Appendix C

RESEARCH QUESTIONNAIRE

TOPIC: Impact of Planned Maintenance Practices on Coal Powered Power Plant Performance

Instructions

1. Answer all questions/statements.
2. Place a tick on the selected option for each question/statement.
3. Please do not leave any question/statement blank.

Section A: Demographic information

1. Please indicate your gender.

1.1	Male
1.2	Female

1. Please indicate your age group.

2.1	Less than 20 years
2.2	20-30 years
2.3	30-40 years
2.4	40-50 years
2.5	50 years and older

1. Indicate your length of tenure at the company.

3.1	1-5 years
3.2	5-10 years
3.3	10-15 years
3.4	15-20 years

1. Please indicate your highest level of education.

4.4	Certificate
4.5	Diploma
4.6	Undergraduate degree
4.7	Postgraduate degree

1. indicate your position/Job title within the maintenance department

Engineering manager

Section B: Planned Maintenance Strategy, Tactics and Performance

Objective 1: To assess the impact of meticulously planned maintenance practices on energy output and plant efficiency.

B1: Planned Maintenance

Question B1: Can you provide an estimate of how much planned and unplanned maintenance is being performed at your power station as a percentage of the total amount of maintenance performed?

1. Approximately 70% of the maintenance activities at our power station are planned, while the remaining 30% are unplanned. 2. Out of the total maintenance conducted, around 70% is planned, with the remaining 30% being unplanned. 3. We allocate roughly 70% of our maintenance efforts to planned activities, and the remaining 30% to unplanned tasks. 4. Planned maintenance accounts for about 70% of our total maintenance workload, whereas unplanned maintenance makes up the remaining 30%. 5. Of all maintenance tasks carried out at our power station, approximately 70% are scheduled in advance, while the remaining 30% are unforeseen and addressed as they arise

B2: Role and Benefits of Maintenance Strategy

Question B2: Indicate whether there is a maintenance strategy in place and what are the benefits of such strategy are there if any?

1. We have a well-defined maintenance strategy in place, which helps us optimize equipment performance, reduce downtime, and extend the lifespan of our assets. 2. Yes, our facility employs a structured maintenance strategy. This approach aids in minimizing disruptions, improving reliability, and ultimately enhancing overall operational efficiency. 3. Our operations are guided by a carefully crafted maintenance strategy. This not only ensures equipment longevity but also contributes to cost savings and sustained high-quality performance. 4. Absolutely, we've implemented a maintenance strategy that plays a pivotal role in maximizing uptime, minimizing unexpected failures, and ultimately bolstering productivity. 5. At our facility, we've established a robust maintenance strategy. This approach not only safeguards against potential breakdowns but also promotes a more cost-effective and smoothly running operation.

B3: Maintenance tactics adopted or implemented

Question B3: What are the maintenance tactics being implemented by your power plant station?

1. Our power plant station is employing advanced predictive maintenance techniques to anticipate potential issues before they occur, ensuring optimal operational efficiency. 2. Weve integrated state-of-the-art automation systems to streamline processes and enhance control over critical operations at our power plant station. 3. Energy optimization is a key focus at our power plant station, with initiatives aimed at maximizing output while minimizing resource consumption. 4. Emphasis on workforce training and skill development is a fundamental tactic, ensuring that our team is equipped to handle evolving technologies and operational challenges. 5. The implementation of a robust safety management system stands as a cornerstone of our approach, prioritizing the well-being of our personnel and safeguarding operations.

B4: Maintenance approaches used by power plants

Question B4: Indicate which of the following maintenance approaches RCM, TPM, BCM or RBM in being adopted or implemented at your power station?

1. At our power station, we've adopted the Reliability Centered Maintenance (RCM) approach, which focuses on analyzing failure modes and their consequences to optimize maintenance activities. 2. We've implemented Total Productive Maintenance (TPM) at our power station, a strategy that emphasizes proactive and holistic maintenance practices to maximize equipment effectiveness. 3. Our power station utilizes Business Continuity Management (BCM) as a maintenance approach, ensuring that critical functions and processes are maintained during unexpected disruptions. 4. We've opted for the Risk-Based Maintenance (RBM) approach at our power station, which prioritizes maintenance activities based on the level of associated risk and potential consequences. 5. The maintenance strategy employed at our power station is Reliability Centered Maintenance (RCM), a method that systematically identifies and addresses failure modes to enhance equipment reliability and performance.

