Reliability Questions

1. Which phase of an asset life cycle has the highest costs?

a. Design
b. Acquisition
c. Operation & Maintenance
d. Decommissioning
2. What is a zero energy state?
a. A condition where all sources of energy have been removed or neutralized
b. A condition where electricity has been safely disconnected
c. A condition where the equipment is turned off on the operating panel
d. A condition where the equipment is no longer pressurized
3. Work permits can be applied to which of the following?
a. Welding and open flames
b. Scaffolding construction
c. Hoisting
d. All of the above
4. Most maintenance costs are fixed:
a. During design
b. At installation
c. During operating life
d. At acquisition
5. Which of the following is NOT a component of equipment taxonomy?
a. Equipment Information
b. Location Information
c. Equipment Drawings
d. Detailed Failure Codes
6. Which of the following is the best metric for determining reliability performance over
time?
a. Availability
b. Mean Time To Repair (MTTR)
c. Mean Time Between Failures (MTBF)
d. OEE
7. Confined spaces include:
a. Tanks, vessels, storage bins
b. Spaces with limited or restricted means for entry or exit and not designed for
continuous occupancy.
c. Both of the above
d. Tanks, vessels, silos, storage bins, hoppers, vaults, pits, manholes, tunnels,
equipment housings, ductwork, pipelines, etc.
8. A work request should contain:
a. Identification of the equipment to be worked on and how it is to be fixed
b. Identification of the equipment to be worked on, the symptom observed, and
potentially which component needs to be addressed
c. Identification of the equipment to be worked on
d. Identification of the equipment to be worked on, the symptom to be observed, and
who should do the work
9. Which of the following would be an example of a condition or damage code in a CMMS?
a. Bearing Failure
b. Operator Error
c. Inspection
d. Worn

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10. Which of the following characteristic does not fit a sporadic failure?
a. High costs per event
b. Occurs frequently for the same failure mechanism
c. Same piece of equipment with multiple failures
d. Takes a lot of time to repair
11. If a failure mode is identified using RCM and has a high impact consequence, what should
be done if the failure cannot be prevented or predicted?
a. Run-to-Failure
b. Redesign the equipment or system
c. Bring in the OEM for consulting
d. Restructure the Pm / PdM strategy
12. Which of the following is a typical obstacle to design review?
a. Customer requirements
b. Manufacturing requirements
c. Resistance from the design department
d. Safety requirements
13. Implementing a preventive quality system will increase which of the following?
a. Failure costs
b. Inspection Time
c. Quality system effectiveness
d. Corrective action effectiveness
14. Which of the following methods is used to determine whether a process functions
properly for its intended use?
a. Capacity
b. Inspection
c. Validation
d. Design Review
15. Which of the following techniques is used to qualify new or revised manufacturing
processes?
a. Benchmarking
b. Design failure modes and effects analysis (DFMEA)
c. Fault Tree Analysis
d. Capability Study/Analysis

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16. Which of the following standards provides guidelines maintaining a calibration system?
a. ISO 9003
b. ISO 55000
c. ISO 14000
d. ISO 17025
17. Typically, what type of gauge is used to measure the distance between two parallel
surfaces on the outside of an object or feature?
a. Ring
b. Micrometer
c. Telescoping
d. Contour
18. Which of the following are tools that can be used for Root Cause Elimination?
a. 5 Why’s
b. Cause-Effect Diagrams
c. 5S
d. a and b
19. Maintenance Scheduling is:
a. To specify what needs to be done to correct or detect a problem, as well as how to
do it.
b. To specify what materials are needed for a job, and who should do it.
c. To detail who should carry out a planned maintenance job, and when.
d. A clerical function to record who worked a job, and what it cost.
20. Predictive and Preventive Maintenance inspection techniques can include the following:
a. Vibration analysis, ultrasonic inspections, oil analysis, operator look/listen feel
inspections
b. Vibration analysis and oil analysis
c. Vibration analysis, ultrasonic inspections, oil analysis, operator look/listen feel
inspections, temperature and pressure checks and setpoints, stroboscopes, and
Shock Pulse Measurement.
d. Vibration analysis, ultrasonic inspections, oil analysis, operator look/listen feel
inspections, temperature and pressure checks and setpoints, stroboscopes, and
Shock Pulse Measurement, re-calibration.

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21. Which one of the following is generally true?
a. Construction contractors are usually equally skilled at performing all maintenance
tasks
b. Maintenance is often reduced through project designs that provide in-place spares
for all rotating equipment and heat exchangers
c. Reliability Centered Maintenance can be applied on capital projects in the pre-
construction stage to determine the maintenance plan
d. Most Mechanics can easily alternate between capital project work and doing
equipment diagnosis and repair work
22. A large manufacturing company installed some asset monitoring devices on large motors
that were deemed critical equipment. The monitoring devices provide engineering with
vibration data, acoustic data, as well as operational performance data. What asset
management strategy has the company selected for the motors?
a. OBM (Operational Based Maintenance) / CM (Corrective Maintenance)
b. PM (Preventive Maintenance) / OBM (Operational Based Maintenance)
c. CBM (Conditioned Based Maintenance) / PdM (Predictive Maintenance)
d. CBM (Conditioned Based Maintenance) / CM (Corrective Maintenance)
23. If a machine is running 2080 hours and five failures are observed during this period, what
is the Mean Time Between Failure?
a. 2080 hours
b. 41.60 hours
c. 416 hours
d. .416 hours
24. Which of the following metrics definitions is not true?
a. Uptime = % of time you run producing quality product at design rate
b. Schedule compliance = How often mechanics are pulled off their current work for
another task
c. MTBF = A measure or indicator of equipment life expectancy
d. Backlog = Past due work orders
25. A qualified scaffolder:
a. Inspects scaffolding and components prior to each work shift
b. Determines feasibility of providing fall protection and access
c. Evaluates connections to support load and prevent swaying
d. All of the above
26. When the time period between testing and inspections which detects a failure. For failures
with significant economic consequences, and when life expectancy is highly variable, a
good maintenance strategy would be:
a. More frequent testing and inspections
b. A more structure preventive maintenance program
c. On-line condition based monitoring
d. Bring in an expert contractor
27. Maintenance Planning is:
a. To specify what needs to be done to correct or detect a problem, as well as how to
do it.
b. To specify what materials are needed for a job, and who should do it.
c. Who should carry out a maintenance job, and when they should do it.
d. A clerical function to record who worked a job, and what it cost.

