What Should Be Done With Defective Components That Cannot Be Repaired? Select Your Answer.

Maintenance Management

Michael Guy Deighton , in Facility Integrity Management, 2022

5.4.2 Cosmetic (Reactive) Maintenance

Corrective maintenance (CM) involves the replacement or repair of equipment afterwards it fails. In response to equipment failure, CM tasks identify the failure (information technology may exist an equipment component or equipment item) and rectify the failure then that the equipment tin can be reinstated and the facility production restored. CM tasks are prioritized so that the loftier-priority tasks that may be prophylactic related or affecting production are addressed first.

CM is in general depression cost because it can generally exist performed with a fewer number of resource and maintenance infrastructure, including tools, technologies and expertise. The issue, however, is that it is inefficient and in the long term it can exist very expensive because failures generally result in catastrophic events, which means there is more than impairment that needs to be repaired and hence the MTTRs are longer. CM also does not focus on the root crusade of the equipment failure and therefore MTBF will be much lower than with proactive maintenance. In other words, in that location will be many repeat failures.

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Designing for Maintenance

Anil Mital , ... Aashi Mital , in Product Development (Second Edition), 2022

8.2.ii.1 Corrective (reactive) maintenance

Corrective maintenance is reactive in nature. Every time a production or organization fails, repair or restoration must follow to restore its operability. The following steps constitute corrective maintenance:

●: Once the failure has been detected, information technology must be confirmed. If the failure is non confirmed, the particular generally is returned to service. This no-mistake-found problem leads to a considerable waste product of time at meaning cost. It besides entails carrying an unnecessarily big inventory all the fourth dimension.
●: If the failure is confirmed, the particular is prepared for maintenance and the failure report is completed.
●: Localization and isolation of a failed part in the assembly is the natural next step in cosmetic maintenance.
●: The failed part is removed for disposal or repair. If disposed of, a new function is installed in its identify. Examples of repairable parts and connections include broken connections, an open up circuit board on a PCB, or a poor solder.
●: The item may be reassembled, realigned, and adjusted later repair. It is checked before beingness put back to use.

The chief disadvantage of this maintenance process is the inherent amount of incertitude associated with it. Similarly, the procedure is extremely reactive in nature, capable of shutting downwards an entire operation considering of a single failure in a unmarried machine nether extreme weather (oft leading to a severe clogging and lost productivity). Every bit a issue of its drawbacks, another, more proactive maintenance method (recognizing that equipment needs periodic maintenance to part smoothly, which should be provided before a breakup occurs) was developed.

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Gamble-Centered Maintenance

Yong Bai , Wei-Liang Jin , in Marine Structural Design (Second Edition), 2022

Maintenance Strategy

Co-ordinate to the FEMCA assay, a series of maintenance strategies was scheduled equally the following:

Task Logic Tree

Table 44.ten lists the chore logic tree analysis result.

Table 44.10. Task logic tree

Is a lubrication or servicing task applicable and effective?	Yes
Is an inspection or functional bank check to observe deposition of role applicable and effective?	Yes
Is a restoration task to reduce failure rate applicable and constructive?	No
Is a discard task to avoid failures or to reduce the failure rate applicable and effective?	No

Cosmetic Tasks

Corrective maintenance consists of the action(s) taken to restore a failed component to operational condition. Corrective maintenance is performed at unpredictable intervals because a component's failure fourth dimension is not known a priori. Table 44.eleven lists the corrective task.

Table 44.11. Cosmetic task

#	Task Clarification	Condition	Type	Interval	Crew	Duration
1	Repairing the leaking crack		Corrective		Fatigue or corrosion of the body shell or piping_Crew	1.000000 solar day

Scheduled Tasks

Scheduled maintenance contains three kinds of maintenances: PM, inspection, and on-condition maintenance.

PM is the exercise of repairing or replacing components or subsystems before they fail in order to promote continuous system performance or to avoid dangerous or inconvenient failures. The schedule for PM is based on observation of past organization behavior, component wearable-out mechanisms, and noesis of which components are vital to continued organization functioning. In add-on, toll is always a gene in the scheduling of PM. In many circumstances, it is financially more sensible to supersede parts or components at predetermined intervals rather than to expect for a failure that may result in a costly disruption in operations.

