Maintenance of Plant

Plant maintenance is the process of keeping the plant operational at regular or fixed time intervals, or as necessary, to ensure long-term, fault-free operation. Maintenance is essentially a function that ensures the plant runs properly and allows various equipment and machinery to be controlled according to practical guidelines (Operating manual).

Therefore, the overall management of the plant—including machinery, equipment, buildings, and other infrastructure—is aimed at reducing deterioration and ensuring the optimal use of resources. In other words, plant maintenance encompasses regular or scheduled upkeep, and developmental activities as needed, to maintain machinery, equipment, buildings, and other infrastructure.

Proper maintenance is a prerequisite for efficient operation and high production in any industrial or power plant. Thus, plant maintenance is a critical aspect of any industrial establishment and is scientifically classified according to maintenance needs.

Types of Maintenance

The classification of maintenance processes for smooth plant or machinery operation is as follows:

1. Preventive Maintenance

• Inspection:

• Daily (Routine)
• Weekly

• Light repairs
• Medium repair

1. Periodical Maintenance

• Monthly
• Quarterly
• Annually

1. Breakdown Maintenance

Purpose of Plant Maintenance

Plant maintenance activities serve as precautionary measures to ensure the plant operates at optimum efficiency. The purposes of plant maintenance are as follows:

1. To produce and supply electricity according to demand schedules.
2. To maintain the voltage of the output.
3. To maintain all plant machinery at maximum efficiency.
4. To increase the plant’s production capacity.
5. To prolong the useful life of plant machinery and equipment.
6. To reduce the overall cost of plant operation through proper maintenance.
7. To minimize downtime for repairs of plant and machinery.
8. To facilitate the installation of new machines and units as needed.
9. Above all, to provide early warning forecasts to prevent major accidents or waste.

Maintenance Efficiency

Maintenance activities are crucial to ensuring the proper functioning of all plant machinery. Regular, time-based maintenance, along with repairs, helps keep the plant operational. Maintenance efficiency depends on the plant’s developmental activities.

Maintenance efficiency refers to the rate at which a plant, machine, or other assets can operate effectively when properly maintained. It is the ratio of the work done by the plant or machine in a running or new condition before maintenance to the work done after maintenance.

• Maintenance Efficiency = (Work done due to maintenance of plant / Work done in new condition) × 100

Proper techniques must be adopted to achieve high maintenance efficiency. The currently recognized steps to achieve effective maintenance skills are as follows:

1. Identifying the actual problem.
2. Analyzing the problem.
3. Exploring alternatives to address the problem.
4. Making optimal decisions.
5. Implementing the chosen solution.
6. Performing maintenance based on the decision.
7. Reviewing the maintenance work.

Preventive Maintenance

Preventive maintenance is the process of keeping a plant or machine in working order by adjusting and cleaning all its parts before an accident occurs or they become unusable. This is typically a daily (routine) task. Proper preventive maintenance can extend the life of a plant or machine by three to four times, ensuring safe operation and full efficiency. Preventive maintenance involves regular inspection and timely adjustments, cleaning, and repairs to preserve plant assets and equipment.

Preventive maintenance activities include regular inspection and cleaning, servicing (e.g., changing lube oil, providing water, fuel, gear oil, and grease), and repairing or replacing worn or broken parts.

Importance of Preventive Maintenance

Preventive maintenance while the plant is operational can prevent major damage and extend its lifespan. The benefits of serious preventive maintenance include:

1. Prolonged plant operation with minimal downtime, which increases production, profit, and customer satisfaction.
2. Reduced maintenance costs through timely repairs.
3. Fewer instances requiring a total overhaul, resulting in lower manpower and resource requirements.
4. Increased plant longevity, which lowers depreciation costs.
5. Reduced need for emergency substitute units, lowering capital costs.
6. Decreased stock of spare parts, reducing inventory costs.
7. Easier plant operation and lower operating costs.
8. Fewer layoffs due to consistent operation, improving relations between management and workers.
9. Enhanced safety for workers and the plant, resulting in lower compensation and insurance costs.
10. Overall, a reduction in production costs per unit.