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 28. A change in the velocity amplitude at the shaft frequency means:
a. Misalignment
b. Unbalanced
c. Bearing Failure
d. Poor Lubrication
29. Arc flash contains this percentage of radiant heat?
a. 15%
b. 48%
c. 85%
d. 98%
30. Non precision alignment of equipment can cause:
a. Seal failures
b. Bearing failures
c. Gear failures
d. All of the above
31. The “F” on the P-F curve indicates that the equipment is still functioning?
a. True
b. False
32. If you have 5 pieces of equipment in a series and they have the following reliability values,
what is the likelihood the system will run one year without a failure? (99%, 97%, 91%,
91%, 87%)
a. 87.23%
b. 69.18%
c. 98.93%
d. 23.76%
33. If you have a MTBF of 500 days, what is the likelihood you will have a failure in a one year
period?
a. 21.32%
b. 0%
c. 73%
d. 51.81%

-(period/MTBF)
Relibility (In Time) = e
Likelyhood of Failure = 1 - Reliability (In Time)
e = number e = 2.7182818284590452353602874713527
period = time you want reliability for
MTBF = Mean time between failures (same unit as the period)

Period = 365 days

MTBF = 500 days
365/500=0.73

e^(-0.73) = 0.4819 Reliability of the system

Likelyhood of failure in 365 days = 1-0.4819=0.5181=51.81%

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34. If you had five (5) failures in a year and each failure caused the system to be down for 24
hours, what is the availability of the system for the year?
a. 90.25%
b. 78.34%
c. 98.63%
d. 99.98%
35. Which of the following inspection methods can be used to detect surface flaws but not
subsurface flaws?
a. Liquid Penetrant
b. Ultrasound
c. Radiographic Magnetic Particle
d. None of the above

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36. Which of the following are leading tools or techniques to help identify maintenance and
reliability improvements?
1. Total Productive Maintenance
2. Reliability Centered Maintenance
3. Historical Analysis and Spending
4. Process Benchmarking
a. 2,3,4
b. 1,3,4
c. 1,2,4
d. 1,2,3

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37. Which of the following defines preventive maintenance?
a. Inspecting or repairing equipment as soon as a predetermined interval has elapsed.
b. Repairing or replacing equipment at time of failure.
c. Performing temperature, vibration, or oil analysis to determine optimum timing of
inspection or repair.
d. Reacting to higher vibration, temperature, or noise levels in equipment.
38. After a repair is made, it is necessary to verify which of the following?
a. That the problem has been corrected
b. Documentation is complete
c. Unused parts are stored properly
d. Energy is de-energized
39. When ascending or descending a ladder, the climber must do which of the following?
a. Notify others in the area
b. Carry tools up in a container
c. Face the ladder
d. Clip tools to his/her belt
40. What is the most common type of respirator used by emergency response team personnel
responding to a chemical spill?
a. Half-mask respirator and filters
b. Constant flow air hood
c. Continuous air-supplied full face respirator
d. Self-contained full face respirator
41. What valve used for on-off service is designed to operate either open or closed?
a. Gate
b. Globe
c. Schroeder
d. Butterfly
42. Two seals that are mounted face to face, with a primary sealing ring rotating on a common
mating ring are called ________ seals.
a. Double
b. Tandem
c. Thrust
d. Deflective
43. What tool should be used when measuring small variations in the size or position of an
object that is being moved slowly?
a. Feeler gauge
b. Micrometer
c. Dial indicator
d. Dial caliper
44. A maintenance mechanic finds pitted turbine blades and deposits in the turbine housing
after disassembling a steam turbine. Which of the following is most probably cause?
a. Contaminated steam supply
b. Contaminated lube oil system
c. Faulty governor operation
d. Running below design speed
45. In troubleshooting, which of the following would cause a pump to have limited flow?
a. Impeller diameter too small
b. Low oil level
c. Pump out of alignment
d. Less discharge head pressure

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46. Which of the following best describes predictive maintenance?
a. Inspection strategies that are performed as soon as a predetermined interval has
lapsed.
b. Inspections at predetermined intervals with the maintenance action performed as a
result of inspection.
c. An inspection performed only from when there is a noticeable change in operating
parameters.
d. An inspection performed only when audible or vibration levels are excessive.
47. A laser alignment tool measures the _______ of a coupling.
a. Parallel offset and angularity
b. Directional offset and corrections
c. Deflection and offset
d. Angle and concentricity
48. Lockout/tagout requirements are defined by which government agency?
a. National Electric Code (NEC)
b. Federal Communications Commission (FCC)
c. Occupational Health and Safety Administration (OSHA)
d. National Fire Protection Agency (NFPA)
49. Troubleshooting exposes you to which of the following activities that other maintenance
activities do not?
a. Tools
b. Parts
c. Hazards
d. Operators
50. The primary purpose of a safe work permit is to inform operations of which of the following?
a. That maintenance work is being done in that area
b. That hazardous equipment is locked out
c. That maintenance personnel are trained for the repair
d. That hazardous materials are present
51. The most important physical property of lubrication oil is its ______.
a. viscosity
b. fire point
c. oxidation resistance
d. flash point
52. Which of the following best describes a check valve?
a. Designed to regulate the flow of fluids
b. Causes a fluid to abruptly change direction
c. Used at point intake to retain fluids in the system
d. Designed to allow fluids to flow in only one direction
53. What is the final step in the lock out / tag out procedure after work has been completed?
a. Verify that the equipment will not operate
b. Remove the locking devices and tags
c. Verify that required work has been finished
d. Identify the energy source that powers the equipment
54. Bearings should be stored:
a. Laying flat
b. Standing on edge
c. In an oven
d. Removed from box

