The document defines maintenance and discusses types of maintenance programs. It outlines key elements of a maintainability program plan including interfaces between maintainability and other project organizations. Various maintenance system procedures are described for equipment like boilers, turbines, generators and switchgear. Maintainability analysis tools including FFBDs, timelines, FMECAs, and models are also summarized. The conclusion states that early maintainability planning can lower risks and costs.

1. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
MAINTENANCE
MANAGEMENT
Maintenance Definition Report
Compiled by
Randall Lavelot

2. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
INTRODUCTION
Scope
 Purpose
 Applicability
Definitions of Maintenance
Types of Maintenance Programmes
Maintenance System and Procedure
Elements of the Maintainability Program Plan
Key Phases and Tasks in a System Life Cycle
Maintainability Analysis Tools and Techniques
CONCLUSION
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3. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
Scope
Purpose
 The objective of this group assignment is to apply SE
principles and theory in resolving complex plant
performance problems by:
Thoroughly studying the outcomes and study content of
Seminar 1;
Locating relevant quality learning material, and studying
such, and;
Completing the assignments of Seminar 1.
Applicability
System engineering assignment is applicable to plant
equipment at the power station at Eskom.
Introduction
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4. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
Maintenance is a combination of any actions carried out
to retain an item in, or restore it to, an acceptable
condition1
.
The dictionary defines maintenance as follows: “the
work of keeping something in proper condition;
upkeep.”
All activities required to retain an item in, or restore it
to an acceptable condition, including the investigation
and evaluation of the actual condition.
No maintenance describes a system which retains
proper functionality over long periods of time despite
no maintenance. It is a system that is self-sufficient and
does not require much attention.
Definitions of Maintenance
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5. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
1. Preventative Maintenance
Maintenance carried out at predetermined intervals, or to
any other prescribed criteria, and intended to reduce the
likelihood of and item not meeting an acceptable
condition.
2. Reliability Centred Maintenance
Is a maintenance concept, recognising hidden failures,
safety, operational and non-consequences.
Types of Maintenance
Programmes
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6. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
3. Predictive Maintenance
It is the measurements that detect the onset of system
degradation (lower functional state), thereby allowing
causal stressors to be eliminated or controlled prior to any
significant deterioration in the component physical state.
4. Reactive Maintenance
Reactive maintenance is basically the “run it till it breaks”
maintenance mode.
Types of Maintenance
Programmes
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7. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
1. Boiler Maintenance
This might include a procedure to perform all statutory
tests and inspections performed according to the OSH
act. (i.e. Boiler Pressure Test – 72 months).
2. Turbine Maintenance
This might include a procedure to perform all statutory
tests and inspections will be scheduled and performed
during unit outages on a predetermined frequency. All
compulsory tests (i.e. over speed trip test etc.) performed
timeously as per OHS Act.
Maintenance System and
Procedure
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8. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
3. Generator Maintenance
This might include a procedure to perform daily
monitoring on:
Generator stator cooling water. (Temp and
conductivity).
Stator winding temp. (Individual status bar temp).
4. Switchgear Maintenance
This might include a procedure to perform daily
monitoring on:
Cooling water temperature
Cooling water flow
Maintenance System and
Procedure
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9. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
5. Transformer Maintenance
This might include a procedure to perform monitoring
timeously on:
Dissolved gas analyses (six (6) monthly)
Water content (six (6) monthly)
6. Motor Maintenance
This might include a procedure to perform monitoring
timeously on:
Insulation resistance
Polarisation index
Maintenance System and
Procedure
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10. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
Interfaces between maintainability and other project
organizations, such as design engineering, software,
reliability, safety, maintenance, and logistics.
Identification of each maintainability task, narrative
task descriptions, schedules, and supporting
documentation of plans for task execution and
management
Description of the nature and extent that the
maintainability function participates in formal and
informal design reviews, and authority of
maintainability personnel in approval cycle for drawing
release.
Elements of the Maintainability
Program Plan 2
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11. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
Key Phases and Tasks in a System
Life Cycle 3
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12. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
1. Maintenance Functional Flow Block
Diagrams (FFBDs)
At the top level, maintenance FFBDs supplement and
clarify the system maintenance concept; at lower levels,
they provide a basis for the logistics support analysis
(LSA's) maintenance task inventory.
2. Maintenance Time Lines
Maintenance time line analysis is performed when time-
to-restore is considered a critical factor for mission
effectiveness and/or safety.
Maintainability Analysis Tools
and Techniques 4
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13. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
3. FMECAs and FMEAs
Failure Modes, Effects, and Criticality Analysis (FMECA)
and Failure Modes and Effects Analysis (FMEA) are
specialized techniques for hardware failure and safety risk
identification and characterization.
4. Maintainability Models
Maintainability models are used in assessing how well
alternative designs meet maintainability requirements,
and in quantifying the maintenance resource
requirements.
Maintainability Analysis Tools
and Techniques 4
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14. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
5. Problem/Failure Reports (P/ FRs)
The maintainability engineer uses the Problem/Failure
Reporting System (or an approved equivalent) to report
maintainability problems and non-conformances
encountered during qualification and acceptance testing
(Phase D) and operations (Phase E).
Maintainability Analysis Tools
and Techniques 4
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15. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
In conclusion, early and effective planning and
implementation of a maintainability program can
significantly lower the risk of reduced system operational
effectiveness resulting from maintainability design
shortfalls. This reduces maintenance time/support, which
directly relates to reduced operating costs and increased
system operational time.
Conclusion
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16. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
1. British Standards Institution (1985), Code of Practice for maintenance of electrical
switchgear and control gear, BS6626, Section 2.9, UK.
2. NASA (2004), Maintainability Program Management Considerations, USA.
Available at:
http://engineer.jpl.nasa.gov/practices/pm2.pdf
[Accessed 9 February 2012].
3. International Council on Systems Engineering (2004), A Consensus of the INCOSE Fellows, USA.
Available at:
http://www.incose.org/practice/fellowsconsensus.aspx
[Accessed 9 February 2012].
4. NASA (1995), System Engineering Handbook, USA.
Available at:
http://snebulos.mit.edu/projects/reference/NASA-Generic/NASA-STD-8739-8.pdf
[Accessed 9 February 2012].
Study Reference
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17. CENTRE FOR RESEARCH AND CONTINUED ENGINEERING DEVELOPMENT (CRCED - VAAL)
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