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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.

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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 ............................................. 24 6.5 Preventive maintenance schedule for AHU ............................................................. 29 6.6 Preventive maintenance schedule for Package Unit ................................................ 30 6.7 Preventive maintenance schedule for Split Unit ...................................................... 31 6.8 Preventive Maintenance schedule for Cool Room ................................................... 31 6.9 Preventive maintenance schedule for Exhaust Fan .................................................. 32 6.10 Preventive maintenance schedule for Air compressor ........................................... 33 6.11 Preventive maintenance schedule for Transformers .............................................. 34
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6.12 Preventive maintenance schedule for Capacitor Bank ........................................... 35 6.13 Preventive maintenance schedule for High Tension Panel .................................... 35 6.14 Preventive maintenance schedule for Illumination System ................................... 36 6.15 Preventive maintenance schedule for Generators .................................................. 37 6.16 preventive maintenance schedule for Boilers ........................................................ 39 6.17 Preventive maintenance schedule for Water Tanks ............................................... 41 6.18 Preventive maintenance schedule for Pumps ......................................................... 41 6.19 Preventive maintenance schedule for Sprinkler System ........................................ 42 6.20 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells ..... 43 6.21 Preventive maintenance schedule for Fire Extinguishers ...................................... 43 6.22 Preventive maintenance schedule for Fire Control Panel ...................................... 43 6.23 Preventive maintenance schedule for Elevators..................................................... 44 6.24 Preventive maintenance schedule for RO Plant ..................................................... 46 6.25 Preventive maintenance schedule for Doors and Windows ................................... 47 6.26 Preventive maintenance schedule for Painting ...................................................... 47 7.0 WORK INSTRUCTIONS FOR MAINTENANCE ACTIVITIES ............................. 48 7.1 General instructions ................................................................................................. 48 7.2 Civil Maintenance working Instruction ................................................................... 49 7.2.1 Cleaning............................................................................................................. 49 8.0 PREDICTIVE MAINTENANCE ................................................................................ 52 8.1 The characteristics of predictive maintenance are the following:............................ 53 8.2 Advantages of predictive maintenance .................................................................... 53 8.3 Thermography .......................................................................................................... 53 8.4 lubricating oil analysis ............................................................................................. 54 8.5 Utrasonic Monitoring ............................................................................................... 54 8.6 Vibration monitoring ............................................................................................... 55 8.7 Motor Analysis ......................................................................................................... 55 8.7.1 Megger Testing.................................................................................................. 55 8.7.2 Resistance Testing ............................................................................................. 56 8.7.3 Impedance Testing ............................................................................................ 56 9.0 PREDICTIVE MAINTENANCE APPLICATIONS .................................................. 57 9.1 PREDICTIVE MAINTENACE STRATEGY ......................................................... 54 10.0 HUMAN RESOURCE ALLOCATION PLAN ........................................................ 55 11.0 CONCLUSIONS ....................................................................................................... 56
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12.0 REFERENCES .......................................................................................................... 57

LIST OF FIGURES
Figure 1 Signs .................................................................................................................... 48 Figure 2 Infrared camera ................................................................................................... 54 Figure 3 Thermal Imaging Camera.................................................................................... 54 Figure 4 Vibration Analyzer .............................................................................................. 55