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55. Measuring the oxygen concentration in the area where respirators will be worn is necessary
to determine which of the following?
a. The type of filter canister required
b. The level of hazardous vapors or gases in the area
c. The immediate danger to life or health
d. Whether an explosive atmosphere exists
56. What can particulate contaminants in oil reveal about equipment?
a. Abnormal wear of internal components or parts
b. Equipment is old and needs to be replaced
c. That an oil with different viscosity is required
d. That the lubrication system needs a new filter
57. Prior to a cold plant boiler start-up, it is typically the maintenance mechanics responsibility to
make sure that all boiler hatch covers are in what condition?
a. Closed and pressure tested
b. Documented on work orders
c. Closed and sealed
d. Closed and vented
58. Which of the following is a good rule of housekeeping?
a. Put tools just out of the way
b. Put flammable and combustible materials in vented containers
c. Allow scrap materials to accumulate prior to disposal
d. Store tools and equipment when you are finished using them.
59. When troubleshooting equipment, which of the following steps should be done first?
a. Find the equipment drawings and specifications
b. Lock out the equipment
c. Disassemble the equipment
d. Talk to the operator
60. The first step in a troubleshooting scenario would be to do which of the following?
a. Do a root cause analysis
b. Verify that the problem exists
c. Research repair manuals
d. Lock out / tag out the equipment
61. Which of the following items provides an overall view of systems?
a. Layout drawings
b. Motor control schematics
c. P&ID’s
d. Loop drawings

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62. Which of the following is best practice for housekeeping?
a. Ensuring adequate lighting and sound suppression
b. Keeping work areas clean and free of scraps or spills
c. Organizing and arranging tools to permit efficient work
d. Painting all walkways and guards properly
63. What minimum eye protection does OSHA require when metal objects are cut with an
oxygen-acetylene torch?
a. A welding helmet
b. Safety eyeglasses with side shields
c. Dark safety eyeglasses
d. Shaded lens
64. When is the best time to perform a Root Cause Analysis?
a. During machine downtime
b. After a failure has occurred
c. Before a failure has occurred
d. During normal machine operation
65. What information should a maintenance history log contain?
a. Operating procedures
b. Recurring malfunctions
c. Material safety data sheets
d. Process Parameters
66. What tool should a CMRT use to measure the speed of a piece of rotating machinery?
a. Digital indicator
b. Tachometer
c. RTD
d. Oscilloscope
67. Vibration monitoring, acoustic emission, and oil analysis are examples of what kind of
maintenance?
a. Preventive
b. Predictive
c. Reactive
d. Proactive
68. Troubleshooting conveyor belts can often be aided by reviewing the plants maintenance
records for similar:
a. Past failures
b. Parts list
c. Maintenance mechanics
d. Equipment types
69. Which of the following items provides an overall view of systems?
a. Layout drawings
b. Motor control schematics
c. P&ID’s
d. Loop drawings
70. A full oil supply bulb is not
a. An indicator that the bearing housing constantly leaks oil
b. A sign that further investigation is needed in a preventive maintenance inspection
c. An indication that the bottle has been overfilled
d. An indication that the bearings have adequate lubrication

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71. What would be the speed of a fan shaft with a 1200 RPM motor that has a 6” pulley, and is
driving a fan shaft with a 12” pulley?
a. 300rpm
b. 1200rpm
c. 600rpm
d. 1800rpm
72. What two issues develop from the friction of two materials moving relative to each other?
a. Corrosion and alignment
b. Heat and wear
c. Balance and level
d. Balance and wear
73. What is the best tool to use to troubleshoot a running v-belt drive system?
a. IR camera
b. Vibration meter
c. Stroboscope
d. Flashlight
74. What effect does careless handling, or improper tool use, while installing bearings have on
the bearings?
a. Loose fit
b. Lubrication
c. Damage
d. Spalling
75. What causes the pointer on a standard dial indicator to move in the positive (clockwise)
direction?
a. The stem moves out
b. The indicator is rotated and the shaft is stationary
c. The shaft is rotated and the indicator is stationary
d. The stem is pushed in
76. Which of the following is an advantage of a preventive maintenance program?
a. Lowers cost of production materials
b. Enhances operators motivation
c. Increases equipment uptime
d. Allows for frequent access to equipment
77. What is the common name for the predictive maintenance technology that is usually
associated with monitoring dynamic effects?
a. Thermography
b. Oil analysis
c. Vibration analysis
d. Non-Destructive Testing (NDT)
78. What lab test is used to determine the amount of water in lubricating oil?
a. Hydrolysis content
b. Karl Fischer
c. Ferrography
d. Dialysis
79. At which level of detail should a facility keep equipment files on its major pieces of
equipment?
a. Process
b. Floor
c. Component
d. System

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80. When should a scaffold inspection form be completed?
a. On the day of use
b. Once per month while in use
c. At the time of delivery to the job site
d. When the job is bid by the contractor
81. Which of the following is the first step in conducting a failure analysis on a piece of
equipment?
a. Reviewing the equipment history
b. Conducting an overview of events
c. Doing a 5S survey
d. Making recommendations on a path forward
82. What type of a pump as a piston and diaphragm?
a. Compactor
b. Systolic
c. Positive displacement
d. Gear
83. Which of the following centrifugal pump conditions is not a result of cavitation?
a. Low discharge pressure
b. High vibration
c. High power draw
d. High bearing temperature
84. What are the three standard methods for how to describe a drill size?
a. Numbered, decimals, and fractional
b. Numbered, lettered, and fractional
c. Numbered, lettered and decimals
d. Numbered, lettered and millimeters
85. Select the part of a DC motor that provides the sliding connection points from the brushes to
the current carrying conductors in the armature:
a. End bells
b. Commutator
c. Risers
d. Brush tensioning devices
86. Which valve is used to prevent reverse flow in piping systems?
a. Check valve
b. By-pass valve
c. Gate valve
d. Globe valve

