MAINTENANCE ANDSAFETY ENGINEERINGB.Tech./ MECHANICAL/IV/VIII SEM

Achariya College of Engineering Technology(Approved by AICTE and affiliated to Pondicherry University)

An ISO 9001:2008 Certified InstitutionAchariyapuram, Villianur, Puducherry 605 110.

www.acet.edu.in

Mr.A.BHOJAN

(For internal circulation only)

MET82 MAINTENANCE AND SAFETY ENGINEERING (3 0 0 3)Unit IObjectives of maintenance - types of maintenance Breakdown, preventive and predictive maintenance - Repair cycle - Repair Complexity, Lubrication and Lubricants. Maintenance of Mechanical transmission systems and process plants.(12hours)Unit IIPredictive Maintenance - vibration and noise as maintenance tool - wear debris analysis -Condition monitoring concepts applied to industries - Total Productive Maintenance (TPM) -Economics of Maintenance- Computer aided maintenance.(12 hours)Unit IIIReliability: Definition, concept of reliability based design, failure rate, MTTF, MTBF, failure pattern, system reliability: Series, Parallel and Mixed configurations -Availability and Maintainability concepts- Applications.(12 hours)Unit IVSafety and productivity - causes of accidents in industries accident reporting and investigation -measuring safety performance - Safety organizations and functions -Factories act and rules.(12 hours)Unit VSafety Codes and Standards - General Safety considerations in Material Handling equipments -Machine Shop machineries-pressure vessels and pressurized pipelines welding equipments operation and inspection of extinguishers prevention and spread of fire emergency exit facilities. (12 hours)Text Books :1.P.Gopalakrishnan - Maintenance and Spare parts Management, Prentice Hall of India Pvt. Ltd., New Delhi, 1990.2.L.S.Srinath - Reliability Engineering, Affiliated East West press, 20033. Rolland P.Blake - Industrial Safety, Prentice Hall of India Pvt. Ltd., New Delhi, 1973.Reference Books :1. R.C. Mishra and K. Pathak, Maintenance Engineering and Management, Prentice Hall of IndiaPvt. Ltd., NewDelhi, 2002.2. H.P. Garg, Industrial Maintenance, S Chand & Co Ltd., New Delhi, 1990.3. E. Balagurusamy, Reliability Engineering, Prentice Hall of India P Ltd., New Delhi, 2003.

CHAPTER NO TITLE PAGE NOUNIT-11.1 MAINTENANCE 21.2 MAIINTENANCE

OBJECTIVES2

1.2.1 MAINTENANCE TERMS 3 1.2.1.1 MAINTENANCE 3 1.2.1.2 MAINTENANCE

ENGINEERING3

1.2.1.3 MAINTENANCE CONCEPT 3 1.2.1.4 MAINTENANCE PLAN 3 1.2.1.5 MAINTENANCE PERSON 31.2.2 MAINTENANCE FUNCTION 31.3 TYPES OF MAINTENANCE 2 1.3.1 CORRECTIVE

MAINTENANCE4

1.3.2 PREVENTIVE MAINTENANCE

4

1.3.3 PREDICTIVE MAINTENANCE 41.3.4 ZERO HOUR MAINTENANCE 41.3.5 PERIODIC MAINTENANCE 5

1.4 BREAKDOWN MAINTENANCE

5

1.5 PREVENTIVE MAINTENANCE

5

1.6 PREDECTIVE MAINTENANCE

6

1.7 REPAIR CYCLE 7

1.8 LUBRICANTS 71.9 LUBRICATIONS 81.9.1 THICK FLIM LUBRICATIONS 81.9.2 THIN FLIM LUBRICATIONS 8

1.9.3 EXTERME PRESSURE LUBRICATIONS

8

1.10 MAINTENANCE OF MECHANICAL TRANSMISSION SYSTEMS AND PROCESS PLANTS

9

1.10.1 GOOD MAINTENANCE PRACTICE OF GEARS

9

1.10.2 MAINTENANCE PRACTICE OF GUIDE WAYS

9

1.10.3 MAINTENANCE PRACTICE OF BEARINGS

10

UNIT -22.1 PREDECTIVE

MAINTENANCE12

2.2 VIBRATION AND NOISE AS MAINTENANCE TOOL

12

2.3 WEAR DEBRIS ANALYSIS 14

2.4 CONDITION MONITORING CONCEPTS APPLIED TO INDUSTRIES

16

2.5 TOTAL PRODUCTIVE MAINTENANCE

17

2.5.1 5S 182.5.2 JISHU HOZEN 192.5.3 KAIZEN 222.5.4 PLANNED MAINTENANCE 242.5.5 QUALITY MAINTENANCE 252.5.6 TRAINING 262.5.7 OFFICE TPM 272.5.8 SAFETY, HEALTH AND

ENVIRONMENT30

2.6 ECONOMICS OF MAINTENANCE

30

2.7 COMPUTER AIDED MAINTENANCE

31

UNIT-33.1 RELIABILITY 343.2 INDICES OF RELIABILITY 343.3 FAILURE RATE 353.4 CALCULATING SYSTEM

RELIABILITY37

3.5 AVAILABILITY AND MAINTAINABILITY CONCEPTS

38

3.5.1 CONCEPT DEVELOPMENT IN MAINTAINABILITY

40

3.5.2 VALIDATION IN MAINATAINABILITY

40

3.5.3 PRODUCTION IN MAINATAINABILITY

40

3.5.4 OPERATION IN MAINATAINABILITY

40

UNIT-44.1 SAFETY AND

PRODUCTIVITY43

4.2 CAUSES OF ACCIDENT IN INDUSTRIES

43

4.3 ACCIDENT REPORTING AND INVESTIGATION

43

4.4 MEASURING SAFETY PERFORMANCE

45

4.5 SAFETY ORGANIZATIONS AND FUNCTIONS

47

4.6 FACTORIES ACT AND RULES

47

UNIT-55.1 SAFETY CODES AND

STANDARDS53

5.2 GENERAL SAFETY CONSIDERATIONS IN MATERIAL HANDLING EQUIPMENTS

56

5.3 MACHINE SHOP MACHINERIES

58

5.4 PRESSURE VESSEL AND PRESSURIZED PIPELINE

60

5.5 WELDING EQUIPMENTS 635.6 PREVENTION AND SPREAD

OF FIRE64

5.6.1 LIQUEFIED PETROLEUM GAS

65

5.6.2 EMPLOYEE TRAINING 665.6.3 FIRE EXTINGUISHERS 67

5.7 EMERGENCY EXIT FACILITIES

67