2A1 Chapter 6 Plant Maintenance

2nd Class Power Engineering

What is the definition of maintenance?

The combination of all technical and administrative actions intended to retain an item in, or restore it to, a state in which it can perform a required function.

What are the major aspects of managing maintenance activities?

Management of maintenance, maintenance program development, planning, scheduling, performing maintenance, assessment, and improvement.

What are the two main approaches to maintenance?

Preventive maintenance and corrective maintenance.

What does preventive maintenance aim to do?

To retain equipment in a functioning state by performing regular maintenance tasks.

What is the goal of corrective maintenance?

To restore equipment to a functioning state after a failure has occurred.

What tools are used for scheduling major maintenance activities?

Gantt charts, PERT charts, and the critical path method.

What is the role of maintenance planners?

To develop maintenance programs, identify preventive maintenance tasks, and plan resources needed for maintenance.

What is involved in maintenance execution?

Obtaining resources, following safety procedures, repairing equipment, and documenting work done.

What is maintenance assessment?

The process of evaluating the success of maintenance actions and measuring performance indicators.

What is the purpose of maintenance improvement?

To incorporate changes and enhancements in equipment, procedures, and maintenance tasks.

How does reliability relate to maintenance?

Reliability is achieved when equipment is designed for operating conditions, operated within limits, and properly maintained.

What is Total Productive Maintenance (TPM)?

A formal approach to maintenance management that focuses on proactive and preventive maintenance.

What are the responsibilities of supervisors in maintenance management?

Developing maintenance strategies, managing budgets, and providing resources for maintenance.

What is the significance of maintenance program development?

It involves identifying preventive maintenance tasks and determining necessary support resources.

What is the continuous improvement loop in maintenance?

A process that incorporates changes and improvements in equipment and procedures based on maintenance assessments.

What factors are important for measuring the success of a maintenance program?

Reliability, availability, product quality, production capacity, and cost.

What does maintenance planning and scheduling involve?

Planning resources and scheduling maintenance tasks within available limits.

What is the role of maintenance staff during maintenance execution?

To carry out the maintenance tasks, including repairs and documentation.

What is the importance of documenting maintenance work?

To keep records of actions taken, resources used, and to assess the effectiveness of maintenance.

What are maintenance performance indicators?

Metrics used to measure the effectiveness and efficiency of maintenance actions.

What does maintenance enhancement include?

Improvements to maintenance tasks, procedures, and program development.

What is the role of computerized systems in maintenance management?

To manage maintenance activities efficiently, including work order systems.

What types of equipment monitoring methods are mentioned?

Log sheets and trending.

What is the purpose of a plant budget in maintenance?

To control maintenance costs and allocate financial resources effectively.

What is the relationship between maintenance and operational reliability?

Effective maintenance is essential for ensuring that equipment operates reliably within its designed capabilities.

What is the first step in preparing for a pressure vessel inspection?

Planning and scheduling the inspection activities.

What is the significance of safety and environmental procedures in maintenance?

To ensure the safety of personnel and compliance with environmental regulations during maintenance activities.

What is the overall goal of maintenance management?

To ensure that equipment operates efficiently and effectively while minimizing downtime and costs.

What are the two major categories of maintenance?

Preventive Maintenance and Corrective Maintenance.

Define Preventive Maintenance.

Maintenance carried out at predetermined intervals to reduce the probability of failure.

Define Corrective Maintenance.

Maintenance carried out after fault recognition to restore an item to a functional state.

What is Condition Monitoring?

A type of maintenance aimed at predicting failures by monitoring equipment condition.

What are the three types of Preventive Maintenance?

Condition monitoring and inspection, functional testing, and interval-based repair or replacement.

What is Functional Testing?

A method aimed at finding hidden failures that do not become evident until a function is activated.

What is Interval-Based Maintenance?

Regular repair or replacement of components after a specified interval, regardless of equipment condition.

What is the purpose of Corrective Maintenance?

To address failures after they occur, prioritizing based on the impact on production.

What is the first step in the planning and scheduling process for maintenance?

Initiating the work by raising a work request.

What triggers a work request for Preventive Maintenance?

It is often triggered automatically by a computer system.

What is the benefit of effective planning and scheduling in maintenance?

It reduces downtime, maintenance costs, and improves resource utilization.

What is the impact of corrective maintenance on production?

It can lead to delays and increased costs if not managed properly.

What is the role of condition monitoring in maintenance?

To determine the most efficient time to perform maintenance just before failure.

What is the significance of hidden failures?

They can lead to catastrophic results if not identified before the function is required.

What is emergency maintenance?

Corrective maintenance that must be done immediately after a failure occurs.

What are the benefits of preventive maintenance?

Reduces the probability of failure and enhances the reliability of equipment.

What is the difference between reactive and proactive maintenance?

Reactive maintenance occurs after failures, while proactive maintenance aims to prevent failures.

What is the goal of a good maintenance program?

To prevent most major failures and minimize costs associated with maintenance.

What factors can trigger interval-based maintenance?

Elapsed time, running hours, number of operating cycles, or other relevant factors.

What is the importance of regulatory compliance in maintenance?

It ensures that maintenance activities meet legal and safety standards.