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87. What background information can operations personnel offer to aid in a troubleshooting
process?
a. Documented repair history of the piece of equipment
b. Who is responsible for the equipment failure
c. Contents of the line log relative to maintenance history
d. Details pertaining to the trouble causing event
88. Before using a drill press, what must a CMRT do to the work piece to prevent injuries
a. Level it
b. Mark it
c. Secure it
d. Center it
89. Cavitation in a hydraulic pump is most often caused by a build up of dirt and contaminants
on the:
a. Working cylinder
b. Accumulator
c. Suction strainer
d. Relief valve
90. When replacing bearings, what is the most important consideration?
a. Manufacturer
b. Cleanliness
c. Age
d. Temperature
91. What kind of permit may be required if combustible materials are stored in close proximity
to a welding job?
a. Hot work
b. Preheating
c. Confined entry
d. Welding
92. What is the first objective of troubleshooting?
a. Assign responsibility for the problem
b. Identify the root cause
c. Modify the equipment
d. Repair the equipment
93. Which of the following pump conditions results from a bent shaft?
a. Low suction head
b. Low power draw
c. High suction pressure
d. High bearing temperature
94. When responding to a process service call, what must a mechanic do to a piece of equipment
when putting it in maintenance mode before troubleshooting or repair?
a. Shutdown
b. Lock-out
c. Clean
d. Prepare
95. A predictive maintenance program relies on data collection to enable comparative analysis
for:
a. Scheduling
b. Setting Warehouse Min/Max levels
c. Ordering of parts
d. Trending

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96. Preventive Maintenance tasks are which of the following?
a. Always used
b. Planned
c. Breakdown driven
d. Not necessary
97. What is a failure mode?
a. Any event that causes machine downtime
b. A method of measuring equipment reliability
c. Any event which causes the equipment to fail to deliver its function
d. A method of operating equipment in breakdown status
98. When troubleshooting a drive belt that is squealing, which of the following is the most likely
cause?
a. Dirty environment
b. Sheaves not balanced
c. Overloaded drive
d. Insufficient arc
99. What is the minimum amount of information required on chemical containers per OSHA
regulation?
a. Substance name, manufacturer and NFPA triangle
b. Substance name, manufacturer and the name of the person that filled the container
c. Substance name, lot number, and NFPA triangle
d. Substance name, manufacturer and emergency contact number
100. What is the major goal of housekeeping
a. To teach the proper use of maintenance equipment
b. To prevent or reduce the occurrence of accidents
c. To put safety policies and procedures in writing
d. To load or place equipment or supplies properly
101. What is a major factor in determining the potential grip of V belts and flat belts?
a. Motor horsepower
b. Contact area
c. Flexibility
d. Oil resistance
102. Which of the following describes storage conditions that could cause most damage
to materials and repair parts?
a. Short term storage in a warehouse with climate control
b. Short term storage in a warehouse without climate control
c. Long term storage in a warehouse with climate control
d. Long term storage in a warehouse without climate control
103. Excessively low viscosity will reduce oil film strength. Weakening the oils ability to
prevent which of the following:
a. Metal to metal contact
b. Water absorption
c. Accumulation of solids
d. Contamination
104. If a hole for a threading tap is too large, which of the following is true:
a. Threads will have little holding power
b. Threads will have incorrect pitch
c. Bolt heads will strip
d. Tapped hold threads will strip.

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105. What two issues develop from the friction of two materials moving relative to each
other:
a. Corrosion and alignment
b. Heat and wear
c. Balance and wear
d. Balance and level
106. How should materials stored in bags, containers, bundles or tiers be stacked?
a. Blocked, interlocked, and limited in height
b. With signs indicating the proper personal protective equipment
c. In a permanent vertical structure
d. In an ANSI approved container
107. Which of the following is an example of predictive maintenance?
a. Oil analysis from a vacuum pump
b. Check calibration loops
c. Analyze prior maintenance work
d. Tear down equipment for inspection
108. Which of the following are the main functions of proper lubrication?
a. To reduce friction and carry away heat
b. To smooth operation and reduce sound
c. To increase speed and reduce friction
d. To carry away heat and reduce corrosion
109. Which type of predictive maintenance technique would be utilized to detect pump
imbalance?
a. Ultrasonic analysis
b. Infrared analysis
c. Lubrication analysis
d. Vibration analysis
110. What information should a maintenance history log contain
a. Operating procedures
b. Material safety data sheets
c. Recurring malfunctions
d. Process parameters
111. What does the acronym FMEA stand for?
a. Failure Maximizing and Enhancement Analysis
b. Failure Minimizing Effectiveness Analysis
c. Failure Modes and Effects Analysis
d. Facilities Maintenance and Engineering Administration
112. A valve sounds like it has small rocks or gravel going through it. Which of the
following is the most probably cause?
a. Steam hammer
b. Restricted flow
c. Cavitation of the process fluid
d. Valve seat disintegration

A pump sounds like it has small rocks or gravel going through it. Which of the following is the
most probably cause?
e. Steam hammer
f. Restricted flow
g. Cavitation of the process fluid
h. Valve seat disintegration

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113. After installing a three phase motor, you find it running in the wrong direction. What
method should be used to correct the problem?
a. Reverse any two of the motor leads
b. Check motor polarity
c. Use a megohmmeter to reverse the rotation
d. Replace the motor

Page 17 of 33
114. Which of the following is a good rule of housekeeping?
a. Put tools out of the way
b. Put flammable and combustible materials in vented containers
c. Allow scrap materials to accumulate prior to disposal
d. Store tools and equipment when you are finished using them
115. Which of the following best describes planned maintenance?
a. Maintenance that can be completed while the asset is still in service
b. Maintenance that is prioritized to be completed at a predetermined time
c. Cycle maintenance carried out at regular intervals
d. Maintenance carried out according to a documented plan of task skills and resources
(what and how)
116. Which of the following maintenance philosophies schedules activities at
predetermined time intervals?
a. Predictive
b. Preventive
c. Condition based
d. Reactive
117. What 3 items must be present to have an accident?
a. Person present, exposed hazard, contact with hazard
b. No signs, no warning, no reporting
c. Poor safety plan, non executed plan, violation of plan
d. Lack of safety rules, posting of rules, potential situation
118. After installing a motor on a recently serviced pump, the mechanic discovers it is not
pumping properly. Which of the following is the most probably cause?
a. Inadequate horsepower
b. Coupling not connected
c. Plugged discharge line
d. Wrong direction of rotation
119. Which of the following is the most probably cause of bearing failure that is not
related to bearing in use stress?
a. The bearing was left out of the box in storage
b. The bearing was in sunlight too long
c. The bearing was wrapped in oil wrapping
d. The bearing was handled with bare hands
120. When ascending or descending a ladder, the climber must do which of the following?
a. Maintain a 3 point contact !
b. Carry tools up in a container
c. Face the ladder
d. a and b
121. Which one of the following is not an example of a Predictive Maintenance task?
a. Oil changes every 6 months
b. Oil sampling for analysis every 6 months
c. Vibration readings and analysis every 6 months
d. Oil changes done when oil analysis indicates it has degraded.

