DEPARTMENT OF CHEMICAL, POLYMER, AND COMPOSITE MATERIALS ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY, LAHORE (NEW CAMPUS)

Subject: Maintenance Engineering, ChE 405
Session: 2016, 8th Semester, SP-2020 Time Allowed: 04 hours
Examination: Final Exam (Online) Total Marks: 50
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Important Instructions for students:
(a) Attempt All Questions
(b) Use White Blank Sheets to Answer all the Questions, By Hand.
(c) Make sure to number each page of answer sheet in sequence (such as 1,2,3,….). Random
page numbers/ No page numbers/ Unknown page number style or similar will not be
marked.
(d) Answers MUST NOT be written on MS Word or any other relevant medium using
Computer. In Such case, the paper will NOT BE CONSIDERED.
(e) Once Completed, Follow the steps
i. All the answer sheets must be arranged in sequence numbers.
ii. Scan images of answer sheets. (The visibility of answers shouldn’t be
compromised, failure to do so, will cause loose of marks of specific unread
portion)
iii. All the scanned images of answer sheets should be COMBINED in SINGLE PDF
FILE.
iv. DONNOT submit multiple files, it will not be considered with “No Result”.
v. The Single PDF file should be named with student’s registration ID only before final
submission.

Question No. 1: (18 Marks) CLO-1

(C2 level)
Total productive maintenance program aims for improving and increasing the productivity of the
process through effective eliminations of losses in the system. Discuss the following:
i. Various cycles of Piller III (5)
ii. Compare in extending discussion with the help of suitable examples (02 each) applicable in
the following organizations with true demonstration: (10)
(a) Education Sector, and
(b) Process Industries
iii. Highlight the best approach taking into account of above discussions in (i) and (ii). (3)

Question No. 2: (32 Marks) CLO-2

(C4 level)
(a) The objective of preventive maintenance is to perform essential and timely servicing in
order to prevent unplanned breakdowns. A manufacturing organization can optimize the (8)
performance of their equipment by using the overall equipment effectiveness tool. A factory
runs a single shift of 8 hours with three breaks, one of 25 minutes and two other breaks of 10
minutes each. The machine being studied is down for 40 minutes of the shift in question. The
machine has a stated production rate of 1 part every 20 seconds. In this particular shift 898
parts are produced. The number of defects produced during this shift is measured as 85 parts
which must be scrapped. Calculate the overall equipment effectiveness?

(b) A worker unintentionally cut 12-inch propane pipeline operating at 800 psi at a natural (6)
gas liquid point terminal. Huge vapor cloud projected to cover 35 acres which ignited about 10
minutes later by an unidentified source. Liquid products from 7 of 30 salt dome caverns fed
the fire with an estimated 16,000-29,000 gal of LPGs for 8 hours before being blocked in and
the fires extinguished. Both engine-driven fire pumps failed, one due to strong emitted heat
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damaged its ignition wires and the other because the explosion damaged sight glass fuel
gauge, leaking diesel fuel, which ignited and destroying fire pump engine. Distinguish the
situation to separate initiation, propagation, and termination steps for the above-mentioned
accident. Report ways to prevent or contain the accident.

(c) Analyze a situation in a process plant where gas toluene (mol. wt. 92g/mol) kept in
storage with designed storage capacity having length, width and depth equivalent to 16ft, 14ft (8)
and 7ft respectively. It is observed that the ventilation system installed in the store improves
the air quality entirely 6 times/hour. The Store room is also well-equipped with vapor
detection system which provides instantaneous alarm notification as soon as vapor
concentration is 25% of the lower flammable Limits (LFL) for toluene. Calculate minimum
spillage rate (lb/hr) of toluene, that will set off the flammable vapor alarm in the room?
Assume a pressure of 1 atm and a temperature of 540oR.
Also assume average ventilation conditions.
Given, parameters are: Rg = 0.73 ft3 atm/lb-mol R
For Toluene= 15,000ppm
Given Equation,

C ppm kQv PM
Qm = x 10 −6
RgT
K factor range at different Ventilation situations
vapors concentrations,
0-90 ppm = 1/12 (poor), 1/10 (average), 1/8 (good)
91-450 ppm = 1/7 (poor), 1/5 (average), 1/3 (good)
Above 450ppm= 1/6 (poor), 1/4 (average), 1/2 (good)

(d) A comprehensive analysis must be considered for safety conditions on a reactor (10)
system shown in the Figure 1. The system is provided with cooling system to eliminate
excessive energy generated as a result of exothermic reaction.
In case of cooling function is lost, the temperature of reactor would increment. This
would lead to increase reaction rate and thus result in extra energy discharge. The
outcome could be a runaway reaction with pressures surpassing the exploding reactor
pressure. The temperature inside the reactor is estimated and is utilized to regulate
cooling water stream rate through valve provided.
Analyze through HAZOP for the given process (Figure 1) which is widely applied in
industrial process design. Complete the missing comprehensive report given in Table
1 on guide words, deviations, causes, consequences and all possible actions to be
taken associated with the process.

Figure 1. Reactor System

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Table1. Provide the Missing Links
Guide Words Deviations Causes Consequences Actions
No No cooling

Reverse Reverse cooling flow

Additional cooling flow
Product in coil
Presences of unwanted
material besides cooling
water

------------------------------------Good Luck--------------------------------

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