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LIST OF TABLES
Table 1 Assets registry for manufacturing equipments ..................................................... 14 Table 2 Assets Registry for Manufacturing Equipment .................................................... 17 Table 3 Preventive maintenance evaluation criteria .......................................................... 20 Table 4 Preventive maintenance prioritization assessment sheet ...................................... 20 Table 5 Preventive maintenance schedule for chiller ........................................................ 22 Table 6 Preventive maintenance schedule for condenser water pump .............................. 23 Table 7 Preventive maintenance schedule for chilled water pump ................................... 24 Table 8 Preventive maintenance schedule for Cooling Tower .......................................... 28 Table 9 Preventive maintenance schedule for AHU.......................................................... 30 Table 10 Preventive maintenance schedule for Package Unit ........................................... 31 Table 11 Preventive maintenance schedule for Split Unit................................................. 31 Table 12 Preventive Maintenance schedule for Cool Room ............................................. 32 Table 13 Preventive maintenance schedule for Exhaust Fan ............................................ 33 Table 14 Preventive maintenance schedule for Air compressor ....................................... 33 Table 15 Preventive maintenance schedule for transformers ............................................ 35 Table 16 Preventive maintenance schedule for Capacitor Bank ....................................... 35 Table 17 Preventive maintenance schedule for High Tension Panel ................................ 36 Table 18 Preventive maintenance schedule for illumination system................................. 37 Table 19 Preventive maintenance schedule for Generators ............................................... 39 Table 20 Preventive maintenance schedule for Boilers ..................................................... 41 Table 21 Preventive maintenance schedule for Water Tanks ............................................ 41 Table 22 Preventive maintenance schedule for Pumps ..................................................... 42 Table 23 Preventive maintenance schedule for Sprinkler System..................................... 42 Table 24 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells.. 43 Table 25 Preventive maintenance schedule for Fire Extinguishers ................................... 43 Table 26 Preventive maintenance schedule for Fire Control Panel ................................... 44 Table 27 Preventive maintenance schedule for Elevators ................................................. 44 Table 28 Preventive maintenance schedule for RO Plant ................................................. 46 Table 29 Preventive maintenance schedule for Doors and Windows ............................... 47 Table 30 Preventive maintenance schedule for Painting ................................................... 47 Table 31 Predictive Maintenance Applications ................................................................. 59 Table 32 Predictive Maintenace Strategy .......................................................................... 54
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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.

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2.0 INTRODUCTION TO THE VISITED SITE


Glaxo Smith Kline (GSK) is one of the worlds 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 GSKs 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.

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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
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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

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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.
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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

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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 Manufactures 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.

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4.0 ASSETS REGISTRY


4.1 Assets registry for manufacturing equipments
Category Liquid Manufacturing Vessel Silversion Mixer Pilot Mixer Drum Lifter New Mono Pump Small Silversion Mixer Drum Pump Filter Press Liquid Filling Suger Syrup Pump Instant Water Heater Hand Dryer Water Geezer Bottie Dryer Bottle Washing Machine Liquid Filling Machine Liquid Packing Belt Conveyer Labelling Machine Gumming Machine Oueter Sealing M/C Gum Tape Machine Auto Cartonner Machine Shirink Sleving Machine Glucolin Production Form,Fill Sealing M/C Mater Burt Filling M/C
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Description

No 8 2 2 1 1 1 1 1 2 2 5 1 2 1 2 1 1 1 1 1 1 1 1 2

Serial No

Location Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Manufacturing Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Filling Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Liquid Packing Area Glucolin Production Area Glucolin Production Area
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Belt Conveyer Spiral Flow Conveyer Band Heat Sealer Dust Collector(Glucolin) TEW Heat Sealer Y Con Blender Printing Equipments Rejafix Printer Leaflet Folder Coding Machine Leaflet Folder (New) OTC Equipments Rejafix Printer Atles Copco Airdryer Storcklin Stacker Dust Collector(Panadol) Drum Lifter Drum Lifter De-Blisterin MC

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1

Glucolin Production Area Glucolin Production Area Gluolin Production Area Glucolin Production Area Glucolin Production Area Glucolin Production Area Ground Floor Ground Floor Ground Floor Ground Floor OTC Section OTC Section OTC Section OTC Section OTC Section OTC Section OTC Section

Table 1 Assets registry for manufacturing equipments

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4.2 Assets Registry for Manufacturing Equipment