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1. A large manufacturing company installed some asset monitoring devices on large motors
that were deemed critical equipment. The monitoring devices provide engineering with
vibration data, acoustic data, as well as operational performance data. What asset
management strategy has the company selected for the motors?
a. OBM (Operational Based Maintenance) / CM (Corrective Maintenance)
b. PM (Preventive Maintenance) / OBM (Operational Based Maintenance)
c. CBM (Conditioned Based Maintenance) / PdM (Predictive Maintenance)
d. CBM (Conditioned Based Maintenance) / CM (Corrective Maintenance)
2. When the time period between testing and inspections which detects a failure is variable.
And the failures h av e significant economic consequences, and when life expectancy is
highly variable, a good maintenance strategy would be:
a. More frequent testing and inspections
b. A more structure preventive maintenance program
c. On-line condition based monitoring
d. Bring in an expert contractor
3. The “F” on the P-F curve indicates that the equipment is still functioning?
a. True
b. False
4. Which of the following defines preventive maintenance?
a. Inspecting or repairing equipment as soon as a predetermined interval has elapsed.
b. Repairing or replacing equipment at time of failure.
c. Performing temperature, vibration, or oil analysis to determine optimum timing of
inspection or repair.
d. Reacting to higher vibration, temperature, or noise levels in equipment.
5. After a repair is made, it is necessary to verify which of the following?
a. That the problem has been corrected
b. Documentation is complete
c. Unused parts are stored properly
d. Energy is de-energized
6. When ascending or descending a ladder, the climber must do which of the following?
a. Notify others in the area
b. Carry tools up in a container
c. Face the ladder
d. Clip tools to his/her belt
7. What tool should be used when measuring small variations in the size or position of an
object that is being moved slowly?
a. Feeler gauge
b. Micrometer
c. Dial indicator
d. Dial caliper
8. A maintenance mechanic finds pitted turbine blades and deposits in the turbine housing
after disassembling a steam turbine. Which of the following is most probably cause?
a. Contaminated steam supply
b. Contaminated lube oil system
c. Faulty governor operation
d. Running below design speed
9. What lab test is used to determine the amount of water in lubricating oil?
a. Hydrolysis content
b. Karl Fischer
c. Ferrography
d. Dialysis

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10. Which of the following is the first step in conducting a failure analysis on a piece of
equipment?
a. Reviewing the equipment history
b. Conducting an overview of events
c. Doing a 5S survey
d. Making recommendations on a path forward
11. Which of the following centrifugal pump conditions is not a result of cavitation?
a. Low discharge pressure
b. High vibration
c. High power draw
d. High bearing temperature
12. In troubleshooting, which of the following would cause a pump to have limited flow?
a. Impeller diameter too small
b. Low oil level
c. Pump out of alignment
d. Less discharge head pressure
13. Which of the following best describes predictive maintenance?
a. Inspection strategies that are performed as soon as a predetermined interval has
lapsed.
b. Inspections at predetermined intervals with the maintenance action performed as a
result of inspection.
c. An inspection performed only from when there is a noticeable change in operating
parameters.
d. An inspection performed only when audible or vibration levels are excessive.
14. A laser alignment tool measures the _______ of a coupling.
a. Parallel offset and angularity
b. Directional offset and corrections
c. Deflection and offset
d. Angle and concentricity
15. Lockout/tagout requirements are defined by which government agency?
a. National Electric Code (NEC)
b. Federal Communications Commission (FCC)
c. Occupational Health and Safety Administration (OSHA)
d. National Fire Protection Agency (NFPA)
16. A qualified scaffolder:
a. Inspects scaffolding and components prior to each work shift
b. Determines feasibility of providing fall protection and access
c. Evaluates connections to support load and prevent swaying
d. All of the above
17. The primary purpose of a safe work permit is to inform operations of which of the following?
a. That maintenance work is being done in that area
b. That hazardous equipment is locked out
c. That maintenance personnel are trained for the repair
d. That hazardous materials are present
18. The most important physical property of lubrication oil is its ______.
a. viscosity
b. fire point
c. oxidation resistance
d. flash point

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19. Which of the following best describes a check valve?
a. Designed to regulate the flow of fluids
b. Causes a fluid to abruptly change direction
c. Used at point intake to retain fluids in the system
d. Designed to allow fluids to flow in only one direction
20. What is the final step in the lock out / tag out procedure after work has been completed?
a. Verify that the equipment will not operate
b. Remove the locking devices and tags
c. Verify that required work has been finished
d. Identify the energy source that powers the equipment
21. Bearings should be stored:
a. Laying flat
b. Standing on edge
c. In an oven
d. Removed from box
22. Measuring the oxygen concentration in the area where respirators will be worn is necessary
to determine which of the following?
a. The type of filter canister required
b. The level of hazardous vapors or gases in the area
c. The immediate danger to life or health
d. Whether an explosive atmosphere exists
23. What can particulate contaminants in oil reveal about equipment?
a. Abnormal wear of internal components or parts
b. Equipment is old and needs to be replaced
c. That an oil with different viscosity is required
d. That the lubrication system needs a new filter
24. Which of the following is a good rule of housekeeping?
a. Put tools just out of the way
b. Put flammable and combustible materials in vented containers
c. Allow scrap materials to accumulate prior to disposal
d. Store tools and equipment when you are finished using them.
25. Which of the following best describes planned maintenance?
a. Maintenance that can be completed while the asset is still in service
b. Maintenance that is prioritized to be completed at a predetermined time
c. Cycle maintenance carried out at regular intervals
d. Maintenance carried out according to a documented plan of task skills and resources
(what and how)
26. Which of the following maintenance philosophies schedules activities at predetermined time
intervals?
a. Predictive
b. Preventive
c. Condition based
d. Reactive
27. Which of the following items provides an overall view of systems?
a. Layout drawings
b. Motor control schematics
c. P&ID’s
d. Loop drawings

