Reactive Maintenance

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Questions and Answers

What is one benefit of preventive maintenance mentioned in the text?

  • Raises energy costs
  • Leads to unexpected breakdowns
  • Prevents major repairs, saving on extensive repair or replacement costs (correct)
  • Increases the need for frequent replacements

How does preventive maintenance contribute to operational continuity?

  • By lowering energy costs
  • By increasing downtime and causing unexpected breakdowns
  • By avoiding asset management
  • By minimizing downtime and preventing unexpected breakdowns (correct)

What does preventive maintenance do for the lifespan of equipment?

  • Increases the lifespan of equipment (correct)
  • Raises energy costs
  • Reduces the lifespan of equipment
  • Improves output quality

Why is asset management important in the context of maintenance practices?

<p>Optimizes inventory and ensures availability of spare parts for timely repairs (C)</p> Signup and view all the answers

How does preventive maintenance help in enhancing a company's reputation?

<p>Enhances the company’s reputation for reliability and professionalism (D)</p> Signup and view all the answers

Which aspect is improved through preventive maintenance to meet customer expectations?

<p>Output Quality (C)</p> Signup and view all the answers

What is reactive maintenance?

<p>A maintenance strategy where no preventive measures are taken (B)</p> Signup and view all the answers

Which of the following is an example of reactive maintenance?

<p>Replacing a light bulb after it burns out (B)</p> Signup and view all the answers

What is a potential advantage of reactive maintenance?

<p>Perceived cost-effectiveness in the short term (C)</p> Signup and view all the answers

Which of the following is a disadvantage of reactive maintenance?

<p>Increased equipment downtime (A)</p> Signup and view all the answers

What is a potential consequence of reactive maintenance?

<p>Tight labor budgets due to overtime for urgent repairs (C)</p> Signup and view all the answers

Which of the following is NOT a characteristic of reactive maintenance?

<p>Maintenance activities are planned and scheduled (B)</p> Signup and view all the answers

What is the basic philosophy of Reliability-Centered Maintenance (RCM)?

<p>Measuring the beginning of system degradation and the present and future functional capability of components (B)</p> Signup and view all the answers

How does Reliability-Centered Maintenance (RCM) differ from preventive maintenance?

<p>RCM uses real-time data instead of predetermined schedules (A)</p> Signup and view all the answers

What are the benefits of Reliability-Centered Maintenance (RCM)?

<p>Lowers costs by eliminating unnecessary maintenance or overhauls (B)</p> Signup and view all the answers

How does Reliability-Centered Maintenance (RCM) utilize data from the equipment?

<p>RCM uses data to map out possible machine breakdowns and identify maintenance needs in a timely manner (C)</p> Signup and view all the answers

What is the main purpose of the Reliability-Centered Maintenance (RCM) strategy?

<p>To maximize the use of limited human and financial resources (B)</p> Signup and view all the answers

How does Reliability-Centered Maintenance (RCM) approach maintenance issues?

<p>RCM utilizes predictive and preventive maintenance techniques, incorporating root cause failure analysis (B)</p> Signup and view all the answers

What does SIS stand for?

<p>Safety Instrumented System (C)</p> Signup and view all the answers

Which organization developed the IEC 61511 standard for Safety Instrumented Systems?

<p>International Electrotechnical Commission (IEC) (D)</p> Signup and view all the answers

What is the purpose of Safety Integrity Level (SIL)?

<p>To measure the performance of a Safety Instrumented System when a demand is made (B)</p> Signup and view all the answers

What is the relationship between a Safety Instrumented System (SIS) and Safety Instrumented Functions (SIFs)?

<p>A SIS is a collection of multiple SIFs, each addressing a specific safety requirement (D)</p> Signup and view all the answers

Which of the following is NOT an example of a Safety Instrumented System (SIS) mentioned in the text?

<p>Distributed Control Systems (DCS) (D)</p> Signup and view all the answers

What is the primary purpose of Safety Instrumented Systems (SIS) as opposed to Basic Process Control Systems (BPCS)?

<p>To perform flawlessly when a safety demand arises (A)</p> Signup and view all the answers

What is the primary function of the solenoid valve when de-energized?

<p>To block air pressure from the I/P and vent air pressure from the actuating diaphragm (A)</p> Signup and view all the answers

What is the purpose of the Support System?

<p>To provide necessary utilities for the system to operate (A)</p> Signup and view all the answers

Which layer utilizes an Instrument Protected Function (IPF)?

<p>Process Alarms and Interlock System (D)</p> Signup and view all the answers

What is an example of a Passive Protection Layer?

<p>Fire Walls (C)</p> Signup and view all the answers

What is the function of a Rapture Disc?

<p>To protect a pressure vessel, equipment, or system from over-pressurization (B)</p> Signup and view all the answers

What is an example of a Final Control Element?

<p>Control Valve (B)</p> Signup and view all the answers

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Study Notes

Safety Instrumented Systems (SIS)

  • SIS examples include Critical Control Systems, Safety Shutdown Systems, Instrument Protective Function (IPF), Equipment Protection Systems, and Emergency Shutdown Systems (ESD)

International Standards for SIS

  • IEC 61508: applicable for manufacturers of devices used in Safety Instrumented Systems (SIS)
  • IEC 61511: "Functional Safety: Safety Instrumented Systems for the Process Industry Sector"
  • ISA 84.01-2004: identical to IEC 61511, "Functional Safety: Safety Instrumented Systems for the Process Industry Sector"

Classification of SIS

  • SIS are classified according to their applicable Safety Integrity Level (SIL)
  • SIL is a measure of the performance of a Safety System under demand

Maintenance Strategies

Preventive Maintenance

  • Benefits: cost savings, operational continuity, extended lifecycle, optimized performance, energy cost savings, safety, and compliance
  • Example: conveyor belt maintenance in a manufacturing setting

Predictive Maintenance (RCM)

  • Measures the beginning of system degradation and predicts future functional capability
  • Uses real-time data to map out possible machine breakdowns and identify maintenance needs
  • Benefits: efficiency, cost reduction, minimized overhauls, and prevention of sudden failures

Reactive Maintenance

  • No preventive measures are taken to keep equipment operating as intended by its design
  • Maintenance is only done when equipment shows indications of failure
  • Advantages: cost-effective in the short term, reduction in upfront maintenance expenses
  • Disadvantages: increased downtime costs, higher labor costs, and overtime

Safety Instrumented Functions (SIF)

  • Can be implemented using several SIF depending on the safety requirement
  • Examples: pressure relief valve, pressure/vacuum valve, and rapture disc

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