Category Description Air Conditioning/ Ventilation Chiller (York) Cooling Tower Condenser Water Pump Chilled Water Pump Air Handling Unit Condenser Water Pump Panel Chilled Water Pump Panel Air Handling Unit Panel Cooling Tower Panel Split Air Conditioner Unit Package Unit VAV Condensation Tank Cooling Tower Fans Air Curtain Air Compressor Toilet Extractor Fan Turbine Ventilator Fresh Air Fan Transformers Capacitor Banks Main Distribution Boards LT Switch Gear Panel HT Switch Gear Panel Main Breakers Bus Riser And Tap Off Point Automatic Transfer Switch Electrical Grounding Distribution System Power Outlets Emergency Exit Lamps Fluorescent Fittings Switches Generators No 3 3 6 6 6 1 1 6 6 16 3 8 1 6 4 2 20 50 2 1 2 1 1 2 2 Serial No Location Ground Floor Ground Floor Ground Floor Ground Floor Ground Floor Ground Floor Ground Floor Ground Floor Ground Floor Cloak Rooms Production Areas Liquid Manufacturing Area Ground Floor Ac Plant Room Production Areas Compressor Room Roof Top Roof Top Ground Floor Transformer Room Electrical Room Electrical Room Electrical Room Electrical Room Electrical Room Electrical Room Electrical Room Ground Floor All Areas All Areas All Areas All Areas All Areas Generator Room
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Electrical

50

Emergency Backup System

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Water Treatment

Heating Fire Protection

Activated Carbon Filter Ultra Violent Lamp Membranes Sand Filter Treated Water Tank Boiler Solar Water Heater Heat Detectors Smoke Detectors Fire Panel Fire Alarm System Fire Hydrants Fire Hose Reel Fire Extinguishes Diesel Engine Pump Fire Pump Fire Doors Water Supply Storage Emergency Lighting

1 1 4 2 1 1 2

2 5 2 177 1 2 2 1 50 1 2 2 1 5 5 5 1 1 1 1 1 1 1 4

Building Transportation

Lift Cars(Goods) Lift Motors Lift Cables Lift Control Panel (Goods) Instruments/Tools Volt Meter Ohm Meter Tachometer Flame Guard Tester Air Sampling Pump Light Meter Sound Level Meter Air Sampling Meter Enviro Meter Personal Dose Meter Structural Door Closers Automatic Doors Claddings Dock Leveler Roofing Roof Penetrations Roof Drains Roof Flashing
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Ro Plant Ro Plant Ro Plant Ro Plant Ro Plant Boiler Room Roof Top All Areas All Areas Panel Room All Areas Ground Floor All Areas All Areas Pump Room Pump Room Office Pump Room All Areas Liquid Manufacturing Area Lift Motor Room Lift Motor Room Lift Motor Room Electrical Room Electrical Room Electrical Room Welding Room Electrical Room Manufacturing Area Manufacturing Area Manufacturing Area Manufacturing Area Manufacturing Area All Areas Office Entrance Building Exterior All Areas Roof Roof Roof Roof
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Administrative

Laboratory

Gutters/Downspouts Fax Security Alarms Telephone Computers Conveyors Photo Copy And Scanning Steam Sterilizers De-Ionized Water Bottle Washer ETO Sterilizers Fume Cupboard Oven Heater Kheldal Apparatus Burner Gas Chromatogram

30 50 1 2 1 2 2 2 4 4 1 3 1

Building Exterior Office Security Room Office Office Office Office Chemical Laboratory Chemical Laboratory Chemical Laboratory Chemical Laboratory Chemical Laboratory Biological Lab Chemical Laboratory Chemical Laboratory Biological Laboratory Biological Lab

Table 2 Assets Registry for Manufacturing Equipment

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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

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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 Medicine manufacturing area Laboratory areas, purifying plant (RO) Manufacturing store Primary and secondary packing area Risk Category I Equipment Functional Area Over Printing, labelling areas Plant Room All over the building structure (other) Administrative Areas Employee Quarters Outside of the factory Potential peoples death Risk Category II Impact Of Failure Or Malfunction Potential peoples or staff injury Potential peoples or staff health problem Discomfort or Inconvenience No significant risk Points 10 9 8 7 6 5 4 3 2 1 5 4 3 2 1

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Monthly Risk Category III Preventive Maintenance Frequency Semi-annually Annually Not Required Table 3 Preventive maintenance evaluation criteria Quarterly