B5: Power plant availability and performance

Question B5: Indicate the average availability of your power plant station in the past year?

1. Our power station achieved an impressive availability rate of 95% over the past year, showcasing our commitment to reliable energy production. 2. Throughout the previous year, our power station maintained an exceptional availability level of 98%, ensuring a consistent and dependable energy supply. 3. We are proud to report that our power station's availability remained consistently high at 96% for the entire last year, attesting to our operational efficiency. 4. Over the past year, our power station demonstrated a commendable availability record, with an average uptime of 97%. 5. Our power station's availability for the previous year was noteworthy, standing at 94% and underscoring our dedication to providing a reliable source of power.

Section C: Power Plant Maintenance Cost, Associated Budget and Information Management

Objective 2: To analyse the cost implications of different maintenance planning approaches and their subsequent effects on operational budgets.

C1: Maintenance Costs

Question C1: What is the approximate value of maintenance cost ratio associated with your power plant?

2. Over the past fiscal year, the maintenance cost ratio at our power plant averaged around 10%, demonstrating our focus on cost-effective upkeep. 3. We maintain a competitive maintenance cost ratio of roughly 9% relative to our overall operational expenditures, showcasing our dedication to cost-conscious strategies. 4. The maintenance cost ratio at our power plant hovers at about 7% on average, underscoring our emphasis on prudent spending and resource management. 5. With a maintenance cost ratio of approximately 6% of total operational costs, we demonstrate a disciplined approach to sustaining our power plants efficiency.

C2: Subsequent effects on Operational Budget

Question C2: What effect does poor maintenance planning have on the operational budget of your power plant?

1. Inadequate maintenance planning leads to increased emergency repairs and replacements, significantly inflating our operational budget due to unexpected expenses. 2. Poorly planned maintenance results in extended downtimes, reducing our revenue-generating capacity and ultimately impacting the profitability of our power plant. 3. Without efficient maintenance planning, we experience higher costs associated with equipment failures, spare parts, and overtime wages for unscheduled repairs, straining our operational budget. 4. It exacerbates wear and tear on critical components, accelerating their deterioration and necessitating premature replacements, which can have a substantial impact on our budget allocations. 5. Insufficient maintenance planning often leads to a higher consumption of resources, including energy and materials, driving up operational costs and affecting the overall budgetary balance.

C3: Maintenance Information Management

Question C3:Indicate which information system has been implemented to assist the maintenance-planning department in analysis and decision-making?

1. Our maintenance-planning department relies on a sophisticated Computerized Maintenance Management System (CMMS) to streamline workflows, track asset performance, and make data-driven decisions. 2. The implementation of an Enterprise Asset Management (EAM) system has revolutionized our maintenance planning, providing powerful tools for analysis and informed decision-making. 3. Weve integrated a state-of-the-art Predictive Maintenance System (PdMS) that utilizes advanced analytics to optimize resource allocation and enhance decision-making in the maintenance-planning process. 4. Through the adoption of a Reliability Centered Maintenance (RCM) software, our maintenance-planning department now has access to comprehensive data for analysis and strategic decision-making. 5. The incorporation of a Data Analytics Platform has empowered our maintenance-planning team to perform in-depth analysis, enabling more informed and effective decisions regarding asset management and maintenance strategies.

C4: Benefit/s Information Management System

Question C3: Estimate the return on investment (ROI) for implementing a maintenance information management system at your power station?

1. Based on industry averages, implementing a Maintenance Information Management System at our power station is projected to yield a return on investment of approximately 20% within the first year. 2. Preliminary assessments suggest that the introduction of a Maintenance Information Management System could result in a return on investment of around 15% over a three-year period. 3. While specific figures may vary, the implementation of a Maintenance Information Management System is generally expected to generate a return on investment of 10% to 30% over its operational lifespan. 4. Considering the efficiencies gained in maintenance operations and reduced downtime, the anticipated return on investment for our Maintenance Information Management System implementation is estimated to be in the range of 12% to 18%. 5. It is anticipated that the implementation of a Maintenance Information Management System will result in a return on investment ranging from 15% to 25%, largely driven by improvements in maintenance efficiency and asset longevity.

question1

1.1with the information above please construct in your words the results,discussion and interpretation of findings

1.2conclusion and recommendation