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28. What is the most common type of respirator used by emergency response team personnel
responding to a chemical spill?
a. Half-mask respirator and filters
b. Constant flow air hood
c. Continuous air-supplied full face respirator
d. Self-contained full face respirator
29. Which of the following is best practice for housekeeping?
a. Ensuring adequate lighting and sound suppression
b. Keeping work areas clean and free of scraps or spills
c. Organizing and arranging tools to permit efficient work
d. Painting all walkways and guards properly
30. What minimum eye protection does OSHA require when metal objects are cut with an
oxygen-acetylene torch?
a. A welding helmet
b. Safety eyeglasses with side shields
c. Dark safety eyeglasses
d. Shaded lens
31. When is the best time to perform a Root Cause Analysis?
a. During machine downtime
b. After a failure has occurred
c. Before a failure has occurred
d. During normal machine operation
32. What information should a maintenance history log contain?
a. Operating procedures
b. Recurring malfunctions
c. Material safety data sheets
d. Process Parameters
33. What tool should a CMRT use to measure the speed of a piece of rotating machinery?
a. Digital indicator
b. Tachometer
c. RTD
d. Oscilloscope
34. Vibration monitoring, acoustic emission, and oil analysis are examples of what kind of
maintenance?
a. Preventive
b. Predictive
c. Reactive
d. Proactive
35. Which of the following items provides an overall view of systems?
a. Layout drawings
b. Motor control schematics
c. P&ID’s
d. Loop drawings
36. When troubleshooting equipment, which of the following steps should be done first?
a. Find the equipment drawings and specifications
b. Lock out the equipment
c. Disassemble the equipment
d. Talk to the operator

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37. The first step in a troubleshooting scenario would be to do which of the following?
a. Do a root cause analysis
b. Verify that the problem exists
c. Research repair manuals
d. Lock out / tag out the equipment
38. What is the best tool to use to troubleshoot a running v-belt drive system?
a. IR camera
b. Vibration meter
c. Stroboscope
d. Flashlight
39. What effect does careless handling, or improper tool use, while installing bearings have on
the bearings?
a. Loose fit
b. Lubrication
c. Damage
d. Spalling
40. Which of the following is an advantage of a preventive maintenance program?
a. Lowers cost of production materials
b. Enhances operators motivation
c. Increases equipment uptime
d. Allows for frequent access to equipment
41. What is the common name for the predictive maintenance technology that is usually
associated with monitoring dynamic effects?
a. Thermography
b. Oil analysis
c. Vibration analysis
d. Non-Destructive Testing (NDT)
42. What background information can operations personnel offer to aid in a troubleshooting
process?
a. Documented repair history of the piece of equipment
b. Who is responsible for the equipment failure
c. Contents of the line log relative to maintenance history
d. Details pertaining to the trouble causing event
43. Before using a drill press, what must a CMRT do to the work piece to prevent injuries
a. Level it
b. Mark it
c. Secure it
d. Center it
44. When replacing bearings, what is the most important consideration?
a. Manufacturer
b. Cleanliness
c. Age
d. Temperature
45. What kind of permit may be required if combustible materials are stored in close proximity
to a welding job?
a. Hot work
b. Preheating
c. Confined entry
d. Welding

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46. When responding to a process service call, what must a mechanic do to a piece of equipment
when putting it in maintenance mode before troubleshooting or repair?
a. Shutdown
b. Lock-out
c. Clean
d. Prepare
47. Preventive Maintenance tasks are which of the following?
a. Always used
b. Planned
c. Breakdown driven
d. Not necessary
48. What is a failure mode?
a. Any event that causes machine downtime
b. A method of measuring equipment reliability
c. Any event which causes the equipment to fail to deliver its function
d. A method of operating equipment in breakdown status
49. What is the minimum amount of information required on chemical containers per OSHA
regulation?
a. Substance name, manufacturer and NFPA triangle
b. Substance name, manufacturer and the name of the person that filled the container
c. Substance name, lot number, and NFPA triangle
d. Substance name, manufacturer and emergency contact number
50. Excessively low viscosity will reduce oil film strength. Weakening the oils ability to prevent
which of the following:
a. Metal to metal contact
b. Water absorption
c. Accumulation of solids
d. Contamination
51. Which of the following is an example of predictive maintenance?
a. Oil analysis from a vacuum pump
b. Check calibration loops
c. Analyze prior maintenance work
d. Tear down equipment for inspection
52. Which of the following are the main functions of proper lubrication?
a. To reduce friction and carry away heat
b. To smooth operation and reduce sound
c. To increase speed and reduce friction
d. To carry away heat and reduce corrosion
53. Which type of predictive maintenance technique would be utilized to detect pump
imbalance?
a. Ultrasonic analysis
b. Infrared analysis
c. Lubrication analysis
d. Vibration analysis
54. What information should a maintenance history log contain
a. Operating procedures
b. Material safety data sheets
c. Recurring malfunctions
d. Process parameters

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55. What does the acronym FMEA stand for?
a. Failure Maximizing and Enhancement Analysis
b. Failure Minimizing Effectiveness Analysis
c. Failure Modes and Effects Analysis
d. Facilities Maintenance and Engineering Administration
56. A valve sounds like it has small rocks or gravel going through it. Which of the following is the
most probably cause?
a. Steam hammer
b. Restricted flow
c. Cavitation of the process fluid
d. Valve seat disintegration
57. Which of the following is a good rule of housekeeping?
a. Put tools out of the way
b. Put flammable and combustible materials in vented containers
c. Allow scrap materials to accumulate prior to disposal
d. Store tools and equipment when you are finished using them
58. What 3 items must be present to have an accident?
a. Person present, exposed hazard, contact with hazard
b. No signs, no warning, no reporting
c. Poor safety plan, non executed plan, violation of plan
d. Lack of safety rules, posting of rules, potential situation
59. When ascending or descending a ladder, the climber must do which of the following?
a. Maintain a 3 point contact
b. Carry tools up in a container
c. Face the ladder
d. a and b
60. Which one of the following is not an example of a Predictive Maintenance task?
a. Oil changes every 6 months
b. Oil sampling for analysis every 6 months
c. Vibration readings and analysis every 6 months
d. Oil changes done when oil analysis indicates it has degraded.

