30 Questions
What is one benefit of preventive maintenance mentioned in the text?
Prevents major repairs, saving on extensive repair or replacement costs
How does preventive maintenance contribute to operational continuity?
By minimizing downtime and preventing unexpected breakdowns
What does preventive maintenance do for the lifespan of equipment?
Increases the lifespan of equipment
Why is asset management important in the context of maintenance practices?
Optimizes inventory and ensures availability of spare parts for timely repairs
How does preventive maintenance help in enhancing a company's reputation?
Enhances the company’s reputation for reliability and professionalism
Which aspect is improved through preventive maintenance to meet customer expectations?
Output Quality
What is reactive maintenance?
A maintenance strategy where no preventive measures are taken
Which of the following is an example of reactive maintenance?
Replacing a light bulb after it burns out
What is a potential advantage of reactive maintenance?
Perceived cost-effectiveness in the short term
Which of the following is a disadvantage of reactive maintenance?
Increased equipment downtime
What is a potential consequence of reactive maintenance?
Tight labor budgets due to overtime for urgent repairs
Which of the following is NOT a characteristic of reactive maintenance?
Maintenance activities are planned and scheduled
What is the basic philosophy of Reliability-Centered Maintenance (RCM)?
Measuring the beginning of system degradation and the present and future functional capability of components
How does Reliability-Centered Maintenance (RCM) differ from preventive maintenance?
RCM uses real-time data instead of predetermined schedules
What are the benefits of Reliability-Centered Maintenance (RCM)?
Lowers costs by eliminating unnecessary maintenance or overhauls
How does Reliability-Centered Maintenance (RCM) utilize data from the equipment?
RCM uses data to map out possible machine breakdowns and identify maintenance needs in a timely manner
What is the main purpose of the Reliability-Centered Maintenance (RCM) strategy?
To maximize the use of limited human and financial resources
How does Reliability-Centered Maintenance (RCM) approach maintenance issues?
RCM utilizes predictive and preventive maintenance techniques, incorporating root cause failure analysis
What does SIS stand for?
Safety Instrumented System
Which organization developed the IEC 61511 standard for Safety Instrumented Systems?
International Electrotechnical Commission (IEC)
What is the purpose of Safety Integrity Level (SIL)?
To measure the performance of a Safety Instrumented System when a demand is made
What is the relationship between a Safety Instrumented System (SIS) and Safety Instrumented Functions (SIFs)?
A SIS is a collection of multiple SIFs, each addressing a specific safety requirement
Which of the following is NOT an example of a Safety Instrumented System (SIS) mentioned in the text?
Distributed Control Systems (DCS)
What is the primary purpose of Safety Instrumented Systems (SIS) as opposed to Basic Process Control Systems (BPCS)?
To perform flawlessly when a safety demand arises
What is the primary function of the solenoid valve when de-energized?
To block air pressure from the I/P and vent air pressure from the actuating diaphragm
What is the purpose of the Support System?
To provide necessary utilities for the system to operate
Which layer utilizes an Instrument Protected Function (IPF)?
Process Alarms and Interlock System
What is an example of a Passive Protection Layer?
Fire Walls
What is the function of a Rapture Disc?
To protect a pressure vessel, equipment, or system from over-pressurization
What is an example of a Final Control Element?
Control Valve
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
Learn about reactive maintenance, a strategy where equipment is only repaired when it shows signs of failure. Explore examples such as replacing a light bulb and repair work when machinery breaks down.
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