oil bulbs and level windows

 Check the pump guards and replace them if needed

 Clear out dirt and debris from bearings and grease them

 If applicable, check that the hydraulic governors are working properly

 Check overall pump systems for leaks and clean the pumping system surroundings

3. Air Compressor

 Below is a checklist of things that you should check every time you maintain your air
compressor.

 Typically, this relies on operating hours, so consult your owner's manual to see specific
maintenance schedules.

1. Check the Oil

 This is very important for any engine (large or small).

 If your air compressor takes oil, make sure you check it before you start it up
each time. If the oil is low, you could find yourself doing serious damage to the
compressor. Whenever the oil is low, top it off.

2. Remove Moisture and Contaminants

 Filters, dryers, oil separators, and even the air tanks collect water, oil, and
other contaminants from the air.

 The only way these components can operate efficiently is if you drain the
waste from them.

 It should be done every time you've finished using the air compressor but
needs to be inspected closely during maintenance.

3. Replace the Air Filter(s)

 Frequently check all of your filters, and change them if there's heavy build-
up. If you rarely use your air compressor, change the air filter every 3-6 months
for optimal performance.

 If your air filter is dirty, your air compressor will work much harder to do its
job. And even worse, you'll run the risk of contaminating the compressor.

4. Replace the Separator Element—

 The separator element prevents excessive use of oil.

  You may not want to pay for a replacement separator, but it's honestly cheaper
than the rise in energy costs over time due to a drop in separator pressure.

 For every 2 PSI the separator pressure drops, your energy costs can increase
by 1 percent.

 Periodically replacing your separator element will keep your compressor

healthy and reduce how much you're spending on energy costs.

5. Clean the Fuel Tank—

 If you've got an oiled compressor, you'll need to clean the fuel tank during
servicing to ensure it remains clear of gunk and contaminants to continue
running effectively.

6. Test Safety Shutdown Features—

 At a minimum, this should be done each time a compressor is fully serviced.

 Run through your company's safety procedure and follow protocol to ensure
the compressor will operate correctly according to the plan.

4. Diesel Generator

Lubrication Service

 The Engine oil must be checked while powering off the generator at regular intervals using a
dipstick.

 Allow the oil in the upper portion of the engine to drain back into the crankcase and follow
the engine manufacturer’s recommendations for API oil classification and oil viscosity.

 Keep watching the oil level as near as possible to the full mark on the dipstick by adding the
same quality and brand of oil.

Cooling System

 Check the coolant oil level during shutdown periods at the specified interval.

 Must be noted these points “remove the radiator cap after allowing the engine to cool, and, if
necessary, add coolant until the level is about 3/4 in” And a More critical role in balancing
diesel engines require a balanced coolant mixture of water, antifreeze, and coolant additives.

 Examine the exterior of the radiator for obstructions, and remove all dirt, grimy or foreign
material with a soft brush or cloth with caution to avoid damaging the fins.
 If available means, use the low-pressure compressed air or a stream of water in the opposite
direction of normal airflow to clean the radiator.

Fuel System

 This is the important point when it comes to the maintenance of diesel generators.

 Diesel is subject to contamination and corrosion within a period of time is one year, and
therefore regular generator set exercise is highly recommended to use up stored fuel before it
degrades.

 The fuel filters should be drained at the designated intervals due to the water vapour that
accumulates and condenses in the fuel tank.

 Better check regularly testing and fuel polishing may be required if the fuel is not used and
replaced in three to six months.

Testing Batteries

 If the battery’s charges reach the dead-end level is a common cause of standby power system
failures.

 The battery must be kept fully charged and well-maintained at an all-time 40% to 100% to
avoid regular testing and inspection to know the current status of the battery and avoid low
battery levels.

Routine Engine Exercise

 Regular exercising keeps the engine parts lubricated and thwarts oxidation of electrical
contacts, uses up the fuel before it deteriorates, and helps to provide diesel generator
maintenance to reliable engine starting.

 Engine exercise is recommended to be executed 15 days once or 25 days once for a minimum
of 30 min

Keep your Diesel Generator Clean

 Maintain your engine all-time nice and clean because it will be taken care of Oil drips and
other issues.

 Check day-by-day hoses and belts that are in good condition or not.

 Frequent checks can keep better conditions and other nuisances from nesting in your
equipment.
Exhaust system inspection

 In case of any leaks along the exhaust line which usually occur at the connection points, the
welds, and the gaskets.

 Find the place of leakages and repair them immediately by a technician.

Programming and scheduling concept of preventive maintenance.

Program and Schedule of Preventive Maintenance of

1. Mechanical Equipment.

 Every PM program is developed to increase the equipment life and reduce unscheduled
downtime.

 However, you should list all other objectives of developing a PM plan.