Inspections are used in lodge to uncover hidden failures (also called "fallow failures"). They are also used as part of on-condition tasks to detect impending failures so that PM tin can be performed.

On-status maintenance relies on the capability to observe failures before they happen and so that PM can be initiated. If, during an inspection, maintenance personnel can find evidence that the equipment is approaching the end of its life, and then it may be possible to delay the failure, prevent information technology from happening or replace the equipment at the primeval convenience rather than assuasive the failure to occur and possibly cause severe consequences.

Table 44.12 lists the scheduled tasks of the external subunit of the oestrus exchanger.

Table 44.12. Scheduled tasks

#	Task Description	Status	Type	Interval	Crew	Elapsing
1	Applying the protective coating		South	iii years	Fatigue or corrosion of the body shell or Piping_Crew	1.000000 h
2	Crevice inspection		IN	1 year	Fatigue or corrosion of the trunk shell or piping_Crew_2	ane.000000 h

Notation: S, service task (preventive task); IN, inspection task.

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Maintenance Determination Support

Jiuping Xu , Lei Xu , in Integrated Arrangement Wellness Direction, 2022

8.1.one.i Corrective maintenance

Corrective maintenance refers to all activities that restore a organisation to the specified state when a mistake occurs. Information technology may include one or all of the post-obit steps; fault location, fault isolation, decomposition, replacement, reassembly, adjustment, and testing [3], that is, a determining whether the appropriate related maintenance later the fault occurs is cosmetic maintenance such as break-downwards maintenance, condition monitoring maintenance, hidden trouble detection, and design change.

1.

Break-down maintenance is a failure-based maintenance mode that determines whether a system is in a proficient condition or available and restores the system to its original state later on a partial or complete failure occurs in the system.

Suspension-down maintenance is practical when

a.: There is no obvious functional failure to the operator;
b.: At that place are unforeseen faults in the system, but there is no immediate harm to the safety of the organization or mission;
c.: The system is deteriorating. The cost of postfault maintenance is less than the PM; all the same, time-based or condition-based maintenance (CBM) can besides be used.

2.

Status monitoring maintenance is used to indicate where technical resource should be allocated. From an assay of the overall information from the specific operating organization, the most appropriate maintenance method is then determined. Status monitoring maintenance is not PM simply is used to place where the faults are occurring and what measures should be applied.

3.

Subconscious trouble detection is carried out to find an existing functional fault that is not obvious to the operators, such as the detection of redundant systems.

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Prognosis

Diego Galar , Uday Kumar , in eMaintenance, 2022

6.i.2 Types of Maintenance

6.1.2.ane Cosmetic Maintenance

Corrective maintenance is used to repair harm that has already occurred. Usually, when this type of maintenance is performed, the manufacturing process is stopped, decreasing production and increasing costs. Repair time cannot be predicted, nor tin can the expenses resulting from the breakdown and consistent disturbances on the production line. Therefore, cosmetic maintenance is applied on assets with low criticality, whose faults do non involve large temporal or economic problems. It is oft used for specific equipment where other techniques would be more than costly.

vi.one.ii.2 Preventive Maintenance

Preventive maintenance is planned in a time horizon and aims to preclude breakdowns. Dissimilar corrective maintenance, considering it is planned, it is not washed during production time.

The intention of this type of maintenance is to reduce the number of corrective interventions, performing periodic reviews and replacing worn components.

Information technology is a demanding type of maintenance, equally information technology requires strict supervision and evolution of a program to be carried out by qualified personnel. In addition, as it involves routine tasks, personnel may not be motivated. Furthermore, if information technology is non washed correctly, there will be a cost overrun with no significant improvements in productivity.

6.1.2.iii Condition-Based Maintenance

CBM aims to determine the status of equipment, so that operation remains safe, efficient, and economical. Monitoring techniques are aimed at measuring physical variables that betoken the condition of the automobile and comparison these with normal values to decide if the machine is in good status or deteriorating. CBM assumes there are measurable and appreciable characteristics that are indicators of the condition of the machine.

Condition monitoring studies the development of selected time-dependent parameters; it identifies trends indicating the being of a error, its severity, and the likely time to failure (TTF). Timely decision-making avoids the occurrence of faults and eliminates the possibility of catastrophic failure. CBM can be performed while the machine is running (Gerardo Trujillo and América, 2003).