5 4 3 2 1

5.2 Preventive maintenance prioritization assessment sheet


Risk Facility Name Risk Risk Category III Total Points Maintenance Priority

Category Category I II

Air Conditioning/Ventilation building Transportation Potable Water/Plumbing Fire Protection Electrical Structural Administrative Laboratory Instruments/Tools Heating Emergency Backup power Water treatment (RO) 5 5 5 10 5 4 3 9 3 5 5 9 4 2 4 5 5 2 2 4 2 3 5 4 5 5 5 5 4 2 2 5 5 4 4 5 14 12 14 20 14 8 7 18 10 12 14 18 3rd 4th 3rd 1st 3rd 4rd 5th 2nd 5th 4th 3rd 2nd

Table 4 Preventive maintenance prioritization assessment sheet

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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.

6.1 Preventive maintenance schedule for chiller


Activity Duration 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

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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


Activity Check inlet pressure Check outlet pressure Check water leak Clean pump and motor Duration D W M Q BA A

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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 D Check inlet pressure Check outlet pressure W Duration M Q BA A

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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 D W Duration M Q BA A

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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 Check motor supports and alignment Clean fan blades

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Check lubrication Check water distribution and sprinkler operation 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 Check tower structure Clean tower Strainer cleaning Check motor supports and alignment

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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 Check tower structure Check bearings Clean tower Paint tower

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Table 8 Preventive maintenance schedule for Cooling Tower

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6.5 Preventive maintenance schedule for AHU


Activity D W Duration 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

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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 D 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
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Duration W
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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 D 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 W M Duration Q BA A

6.8 Preventive Maintenance schedule for Cool Room


Activity D W Duration M Q BA A

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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

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D 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.

BA A

Table 13 Preventive maintenance schedule for Exhaust Fan

6.10 Preventive maintenance schedule for Air compressor


Activity D 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 W Duration M Q BA A

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6.11 Preventive maintenance schedule for Transformers


Activity D 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 W Duration M Q BA A

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Check fans, controls, alarms & anounciator points Table 15 Preventive maintenance schedule for transformers

6.12 Preventive maintenance schedule for Capacitor Bank


Activity D 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 W Duration M Q BA A

6.13 Preventive maintenance schedule for High Tension Panel


Activity D Check all indicators Dust clean the enclosure Check all indicators Check cable termination W Duration M Q BA A

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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

Table 17 Preventive maintenance schedule for High Tension Panel

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Duration Activity 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 D W M Q BA A

6.15 Preventive maintenance schedule for Generators


Duration D
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Activity W

BA

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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
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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


Duration D W M Q BA A

Activity

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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
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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 D Check the seal of the access panel Drain and clean the tank Table 21 Preventive maintenance schedule for Water Tanks W Duration M Q BA A

6.18 Preventive maintenance schedule for Pumps


Activity W 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 Duration M Q A

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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 W 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
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Duration M Q A d d

Developing a Maintenance Plan

6.20 Preventive maintenance schedule for Smoke, Heat detectors and Alarm bells
Duration Activity D 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 W M Q A

6.21 Preventive maintenance schedule for Fire Extinguishers


Duration Activity D Inspect maintenance and testing of all fire extinguishers Refill the fire Extinguishers Table 25 Preventive maintenance schedule for Fire Extinguishers W M Q A

6.22 Preventive maintenance schedule for Fire Control Panel


Activity D 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
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Duration W M Q A
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Check security of electrical connections Table 26 Preventive maintenance schedule for Fire Control Panel

6.23 Preventive maintenance schedule for Elevators


Duration Activity D 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 W M Q A

Table 27 Preventive maintenance schedule for Elevators

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6.24 Preventive maintenance schedule for RO Plant


Activity D 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 W Duration M Q A

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CIVIL WORKS SCHUDLE

6.25 Preventive maintenance schedule for Doors and Windows


Activity 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 Duration D W M Q A

Table 29 Preventive maintenance schedule for Doors and Windows

6.26 Preventive maintenance schedule for Painting


Activity Duration D Staircase Steps Painting Pipe Painting Corridor Painting Skirting Painting Door Frame Painting Arrow Painting Windows Painting Table 30 Preventive maintenance schedule for Painting W M Q A

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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.

