maintenance and safety engineering
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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)
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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.
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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
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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
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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
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