CONFIDENTIAL

UNIVERSITI KUALA LUMPUR

Malaysian Institute Of Chemical & Bioengineering Technology

FINAL EXAMINATION
JANUARY 2016 SESSION

SUBJECT CODE : CPB 20004

SUBJECT TITLE : PLANT UTILITIES AND MAINTENANCE

LEVEL : BACHELOR

TIME / DURATION : 2 Hours 30 Minutes

INSTRUCTIONS TO CANDIDATES

1. Please read CAREFULLY the instructions given in the question paper.

2. This question paper has information printed on both sides of the paper.

3. This question paper consists of TWO (2) sections; Section A and Section B.

4. Answer ALL questions in Section A and Section B

5. Please mark your answers for Section A on the OMR answer script provided.

6. Write your answers for Section B in Answer Booklet provided.

7. Answer all questions in English Language ONLY.

THERE ARE 11 PAGES OF QUESTIONS INCLUDING THIS PAGE.

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SECTION B (TOTAL MARKS: 75)

INSTRUCTION: Answer ALL questions.

Please use the answer booklet provided.

Question 1

Steam Generator System is a type of system that has the capability to produce Electricity as one
of its final outcome. But first, Steam needs to be produced by Boiler with continuous supply of
Water that comes from Water Treatment System and also with Furnace being utilized as the
Heating Medium. Steam that has been generated can either be sent directly to Electrical
Generator Unit or to other Processing area with the usage of Compressor.

(a) State the definition of Prime Movers

(2 marks)

(b) Give three examples of Prime Movers being used in Industry.

(3 marks)

(c) i. State the Basic Concept of Boiler.

(2 marks)
ii. There are six different classifications of Boiler. Briefly describe four of them.
(8 marks)

(d) Waste Water Treatment can be categorized into Physical Unit Operation, Chemical Unit
Operation and Biological Unit Operation. Briefly describe EACH of these categories.
(6 marks)

(e) Sketch the simplified and completely labeled diagram of this Steam Generator System that
consists of Boiler, Furnace, Compressor and Electrical Generator Unit.
(4 marks)

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Question 2

(a) Spare Part And Inventory Management can be considered as among the methods that can
be fully utilized as part of Preventive Maintenance Strategy. Therefore, it comes as no
surprise that Spare Parts must be effectively monitored. That is the reason behind the act
of keeping Spare Parts for major equipment is to be considered essential to ensure a
properly run Maintenance System. The following list indicates factors to be considered in
any Spare Part Management System. Briefly describe each one of them.

i. Spare Part List

(3 marks)
ii. Purchasing Method
(3 marks)
iii. Supplier Service Levels
(3 marks)
iv. Plant Storage Capacities
(3 marks)

(b) The importance of having Scheduling as part of Preventive Maintenance Strategy can be
seen from the following statement:

In any Maintenance Department with more than 10 men and more than two/three crafts,
some planning can result in improved efficiency. As size of Maintenance Organization
increases, extent which Work Planning can be formalized and amount of time should be
spent on this activity are increased. There should be as much planning as necessary
for Maximum Overall Efficiency so long as the system costs less than the cost of operating
without it.
R. Keith Mobley
President, The Plant Performance Group, Knoxville, USA.

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The following list shows the aspects to be considered for Sound Work-Scheduling
Procedure. Explain briefly each factor.
i. Work Unit
(3 marks)
ii. Size Of Jobs
(3 marks)
iii. Percentage Of Total Work Load
(3 marks)
iv. Lead Time
(4 marks)

Question 3

(a) Basically, Maintenance Strategies can be broadly classified into Planned and Unplanned
Maintenance. For the strategy of Planned Maintenance can be broken down into
Preventive, Corrective and Predictive Maintenance. Scheduled Maintenance is one
category under Preventive Maintenance which requires both Monitoring as well as
Inspection activities to be done. The following list indicates the list of typical aspects of
Maintenance and Inspection in a Processing Plant. Briefly describe each one of them.

i. Mechanical Equipment/Plant Utilities

(3 marks)
ii. Lubrication
(3 marks)
iii. Electrical Equipment
(3 marks)
iv. Instrument For Measuring/Monitoring/Control
(3 marks)
v. Building And Structures
(3 marks )

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(b) Analyze the following Case Study and answer the following questions.

A Pump handling an Inflammable Liquid was to be replaced. The fixing Bolts/Nuts had
seized due to rusting. It was decided by the Maintenance Staff to cut the Bolts using an
Oxyacetylene Cutting Torch after the Inflammable Liquids were drained out. The drain,
which contained some Residues of the Inflammable Liquid due to Level Defects, was
merely covered by a Polyethylene Sheet ( instead of a Steel Sheet ). The Hot Metal
thrown out during the cutting operation burnt through the Polyethylene Sheet and ignited
the Inflammable Liquid Residues in the Drain. The fire was extinguished and there were
no casualties in this incident but it was a narrow escape from a Major Fire.
( A Small Fire Pg 13 14 : Learning From Accidents By T. Kletz. )

i. Identify the classification of Chemical Plant Failures.

(1 mark)
ii. State the possible causes of accident based on the Case Study.
( 4 marks)
iii. Explain briefly with justification the most important cause of this accident based on
your answer in ii.
(2 marks)
iv. Describe briefly three possible suggestions in order to ensure the incident does not
repeat in the future.
(3 marks)

END OF QUESTION

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