Module 9 – Equipment Maintenance & Reliability

Objective:
By the end of this module, a trainee will be able to:

1. Understand the role of maintenance in safe and reliable plant operation.

2. Recognize different types of maintenance: preventive, predictive, and corrective.

3. Perform routine equipment inspections and basic maintenance tasks conceptually.

4. Understand lubrication, cleaning, and reliability principles.

5. Identify early signs of equipment wear or failure.

9.1 – Introduction to Maintenance & Reliability

Definition:

• Maintenance = activities to keep equipment in optimal working condition.

• Reliability = ability of equipment to perform required function consistently.

Importance:

• Prevents unplanned shutdowns, safety incidents, and production loss.

• Extends equipment life and efficiency.

• Supports safe and stable operations.

Analogy:

• Maintenance = “regular car servicing to prevent breakdowns”

• Reliability = “knowing your car will start and run smoothly every day”

9.2 – Types of Maintenance

1. Preventive Maintenance (PM):

   • Scheduled checks and service to prevent failure.

   • Examples: lubrication, filter/strainer cleaning, valve inspection.

   • Operator Role: follow routine checklist and log actions.

2. Predictive Maintenance (PdM):

   • Condition-based maintenance using data: vibration analysis, temperature, pressure trends.

   • Helps identify early signs of wear or malfunction.

3. Corrective Maintenance (CM):

   • Performed after equipment fails or malfunctions.

   • Requires troubleshooting, repair, or replacement.

Analogy:

• Preventive = “change oil every 5,000 km”

• Predictive = “monitor engine vibration to detect bearing wear”

• Corrective = “replace engine after breakdown”

9.3 – Routine Operator Checks

Purpose:

• Detect abnormalities early to prevent failure.

Typical Checks:

1. Pumps & Compressors: vibration, noise, seal/leakage, bearing temperature

2. Valves: operation, leakage, actuator function

3. Strainers & Filters: check cleanliness, differential pressure

4. Heat Exchangers & Coolers: pressure drop, temperature difference

5. Instrumentation: check calibration, responsiveness

Operator Tips:

• Perform checks according to daily, weekly, or monthly schedule.

• Record findings in logbook or digital maintenance system.

• Report anomalies to maintenance or supervisor.

Analogy:

• Routine check = “checking your tires, brakes, and lights before a long trip”

9.4 – Lubrication & Cleaning

Lubrication:

• Reduces friction, wear, and overheating in moving parts (pumps, compressors, motors).

• Operator Role:

  • Verify lubrication level

  • Use correct type of lubricant (per SOP)

  • Log lubrication activity

Cleaning:

• Ensures efficient heat transfer and fluid flow.

• Examples: heat exchanger surfaces, strainers, filters, piping.

• Operator Role: follow cleaning schedule and safety procedures

Analogy:

• Lubrication = “oiling bicycle chain”

• Cleaning = “descaling coffee machine for proper function”

9.5 – Reliability Concepts for Operators

Definition:

• Reliability = equipment’s ability to function without unexpected failure.

Operator Contribution:

1. Perform routine checks consistently.

2. Respond to alarms and abnormal conditions promptly.

3. Record observations accurately for maintenance planning.

4. Support preventive and predictive maintenance initiatives.

Common Reliability Indicators:

• Vibration levels

• Bearing temperature

• Pressure and flow stability

• Leak occurrence

Analogy:

• Reliable equipment = “trustworthy tool that works every time you need it”

9.6 – Early Warning Signs of Equipment Issues

• Pump

Noise, vibration, reduced flow

Check suction, strainer, standby pump

• Compressor

Overheating, pressure drop, unusual sound

Verify inlet/outlet valves, cooling, notify maintenance

• Heat Exchanger

Pressure drop, poor heat transfer

Schedule cleaning, monitor temperature difference

• Valves

Leakage, actuator malfunction

Test operation, tag for maintenance

• Electrical Motors

Excessive heat, tripping

Check alignment, load, lubrication, notify maintenance

Operator Tips:

• Early detection prevents costly downtime.

• Record abnormal signs immediately.

• Escalate critical issues to supervisor.

9.7 – Operator Involvement in Maintenance

Responsibilities:

1. Conduct daily/weekly routine checks.

2. Lubricate and clean equipment per SOP.

3. Log observations in maintenance or digital system.

4. Assist maintenance team with safe isolation or shutdown for service.

5. Participate in continuous improvement and reliability initiatives.

Analogy:

• Operator = “first line of defense” for equipment reliability

9.8 – Quiz / Knowledge Check

1. Name three types of maintenance and their purpose.

2. List three routine checks an operator should perform.

3. Why is lubrication important for moving equipment?

4. What are two early warning signs of pump failure?

5. How does operator action contribute to equipment reliability?

6. Give an analogy for preventive maintenance.

9.9 – Media Sites Integration

• Videos:

  • Routine equipment inspection walkthrough

  • Lubrication and filter cleaning demonstration (conceptual)

  • Trend-based predictive maintenance overview

• Diagrams / Infographics:

  • Equipment checklists

  • Reliability bathtub curve

  • Maintenance schedule example

• PDF Downloads:

  • Operator routine check template

  • Lubrication log sheet

  • Preventive maintenance guide

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect abnormal equipment signs and suggest actions

9.10 – Summary & Key Takeaways

1. Maintenance ensures safe, efficient, and reliable plant operation.

2. Operators support preventive, predictive, and corrective maintenance.

3. Routine inspections, lubrication, and cleaning are key operator responsibilities.

4. Early detection of abnormal signs prevents downtime and equipment failure.

5. Accurate logging and communication enhance overall reliability.