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* ?What is main purpose of Asset management and reliability .1

a. Reduce the energy consumption.

b. Make business more sustainable by increasing the reliability of the assets.

c. Improve the value of the business model using better cost model by producing
more for less.

d. Reliability improve the OEE by reducing failure rates while asset management is a
more holistic model to manage the physical assets.

* The compressed air systems are usually in utilities department, the most .2
:common maintenance strategy applied is

a. Proactive maintenance.

b. Preventative maintenance with some CM.

c. Pure run to fail.

d. CBM is the most common.

* One of the main steps in reliability analysis process is understanding the .3

operational context of your system. For a compressed air system (CAS) which
:one of them should be the operational context

a. CAS should be able to deliver air 24/7 365 days.

b. CAS should be able to deliver compressed air with the correct pressure and flow.

c. CAS should be able to deliver compressed air with the correct pressure and flow
with correct quality of pressure due point.

d. CAS should be able to deliver compressed air with the correct pressure and flow
with correct quality of pressure due point and acceptable power consumption.

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* :The main purpose of compressed air in every plant is .4

a. Because it is safe, abundant, free.

b. It is a medium to transfer work energy (joules) which is represented by high

pressure.

c. It is a form of power that is considered cheap.

d. It is the best cooling medium that can travel in pipes.

* ?What is the function of the dryer in the compressed air system .5

a. It will maintain quality of the compressed air by drying it from humidity.

b. A dryer will maintain constant levels of humidity in compressed air.

c. It will maintain a pre-selected pressure due point based on the production process.

d. A dryer will cool the air down to 3 C and thus make more at usable temperature and
also dry.

* What are the main properties that all successful asset management and .6
?reliability programs have in common

a. Planned, organized and have a proper reporting system.

b. Based in culture change ACR and FMECA.

c. MOC and FEMCA and BPR is the most common factors of all successful programs.

d. Successful programs are systematic, sustainable, and deliver economical value.

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* ?What is the purpose of calculating the Overall machine criticality OMC .7

a. Its main purpose; is to be able to define the failure impact better.

b. Its main purpose; is to be able to define the relation between failure impact and the
machine criticality along with the rate of failure mode occurrence.

c. Its main purpose; is to implement the maintenance strategy on the correct assets
as per need.

d. Its main purpose; it a systematic process that relates failure rate to machines.

* What are the steps/ components of building a proper asset management .8

?strategy

a. Start with a Business process review and align with the asset criticality ranking,
while reviewing the failure history and use it to built a proper failure analysis
techniques.

b. It is built as a strategy to manage your facility in order to align the business

objectives with the floor of the planet.

c. There are simple steps based on standards Plan Act and assess.

d. The steps are using risk base analysis while utilizing management of change to
align management business objectives with assets criticality and failure analysis
while preforming a sustainable reliability data analysis with a conception
understanding of the production process.

* What all failed reliability and asset management programs have in .9

?common

a. Lack of understanding of assets and their failure modes.

b. A poor condition monitoring program.

c. Lack of leader ship and change management.

d. Lack of financial support.

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* Reliability block diagrams are on of the common way to analyze the .10
reliability of complex production systems. If we want to perform this type of
  ?analysis on the system below. What is the total Reliability of the system

a. R= 0.3

b. R=0.99

c. R=0.95

d. R=0.9

* The OEE is the calculated based in Availability and speed factor and quality .11
rate. So the if the availability= 0.85 and the ration between ideal time and
production time is 0.78 and the quality of the system rate is 0.95, what is the
?.OEE approx

a. 63%

b. 75%

c. 85%

d. 90%

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* Now let’s take it to the next level, if we assume that the product, we are .12
producing is cans of soft drinks. The production plant can produce 100 K of
cans per day. The cost of compressed air produced is 1 $ / m3 total cost
including power consumption maintenance and other costs. And the amount of
compressed air per production unit is 0.05 m3/can. Based on this information if
we manage to reduce the cost of compressed air by 25%, what will be the
.amount of saving on compressed air per day

a. 5000$ per day.

b. 1250$ per day.

c. 2500$ per day

d. 3750$ per day

* The biggest form of losses in compressed air systems is leakages, what is .13
?the best technology to detect these losses

a. Soap and water used to locate losses.

b. Flow meters and pressure gauges installed in multiple points of the system.

c. Regular ultrasound scans to allocate and fix losses.

d. Modern compressor control systems have the ability to calculate total leak losses.