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126. To check bar sag, a maintenance mechanic mounts the indicator jig on top of the
solid shaft, and rotates the shaft how many degrees?
a. 120°
b. 90°
c. 180°
d. 60°
127. Which of the following best describes predictive maintenance?
a. Inspection strategies that are performed as soon as a predetermined interval has
lapsed.
b. Inspections at predetermined intervals with the maintenance action performed as a
result of inspection.
c. An inspection performed only when audible or vibration levels are excessive.
d. An inspection performed only when there is a noticeable change in operating
parameters.
128. CMRT is determining whether oil is flowing into a bearing. After drawing an oil
sample from the bearing housing, the CMRT notices bubbles rising from the bottom of the
oiler. This indicates which of the following.
a. The pipe nipple between oiler and bearing is plugged with sludge, causing the oil
bottle to over pressurize.
b. Air has entered the bearing housing and is interacting with the oil in the reservoir.
c. The level in the bearing housing has dropped and is being refilled by the reservoir
bottle.
d. The oiler temperature is rising to a boiling point and is interacting with the oil in the
reservoir.
129. Which of the following can be used to monitor bearings, pipe thickness, and
weakness, lubrication and steam traps?
a. Thermographic imaging
b. Vibration analysis
c. Ultrasonic testing
d. Tribology
130. Cavitation in a hydraulic pump is most often caused by a build up of dirt and
contaminants on the:
a. Working cylinder
b. Accumulator
c. Suction Strainer
d. Relief Valve
131. What is the primary determinant of the load carrying capacity of an oil film:
a. Viscosity
b. Revolutions per minute
c. Temperature
d. Contamination
132. Which one of the following is least likely to be a symptom of pump misalignment?
a. High discharge pressure
b. High power draw
c. Seal leaking
d. Squealing noise

Page 26 of 33
 133. Using chart below, what would be the best materials to use for a gasket that will be
exposed to 300°F and 1500psi?
a. Nitrile
b. SBR
c. EPDM
d. Asbestos
Material Temperature Max Deg Pressure Max PSI/Bar PxT Max/Bar
F / Deg C
EPDM 300/149 150/10.3 20000/1380
Natural Rubber 200/93 100/6.9 15000/1034
SBR 200/93 100/6.9 15000/1034
Neoprene 250/121 150/10.3 20000/1380
Nitrile 250/121 150/10.3 20000/1380
Asbestos Rubber 900/480 3000/207 35000/24130
Binder
Asbestos / SBR Binder 750/400 1800/124 35000/24130
Asbestos / Neoprene 750/400 1500/103 35000/24130
Binder
Asbestos / Nitrile 750/400 1500/103 35000/24130
Binder

134. A predictive maintenance program relies on data collection to enable comparative

analysis for:
a. Trending
b. Replacements of maintenance inventories
c. Scheduling
d. A one time snapshot of conditions.
135. A job has been assigned to repair a reciprocating compressor. When planning this
job, which sequence should be followed to break down the scope of work?
a. Disassemble, reassemble, test, document
b. Disassemble, inspect or repair, reassemble, test
c. Inspect, document, repair, test
d. Test, disassemble, repair, test
136. How can a centrifugal pump be stopped from cavitating?
a. Increase net positive suction head (required) and increase flow rate
b. Increase net positive suction head (available) and decrease flow rate
c. Increase volumetric flow rate and decrease discharge head
d. Increase pump RPM and increase fluid temperature
137. The scale on a micrometer that reads in ten thousandths of an inch is called a
a. Tramel scale
b. Depth scale
c. Thimble scale
d. Vernier scale
138. Which statement illustrates the effects on slings in relation to the sling angle
a. The sling angle is dependent on the size of the sling
b. The sling angle has no effect on lifting capacity
c. The smaller the sling angle, the lower the lifting capacity
d. The greater the sling angle, the lower the lifting capacity

Page 27 of 33
139. Which of the following is the most probably cause of bearing failure that is not
related to bearing in use stress?
a. The bearing was left out of the box in storage
b. The bearing was in sunlight too long
c. The bearing was wrapped in oil wrapping
d. The bearing was handled with bare hands
140. What pipe parameter is identified by the schedule attached?
a. Wall thickness
b. Pipe thread
c. Pipe length
d. Pipe composition
141. If a coolant is being used with a grinder and the splash shields have been removed, a
CMRT should do which of the following?
a. Operate the grinder with care to watch for flying fragments
b. Remove the grinder from service until repairs can be made
c. Use a face shield over his or her safety glasses before operating
d. Complete grinding and then reinstall the splash shields
142. After performing a preventive or corrective maintenance task, the results for each
equipment should be located in which of the following?
a. P&ID files
b. Work Permits
c. Shop logs
d. Equipment files
143. A full oil supply bulb is not
a. An indicator that the bearing housing constantly leaks oil
b. An indication that the bottle has been overfilled
c. An indication that the bearings have adequate lubrication
d. In need of further investigation in a preventative maintenance inspection
144. It is extremely important that all documentation be which of the following?
a. Kept up to date
b. Organized according to equipment number
c. Locked up securely
d. Stored in fireproof cabinets
145. Which of the following centrifugal pump conditions is not the result of cavitation?
a. Low discharge pressure
b. High power draw
c. High bearing temperature
d. High bearing vibration
146. What is the major goal of housekeeping
a. To teach the proper use of maintenance equipment
b. To prevent or reduce the occurrence of accidents
c. To load or place equipment or supplies properly
d. To put safety policies and procedures in writing
147. When is a piece of equipment considered to be in a zero energy state?
a. When pump and motor are uncoupled and locked out
b. The primary energy source is de-energized and locked out
c. It has been isolated from the electrical power source of the specific piece of
equipment
d. It has been isolated from sources of energy associated with the specific piece of
equipment