What is the role of personnel safety in maintenance planning?

To ensure that maintenance activities do not pose risks to workers.

What is the impact of maintenance on environmental compliance?

Effective maintenance can reduce environmental impact associated with operations.

What is the significance of measuring maintenance performance?

It helps in assessing the effectiveness of maintenance strategies and improving them.

What is the difference between planned and unplanned maintenance?

Planned maintenance is scheduled in advance, while unplanned maintenance occurs due to unexpected failures.

What is the purpose of screening work requests?

To ensure that only necessary and approved tasks move to the planning stage.

What is the role of maintenance costs in planning?

To evaluate and optimize the budget allocated for maintenance activities.

How can maintenance activities impact production schedules?

Poorly managed maintenance can lead to delays and disruptions in production.

What is the first step in maintenance planning?

Identifying required resources.

What does the scheduling step in maintenance involve?

Deciding the most appropriate time for the work to be carried out.

What is a work order?

A document that turns a work request into actionable tasks.

List some tasks involved in acquiring resources for maintenance.

Obtaining parts, reserving tools, identifying personnel, and transporting resources.

What does finalizing maintenance work include?

Documenting results and returning tools and unused materials to inventory.

What is the backlog in maintenance?

The total amount of work yet to be completed.

What is the average duration of a maintenance backlog?

About three weeks of work.

What are the two types of maintenance activities mentioned?

Preventive maintenance and corrective maintenance.

What is involved in the planning stage of maintenance?

Identifying tasks, required resources, and safety procedures.

What is the purpose of scheduling in maintenance?

To accomplish tasks efficiently within existing constraints.

What factors influence the scheduling of maintenance tasks?

Task urgency, equipment shutdown timing, and availability of resources.

What is a major maintenance shutdown?

A significant event requiring intensive planning and scheduling for multiple tasks.

What is the critical path in scheduling?

The sequence of tasks that determines the minimum project duration.

What is the first step in the scheduling process?

Identify all required tasks.

What does 'early start' refer to in scheduling?

The earliest time that a task can begin.

What is 'slack' in the context of scheduling?

The amount of time a task can be delayed without affecting overall completion.

What is the significance of estimating task duration?

It helps in planning and scheduling tasks effectively.

What is meant by 'dependencies between tasks'?

The relationships that dictate the order in which tasks must be completed.

What role do external contractors play in maintenance?

They provide specialized services and support for maintenance tasks.

What is involved in managing the maintenance backlog?

Adjusting priorities and resources in response to new tasks and changes.

Why is it important to document maintenance results?

To track progress and ensure accountability for completed tasks.

What is the purpose of applying resource constraints in scheduling?

To ensure that the scheduling process is realistic and achievable.

What are some common types of specialized tools needed for maintenance?

Lifting equipment, safety gear, and specific maintenance tools.

What is a major function of the planning process in maintenance?

To manage the backlog and ensure timely completion of tasks.

What happens if the maintenance backlog becomes too large?

It indicates insufficient resources and potential delays in required work.

What is the significance of safety procedures in maintenance?

To ensure the safety of personnel and compliance with regulations.

What is the role of financial account codes in maintenance?

To track costs associated with maintenance tasks.

What is the purpose of determining task dependencies in scheduling?

To understand the relationships between tasks and optimize the scheduling process.

What does 'parallel' dependency mean in task scheduling?

Two tasks are independent and can be completed simultaneously if resources are available.

What is 'finish to start' dependency?

Task C cannot start until Task B has been completed.

What does 'start to start with delay' mean?

Task B cannot start until after a delay following the start of Task A.

What is a PERT chart?

A Program Evaluation and Review Technique chart used to organize tasks into a schedule.

What are the steps to calculate early start and finish times in a PERT chart?

1. Set early start time to 0 for the first set of tasks. 2. Add duration to early start to get early finish.

How is late finish time determined in a PERT chart?

By adding the longest duration of parallel tasks to the early start time.

What is slack time in task scheduling?

The amount of time that a task can be delayed without affecting the overall project timeline.

What is a Gantt chart?

A timeline-based chart that visually represents the schedule of tasks in a project.

Who developed the Gantt chart concept?

Henry Gantt, in the early 1900s.

What is the critical path in project management?

The sequence of tasks that determines the minimum completion time for a project.

What happens if a task on the critical path takes longer than planned?

The overall project completion time will increase.

What types of tasks should be considered for a pressure vessel inspection?

Preparation, safety requirements, inspection, and completion tasks.

What is included in the preparation tasks for a pressure vessel inspection?

Obtaining special tools, picking up spare parts, and traveling to the inspection location.

What safety requirements must be met before a pressure vessel inspection?

Obtaining a work permit, isolating and depressurizing the vessel, and performing a safety check.

What does the actual inspection of a pressure vessel involve?

A visual inspection, ultrasonic inspection of wall thickness, and replacement of the relief valve.

What are the completion tasks after a pressure vessel inspection?

Returning the vessel to service, documenting results, and traveling back to the maintenance shop.

What skills are required for a pressure vessel inspection?

An operator, a technician for ultrasonic inspection, and a maintenance worker for valve replacement.