Figure 1 Signs

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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. Proper PPE should be worn by the work force. Make sure theres 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.
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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.

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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.

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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.

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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 cant 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
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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
Figure 2 Infrared camera

Figure 3 Thermal Imaging Camera

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
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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

Figure 4 Analyzer

Vibration

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-voltagerelated problems with respect to ground.

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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

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9.0 PREDICTIVE MAINTENANCE APPLICATIONS


Plant Types of Tests Description This test would show indicators of wear metals, contaminants, viscosities and inhibitor level This analysis shows what the chemical balance Lithium bromide Analysis is of the solutions in the absorber, inhibitor levels are, whether ammonia is present, solutions percentage, octyl alcohol content, alkalinity, copper and foreign contaminants This test indicates an imbalance, misalignment, Vibration Analysis bearing defects, open rotor bar conditions, gear wear, harmonics and excessive shaft run-out This is a non - destructive test of the heat Air Conditionin Eddy Current Testing g and Air Distribution System Motor Current Analysis Motor amperage should not exceed manufacturer's specification Accurately forecast future equipment downtime Shock Pulse Measurement (SPM) 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. Bearing wear and fatigue can cause high Computerized/laser alignment 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
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Frequency

Oil Analysis

Annually

Annually

Annually

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

Annually

Annually

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Developing a Maintenance Plan

the equipment 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 Daily access doors not being properly closed. Verify that any internal lighting is off. Verify all safety guards are in place. Visual Inspection Inspect belt tension and alignment. Look for rubber shavings under the pulleys. Inspect visible grease for metal shavings, indicating a possible failing bearing. Wipe away all excess grease after greasing. Inspect grease tubing if installed for integrity to make sure grease is getting to the bearings. Check bearings for excessive heat, noise, or vibration. Check all set points such as pressure and temperature for proper setting and function. provide non-contact temperature mapping of abnormal heating or cooling in systems Semi Annually

Weekly

Fill out daily log

Daily

Infrared thermograph surveys Airbourne Electricity Distribution System Visual Inspection ultrasonic detection

Every 3 months

For arcing or corona.

Every 6 months

System load, amperage, power factor and/or voltage recording reducing catastrophic cable failure and downtime Line disturbance detection, location and

Daily

Insulation testing

Every 6 months Every 3

Line disturbance

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detection Carry oil analysis tests Generator Carry out visual inspection

analysis. Only if the results show it should be changed, the oil filters should be changed Record Water, oil and battery levels

months

Annually

Weekly

Inspect and record data regarding the governor Visual Inspection Lift and Escalators Motor Current Analysis Motor amperage should not exceed manufacturer's specification This test would show indicators of wear metals, contaminants, viscosities and inhibitor level this test indicates an imbalance, misalignment, Vibration Analysis bearing defects, open rotor bar conditions, gear wear, harmonics and excessive shaft run-out Table 31 Predictive Maintenance Applications rope, counter weight, control panel, data transmit cable, etc.

Once a month

Every 3 months

Oil Analysis Water Pumps

Annually

Annually

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9.1 PREDICTIVE MAINTENACE STRATEGY


Mortor Analysis Chemical Oil Ultrasonic Vibration Megger Ressistance Impedence Attack Analysis Analysis Analysis Test Testing Testing Testing

Service Category

Equipment Name

Thermography

HT Breakers Transformer Generator System Electrical System Main Distribution Boards LT Panel Central Ups System Capacitor Bank System Chiller Cooling Tower Air-Conditioning System Condenser Water Pump AHU Supply Exhaust Fans Water Pump Water/Drainage And Fire Dosing Pump Pump System Main Receiver Tank Smoke Extraction Fan Fire Protection System Staircase Pressurization Fan Lift Motors Lift & Escalators Escalators Water Purificators Water Purifier

Table 32 Predictive Maintenace Strategy


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10.0 HUMAN RESOURCE ALLOCATION PLAN

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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.

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12.0 REFERENCES

Dodson, Bryan (1994). Arizona.

Reliability Engineering, Quality Publishing, Tucson,

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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