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* The P-F curve is a very famous curve in the domain of reliability; if you aim .14
to be proactive what is the type of activity you should be focusing your
?inspection and CM activity on

a. Finding failures as early as possible using very sensitive vibration sensors.

b. Designing the activities based on a careful study root cause and their symptoms.

c. Preforming the PM activities on less than MTBF which is the time between the P
and the F on the curve.

d. Install online monitoring systems to monitor almost every aspect and possibility for
the machine failure.

* The key of the case on this session in the RCA was an oil analysis sample, .15
the particle count found was 21/19/16. If the new oil from the OEM cleanness
?was 19/17/14. According  ISO4406 the oil became how many times dirtier

a. One time dirtier.

b. Two times dirtier.

c. Three times dirtier

d. Four times dirtier.

* The cause of the crack that was discovered in the inner race was because .16
:which of the following failure mode

a. Three body abrasion.

b. Particle induced fatigue.

c. Crack network that leads to a complete crack.

d. Oxidization of the oil that led to viscosity increase that lead to adhesion leading to
failure fatigue.

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* If you are preforming a vibration analysis to a screw compressor on the .17

spectrum of a healthy air end you should see which set of the following peaks.
(With enough Fmax on the measurement)

a. The main RPM of the motor and the male RPM of the air end if they have different
speeds, are the dominant peaks in the air end.

b. The RPM of the male rotor divided by 60 is going to be the dominating peak in the
spectrum.

c. The dominating peaks on the air end will be; the male RPM and the female RPM and
the multiple of those peaks by the number of loops on each of them.

d. The dominating peaks will be the male RPM and the female RPM divide by 60.

* :The hardness of silicon dioxide on the MOHS scales was .18

a. 20% less hardness than diamond.

b. 50% Less hardness than diamond.

c. 80% less hardness than diamond.

d. As hard as diamond.

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* One of the famous tools of condition monitoring is thermography; one of .19

the guys suggest that you add thermography imaging as a routine inspection
CM method to be used on the air end monitoring to avoid future failures in such
:short period of time. Your answer to that will be

a. Thermography is only effective on electrical assets. So there is no point to use it in

this application.

b. You don’t agree as the P-F curve suggests that heat increase is a very delayed
symptom so it won’t provide the enough pre warning time as expected.

c. Thermography cameras is not sensitive enough to get the temperature increase

that may be caused by a damaged bearing.

d. The air end gets hot very quickly as it is the compression chamber in this
application so the process heat will mask all other heat sources that come from
mechanical components within the air end, so it is not an application where
thermography will excel. ()

* The reliability of a system is defined according to the following equation. .20

Using the below equation can you calculate the reliability of a machine (e.g. a
compressor) if the MTBF is 800 hours and the MTTR is 100 hours, Calculate the
.reliability of the system? Approx. to the second decimal assuming T=1

a. 99.87%

b. 95.85%

c. 99.00%

d. 100%

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* ?Also can you calculate the availability in this case above .21

a. 0.90

b. 0.80

c. 0.95

d. 0.88

* The Asset criticality ranking is a ranking system that helps define the .22
impact of an asset falling on the facility, from your understanding what it is the
correct set of criteria from consequences aspect that should be included in this
.study and what it the correct order

a. Equipment, safety, environment, maintenance cost, production losses.

b. Environment, safety, production losses, maintenance/repair cost, equipment.

c. Environment, safety, production losses, equipment, maintenance/ repair cost.

d. Safety, environment, maintenance /repair cost, equipment, production losses.

* Risk base number or Risk priority number is a way to correlate some .23
:machine factors together what are they from below

a. Severity of the asset and rate of occurrence of failure and detectability of failure.

b. Severity of failure and MTBF and detectability of failure.

c. Severity of failure and rate of occurrence of failure and maintainability.

d. Severity of failure and rate of occurrence of failure and detectability of failure.