 That can include lowering costs, increasing savings, achieving minimal unplanned
downtime, and minimal lost production opportunity time.

 Other things can include reducing spare parts usage, reducing manufacturing
interruptions, reducing labor costs, increase machine life spans, improving the quality of
products, and maximizing manufacturing time per machine.

PM Schedule

 Once you’re done listing the proper PM procedures, you would upload them in your
Computerized Maintenance Management System (CMMS).

 At this point, you have to develop a maintenance schedule, with each PM procedure
scheduled to efficiently make use of the people and resources available.

 Preventive maintenance scheduling is done daily, weekly, monthly, quarterly, semi-

annual, and annual PM events.

 Not all machines require daily or even weekly checks; however, they do need monthly,
quarterly, and annual checks. Your preventive maintenance software keeps track of the
maintenance checks for you.

Machine Lubrication Engineering in PM

 Almost all of the manufacturer recommendations include the importance of lubricating
rotating and reciprocating machine parts.

 Many maintenance professionals misunderstand the importance of lubrication in

preventive maintenance; they consider the PM plan as a means of ensuring a lubrication
program.

 However, the reality is more complicated, and lubrication tasks require much more effort
than is traditionally thought.

 You need to visually and physically inspect the machine and its components to write the
appropriate PM procedures for the lubrication, for starters.

Preventive Maintenance Training

 It’s crucial for each team member to understand all the steps for preventive maintenance
in machines.

 It’s very much possible that individuals are either not utilizing the right tools for
maintenance or doing it completely wrong.

 In the short-term, that won’t matter much, but in the long term, it can lead to multiple
equipment failures.

PM Program Management Plan

 It’s crucial to have a proper preventive maintenance management system in place.

 The best way to go around that is to have a complete work order system in place that
captures labor hours, materials, and task details.

Communication and Collaboration

 The last step of any successful preventive maintenance plan for machines is to develop
proper communication channels.

 Communicating the past success of PM programs is essential for reaffirming your PM

team and developing two-way feedback channels.

2. Electrical Equipment

Residential location checklist

 Residential areas (also known as dwellings) usually have a smaller electric supply
requirement.

 This means fewer circuit panels and less wiring.

 However, a preventive maintenance plan is just as important in a residence as it is in large

facilities.

 Check cable assemblies and other wiring methods in rooms, hallways, stairways, and
attics.

 Check cable installations and circuit boxes for general suitability.

 Examine boxes for warning lights and other irregularities.

Industrial and commercial establishment checklist

 Check all power meters for regular function before shutting them down for maintenance.
 Confirm that indicators, sensors, and warning lights are functioning correctly.

 Torque test and inspect bolted electrical connections to specified levels whenever
needed.

 Visually inspect primary control points for signs of deterioration and overheating.

 Disassemble battery tripping packs and check for signs of general battery integrity and
any signs of corrosion or heat damage.

 Perform thermal imaging surveys using precise thermography equipment.

 Check for signs of persistent overheating and single out specific areas for repair or part
replacement.

Repair Cycle Concept and Importance

 The repeated performance of all/some of the above mentioned activities in sequence

between the successive overhauling is termed as “Repair cycle”. The repair cycle embraces
the following activities. 1. Inspection 2. Repair 3. Overhauling.
 It is clear from that first an inspection activity is scheduled followed by minor/major
activities. Then an inspection takes place followed by a minor repair. Ageing a second
inspection is followed by a major repair.

 Second inspection is followed by a major repair. Like this it goes and completes one
repair cycle.

 The set of these activities between two consecutive overhauling is considered. More the
complexity number more will be the activities involved and in turn more staffing requires
to complete the repair cycle

Symbol Meaning
O₁ Operating/Serviceable component in use (working condition)
I₁, I₂, I₃ Inspection points (initial check, failure diagnosis, quality check)
R₁, R₂ Repair stages (general repairs, machining, refitting etc.)
R₁₁, R₂₁ Reconditioning/overhauling stages (specialized repair operations)

1. O₁ — Component in Operation
The part is installed in the machine and is functioning normally.
2. I₁ — Inspection after removal
The component shows wear/failure symptoms and is removed for diagnosis.
3. R₁₁ / R₂₁ — Repair / Overhauling
The component undergoes repair, replacement of worn parts, machining, etc.
May involve specialized operations.
4. I₂ — Functional Inspection
The repaired component is tested for performance and tolerance accuracy.
5. R₁ — Minor rework
If minor errors are found, the part is returned for small corrections.
6. I₃ — Final Inspection
A final quality check ensures the component meets standards.
7. R₂ — Finishing / Calibration
Fine tuning, cleaning, balancing, surface finishing.
8. O₁ (again) — Returned to Service
The component is ready to be used again in operation.