2. Specific Learning Objective
Maintenance and it’s types
Breakdown maintenance
Preventive Maintenance
Predictive Maintenance
Preventive maintenance Vs Predictive
maintenance
Predictive maintenance in marine vessels
3. What is Maintenance?
The technical meaning of
“maintenance” involves
functional checks,
servicing, repairing or
replacing of necessary
devices, equipment,
machinery and supporting
utilities in industrial and
residential installations.
4. Objectives of Maintenance
Minimize loss of productive time
Minimize repair time & cost
Keep productive assets in working
condition
Minimize accidents
Minimize total maintenance cost
Improve quality of products
5. Types of Maintenance
There are main 3 types of Maintenances:
1. Breakdown maintenance or
reactive maintenance
2. Preventive maintenance or
planned maintenance
3. Predictive maintenance or
condition-based maintenance
6. Breakdown maintenance
It is performed when a machine
part breaks down suddenly.
It becomes a repair work
Since there is no plan for the
machinery maintenance works, to
control the maintenance cost is
not possible in this type of
maintenance.
It is not suitable for marine
vessels
For example, replacing the engine
system lub oil when it is fully
contaminated or degraded
7. Breakdown maintenance
Advantages
Low cost
Less manpower
Disadvantages
Increased cost due to unplanned downtime of equipment
Cost involved with repair or replacement of equipment.
Inefficient use of staff resources.
8. Preventive Maintenance
It is performed regularly on a
machinery as a Planned
Maintenance System (PMS) to
lessen machinery failure
It is performed while the machine
is still working and so avoid
unexpected breakdown of
machinery.
It’s safe but maintenance cost is
very high.
For example, replacing the engine
system lub oil after completion of
running hours according to PMS/
maker’s instruction
9. Preventive Maintenance
There are few basic activities associated with
preventive maintenance:
Inspections: damage, alignment, leaks, cracks, etc.
Servicing: alignment, clearing or replacing filters, and
verifying sensor operation
Lubrication: topping off oils or other fluids and at times
flushing and replacing the fluid
Fastening: Periodical checks for fastening system for
its proper location and alignment.
11. Preventive Maintenance (PM)
Advantages:
Cost effective during the capital investment processes.
Increased component life
Energy savings
Reduces equipment or process failure
Estimated 12% to 18% cost savings over breakdown
maintenance program [2]
Disadvantages:
Catastrophic failures still likely to occur due to lack of
condition monitoring
Labor intensive
Potential for dropping of performance for unneeded
maintenance.
Potential for incidental damage to components
during conducting unneeded maintenance
12. Predictive Maintenance
It’s an advanced scientific technique
to maximize operating time and
minimize unnecessary work.
Conditions of the machinery can be
measured continuously and this
enables the maintenance team to
plan for an overhauling.
In this maintenance lab analysis
method, sensitive instruments and
computerized control system are
used to predict troubles.
For example, replacing the engine
system lub oil on basis of laboratory
analysis report and instructions
13. Predictive Maintenance
It monitors the condition of equipment or systems to
detect/trend the degradation. Techniques include:
1. Vibration monitoring
2. Thermographic inspection
3. Oil analysis
4. Visual inspection
5. Ultrasonic leak detectors
6. Electrical insulation:
A. Megger tests
B. Surge comparison
8. Performance testing
9. Wear and dimensional measurements
10. Nondestructive testing
A. Ultrasonic
B. Borescope inspections
C. Eddy current performance
15. Predictive Maintenance
Advantages
Increased component operational life/availability
Allows for preemptive corrective actions
Decrease in machinery downtime
Decrease in costs for parts and labor
Better product quality
Improved worker and environmental safety
Improved worker morale
Energy savings
Estimated 25% to 30% cost savings over breakdown
maintenance and 8% to 12% over preventive
maintenance
Disadvantages
Increased investment in diagnostic equipment.
Increased investment in staff training.
16. Preventive Maintenance Vs Predictive Maintenance
Preventive maintenance Predictive maintenance
Definition
Preventive maintenance is
performed on a regular,
predetermined schedule
Predictive maintenance is done
only when needed based on real
time conditions of machinery
Trigger Time, meter reading and usage Condition
Investment
Cost
Low Medium/High
Cost Savings 12% to 18% [2] 25% to 30% [2]
Resources
Needed
Maintenance software
Maintenance scheduler
Preventive maintenance
checklists
CMMS
Maintenance scheduler
Condition monitoring software
Condition monitoring tools and
sensors
PdM training
Pros Better than reactive
maintenance or breakdown
maintenance
Relatively easy to implement
Maintenance is performed as
needed
Reduces maximum amount of
downtime
Cons Risk of over-maintaining
Labor intensive (not
performed as needed)
Expensive technology needs
purchased
Time-intensive to implement
correctly
17. Preventive Maintenance Vs Predictive Maintenance
Preventive Maintenance (Time-Based Maintenance)
Basic philosophy
Schedule maintenance activities at predetermined time intervals.
Repair or replace damaged equipment before obvious problems occur.
Cost: $13/hp/yr
Predictive Maintenance (Condition-Based Maintenance)
Basic philosophy
Schedule maintenance activities when mechanical or operational
conditions warrant.
Repair or replace damaged equipment before obvious problems occur.
Cost: $9/hp/yr
Source: Pro-Active Maintenance for Pumps (Piotrowski, 2001)
18. Predictive Maintenance in Marine Vessels
Predictive maintenance is the most modern maintenance system
that should be followed in marine vessels. Because:
1. Preventive maintenance only occurs in accordance with a
program’s schedule. Whereas, predictive maintenance
technologies continuously monitor in-service equipment, and let
crewmembers know when a component needs attention before it
fails. For example,
Maintenance Tasks Preventive Maintenance Predictive Maintenance
Renewing Engine Lub Oil According to running
hours as instructed in
PMS/Maker’s Manual
According to lab analysis
report and instructed in
lab test report.
Overhauling Deck Machinery According to time
duration as instructed in
PMS/ Maker’s Manual
According to CMMS report
/ Condition analysis
Over hauling of Diesel
Generator / Main Engine
According to running
hours as instructed in
PMS/Maker’s Manual
According to CMMS report
/ Condition analysis
19. Predictive Maintenance in Marine Vessels
Additional benefits include:
Knowing what parts to stock in advance
Reduced overhead costs
Energy savings
Overall efficiency improvements
Reduced maintenance and repair costs
Improved productivity
Rate of component failures is very less
20. References
1. Maintenance, P. (n.d.). Preventive and Predictive Maintenance, 1–23.
https://www.lce.com/pdfs/The-PMPdM-Program-124.pdf
2. Types of Maintenance Programs by the Department of Energy, O&M Best
Practices Guide, Release 3.0
https://www1.eere.energy.gov/femp/pdfs/OM_5.pdf
3. https://www.onupkeep.com/learning/maintenance-types/preventive-
predictive
4. https://accendoreliability.com/preventive-maintenance-or-pm-goals-and-
activities/
5. https://www.marineinsight.com/tech/predictive-maintenance-on-board-ships/
6. https://www.fiixsoftware.com/blog/preventive-maintenance-top-priority/
7. Gkerekos, Christos & Lazakis, Iraklis & Theotokatos, Gerasimos. (2017).
Ship machinery condition monitoring using performance data through
supervised learning.
8. Piotrowski, J. April 2, 2001. Pro-Active Maintenance for Pumps, Archives, February
2001, Pump-Zone.com [Report online]. Available URL: http://www.pump-
zone.com. Reprinted with permission of Pump-Zone.com.