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* ?How FMEA influence the machine criticality .24

a. By understanding the FMEA of an asset will help formulize the priority of the root
causes and apply a proper established mitigation plan to reduce the risk of the failure
mode and apply the needed inspection and CM activities with an interval allowing
maximum safety and reducing the RPN.

b. By understanding the FMEA of an asset will help formulize the priority of the root
causes and apply a proper established mitigation plan to reduce the risk of the failure
mode and be quicker when it comes to RCA process.

c. Machine criticality is function of the ease of detectability and maintainability and

compliance of the planning and scheduling of maintenance and a pre-defined FEMA
of an asset can improve greatly the machine failure rate.

d. The FMEA has no direct influence of the machine criticality

* When we discus vibration analysis on rolling element bearings; what is the .25
best frequency range a measuring and detecting very early defects of bearing
:damage is

a. 5000 Hz to 10,000 Hz.

b. 500 Hz to 5000 Hz

c. 30,000 Hz to 40,000Hz.

d. 10,000 Hz to 15,000Hz.

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* Based on the oil circuit diagram and the explanation of its component in the .26
session; where is the ideal oil analysis sampling location that will ensure max.
.detectability for oil properties, contamination and wear particles

a. From the thumb item 5 from the oil drain point.

b. From the pipe between the filter and the thumb.

c. At point 3 before the entry of the air end.

d. The oil sample must be collected from inside the air end with a special sampling
prop.

* From the same diagram what is the best condition monitoring way to .27
?inspect the thermostatic valve located on point 11

a. Use a thermography camera to where is the flow going.

b. Dismantle the thermostatic element and test it with hot water.

c. Use ultrasound contact prop to listen to wising sound of the flow.

d. Install a sensor parentally to know when it is damaged.

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* What is the most common form of Speed losses in the compressed air .28
?system

a. The leakages in the piping systems as it is a complete waste.

b. When the machine is idling for so long without production of compressed air.

c. The mechanical problems that will be present resulting in high vibration that will
result in lowering the operation speed of the machine.

d. When the Delta pressure on the drying and filters increase leading into pressure
losses.

* If we install this inspection CMP site glass what failure modes from the  .29
    .following will be easily detectable by this wonderful tool

a. oxidation and aeration of oil.

b. Aeration and water emulsion.

c. Aeration and foaming.

d. Oxidation acidity and wear ferrous particles.

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* In the session there is a very important information that was mentioned .30
that the amount of silica is going to much higher 4-5 times than the reading
(37ppm) and iron not appearing while the vibration readings are confirming a
?heavily damaged bearings is a big disaster, why

a. The spectrometry analysis works by vaporizing the solid particles in the oil sample
and read the emitted identifying colored light, thus the heavier and bigger the
particles, the most likely they won’t vaporize and the more severe the damage in your
machine is.

b. The spectrometry analysis works by vaporizing the solid particles in the oil sample
and read the emitted identifying colored light, thus the heavier and bigger the
particles, the most likely they won’t vaporize and the less severe the damage in your
machine is.

c. The spectrometry analysis works by melting the solid particles in the oil sample and
read the emitted identifying colored light, thus the heavier and bigger the iron
particles, the most likely they won’t vaporize and the more severe the damage in your
machine is.

d. The spectrometry analysis works by vaporizing the solid particles in the oil sample
and read the emitted identifying colored light, sensitivity to solid particles in the oil
sample are subject to the sampling location and the amount of metal and silica as the
sensors will be saturated very quickly due to their high sensitivity.

* Bonus question: what is the biggest mistake / error or you can say a .31
?problem that led to this huge failure mode and all these losses

a. Lack of maintenance culture and understanding the criticality of the hole in the
hose.

b. Lack of maintenance culture and understanding of the function of the Planning and
scheduling system

c. Lack of maintenance culture and using emails to report defects.

d. It is typically the maintenance manager mistake he doesn’t finish his emails daily as
it is his main function to keep an eye for such defects.

‫ﻣﺣﻭ ﺍﻟﻧﻣﻭﺫﺝ‬ ‫ﺇﺭﺳﺎﻝ‬

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‫ﻋﺩﻡ ﺇﺭﺳﺎﻝ ﻛﻠﻣﺎﺕ ﺍﻟﻣﺭﻭﺭ ﻋﺑﺭ ﻧﻣﺎﺫﺝ ‪ Google‬ﻣﻁﻠﻘًﺎ‪.‬‬

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