Page 28 of 33
148. Immediately following start-up, a newly installed mechanical seal begins to leak. The
gland bolts on the pump are tight. Which of the following may be a cause of the leak?
a. The seal cavity has insufficient pressure
b. The product is vaporizing or flushing across seal faces
c. The throttle bushing clearance is excessive
d. The seal faces may have been damaged during installation
149. What type of maintenance is used when measuring physical parameters against
known engineering limits for detecting, analyzing, and correcting equipment problems
before failure occurs?
a. Reactive
b. Reliability-centered
c. Preventive
d. Predictive
150. Gear backlash is commonly measured by:
a. Holding one gear of the pair stationary and rocking the other gear back and forth
b. Holding both gears stationary and turning the shafts
c. Using vibration analysis equipment
d. Holding one gear of the pair stationary and turning the shaft connected to that gear.

Page 29 of 33
151. Which of the following is an advantage of a preventive maintenance program?
a. Lowers cost of production materials
b. Increases equipment uptime
c. Allows for frequent access to equipment
d. Enhances operator’s motivation.
152. Cavitation in a hydraulic pump is most often caused by a build up of dirt and
contaminants on the:
a. Working cylinder
b. Accumulator
c. Suction strainer
d. Relief valve
153. Prior to a cold plant boiler start-up, it is typically the maintenance mechanics
responsibility to make sure that all boiler hatch covers are in what condition?
a. Closed and pressure tested
b. Documented on work orders
c. Closed and sealed
d. Closed and vented
154. The first step in a troubleshooting process is to define the problem. Which of the
following would be the most important skill to apply?
a. Training
b. Communication
c. Supervision
d. Social
155. After installing a motor on a recently serviced pump, the mechanic discovers it is not
pumping properly. Which of the following is the most probably cause?
a. Inadequate horsepower
b. Coupling not connected
c. Plugged discharge line
d. Wrong direction of rotation
156. What kind of permit may be required if combustible materials are stored in close
proximity to a welding job?
a. Hot work
b. Preheating
c. Confined entry
d. Welding
157. What is the most common tolerance recommended by manufacturers for 1800 RPM
or less coupling alignments using the rim and face method?
a. 0.0035”
b. 0.0025”
c. 0.03”
d. 0.02”
158. What predictive technologies is associated with velocity transducers and
accelerometers?
a. Mechanical ultrasound
b. Thermography
c. Vibration analysis
d. Tribology

Page 30 of 33
159. What information should a maintenance history log contain?
a. Operating procedures
b. Material safety data sheets
c. Process parameters
d. Recurring malfunctions
160. What tool could be used to approximate the speed of a piece of rotating machinery,
by making it appear to the human eye as if the machinery is stopped?
a. Digital indicator
b. Stroboscope
c. RTD
d. Oscilloscope
161. What can particulate contaminants in oil reveal about equipment?
a. Abnormal wear of internal components or parts
b. Equipment is old and needs to be replaced
c. That an oil with different viscosity is required
d. That the lubrication system needs a new filter
162. Which of the following is a good rule of housekeeping?
a. Put tools just out of the way
b. Put flammable and combustible materials in vented containers
c. Allow scrap materials to accumulate prior to disposal
d. Store tools and equipment when you are finished using them.
163. What is the most common type of respirator used by emergency response team
personnel responding to a chemical spill?
a. Half-mask respirator and filters
b. Constant flow air hood
c. Continuous air-supplied full face respirator
d. Self-contained full face respirator
164. Preventive Maintenance tasks are which of the following?
a. Always used
b. Planned
c. Breakdown driven
d. Not necessary
165. Which of the following is essential for the best belt drive performance?
a. Guarded belts and pulleys
b. Light belt lubricant and alignment
c. Proper belt tension and alignment
d. Proper belt tension and speed
166. Preventative maintenance tasks are action performed in an attempt to keep
equipment in a specific operating condition by means of which of the following?
a. Reactive maintenance activities that include replacement tasks
b. Design change to the equipment
c. Fixing what is broken
d. Systematic inspection, detection and prevention of failure
167. Vibration analysis can be used to detect which mechanical movement?
a. Thermal bearing cracks
b. Excessive gear backlash
c. Loose bolts or imbalance
d. Effects of poor lubrication additives

Page 31 of 33
168. What is a failure mode?
a. Any event that causes machine downtime
b. A method of measuring equipment reliability
c. Any event which causes the equipment to fail to deliver its function
d. A method of operating equipment in breakdown status
169. When ascending or descending a ladder, the climber must do which of the following?
a. Notify others in the area
b. Carry tools up in a container
c. Face the ladder
d. Clip tools to his/her belt
170. Before using a drill press, what must a CMRT do to the work piece to prevent injuries
a. Level it
b. Mark it
c. Secure it
d. Center it
171. When replacing bearings, what is the most important consideration?
a. Manufacturer
b. Cleanliness
c. Age
d. Temperature
172. Filling the static oil level above the recommended level in a bearing oil bath
lubrication system will cause:
a. No noticeable difference in bearing operation
b. The bearing assembly to run cooler due to thermal transfer
c. Increased bearing life due to better fluid particle cleansing
d. Excessive oil temperature due to increased churning
173. Which of the following best describes the initial signs of gear misalignment?
a. Noise and vibration
b. Off center gear ear patterns
c. Bearing failure
d. Metal particles in the oil
174. Which of the following is best practice for housekeeping?
a. Ensuring adequate lighting and sound suppression
b. Keeping work areas clean and free of scraps or spills
c. Organizing and arranging tools to permit efficient work
d. Painting all walkways and guards properly
175. The most important physical property of lubrication oil is its ______.
a. viscosity
b. fire point
c. oxidation resistance
d. flash point

Page 32 of 33
Page 33 of 33