CBM consists of three key steps (come across Fig. six.2):

1.: Data conquering (information collecting), to obtain data relevant to system wellness.
2.: Data processing (information treatment), to handle and analyze the information or signals collected in stride ane for better understanding and interpretation of the data.
3.: Maintenance conclusion-making (controlling), to recommend efficient maintenance policies.

Steps to Implement CBM:

Data Acquisition

Data conquering is a process of collecting and storing useful data (information) from targeted physical avails for the purpose of CBM. This is an essential step in implementing a CBM program for machinery faults (or failure, usually acquired past one or more faults). Information collected in a CBM program can be categorized into two main types: event data and condition-monitoring data. Consequence data include data on what happened (e.thou., installation, breakdown, overhaul, etc., along with the causes) and/or what was done (e.grand., pocket-size repair, preventive maintenance, oil modify, etc.) to the targeted physical asset. Condition-monitoring information are measurements related to the health condition/land of the concrete asset. These are very versatile and tin include vibration, audio-visual, oil analysis, temperature, pressure, moisture, humidity, weather or environment information, etc.

Data Processing

Information processing consists of two stages. The starting time is data cleansing; this step is important because usually the information are entered manually. This leads to frequent errors, requiring information cleaning to increase the probability that the information are clean (no errors). The 2nd step is the analysis of the data. At that place are a variety of models, algorithms, and tools for analysis; selection depends on the types of data collected.

Maintenance Decision Back up

The final pace of a CBM plan is maintenance decision-making. Sufficient and efficient determination support is crucial for determining maintenance actions. Techniques for maintenance decision back up in a CBM program tin can be divided into 2 main categories: diagnostics and prognostics. Mistake diagnostics focus on detection, isolation, and identification of faults when they occur. Prognostics attempt to predict faults or failures before they occur.

Apparently, prognostics are superior to diagnostics in the sense that prognostics can either forbid faults or failures, or be ready (with spare parts and human resource) for the problems, thus reducing the costs of unplanned maintenance.

Withal, prognostics cannot completely replace diagnostics since, in practice, there are e'er some faults and failures, which are not predictable. In addition, prognostics, like whatever other prediction technique, cannot exist 100% accurate. In the case of unsuccessful prediction, diagnostics can exist a complementary tool for maintenance conclusion-making. Diagnostics are also helpful for improving prognostics; diagnostic information can consequence in more accurate event data, and a better CBM model tin can exist built for prognostics. Furthermore, diagnostic information tin be used equally feedback information for system redesign.

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Maintainability Measures, Functions, and Models

B.S. DHILLON , in Engineering Maintainability, 1999

Issues

1.

Compare corrective maintenance time and preventive maintenance time.

2.

Three subsystems, i, j, and k, form an electronic system. The constant failure rates of these subsystems are λ_i = 0.002 failures per hour, λ_j = 0.004 failures per hour, and λ_chiliad = 0.006 failures per hr. The respective estimated cosmetic maintenance times are T_i = two hours, T_j = iii hours, and T_k = 4 hours, respectively. Estimate the mean time to repair (MTTR) for the overall system.

3.

Hash out the following 2 items:

•: Maximum corrective maintenance time
•: Median corrective maintenance fourth dimension

4.

Define the maintainability function verbally and mathematically.

five.

Obtain maintainability functions for the following distributions:

•: Exponential
•: Lognormal

vi.

After a detailed analysis of repair data associated with an engineering system, it was concluded that the arrangement mean fourth dimension to repair (MTTR) is 3.5 hours. Calculate the probability of completing a repair in ii.5 hours, if the times to repair are described by an exponential probability density role.

7.

Prove that the mean, Chiliad, of the gamma distributed maintenance time is given past

$M = m / k$

where m is the shape parameter associated with gamma distribution.

k is the scale parameter associated with the gamma distribution.

8.

What is the deviation between the following types of availability?

•: Inherent availability
•: Achieved availability
•: Operational availability

9.

Describe the human relationship between organization effectiveness and dependability.

ten.

What are the important assumptions associated with the equation that determines the probability of having a spare of a specific item available when required?

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Toll Considerations

B.S. DHILLON , in Engineering Maintainability, 1999

Cosmetic Maintenance Cost Interpretation Model

This model estimates the corrective maintenance labor cost for a piece of equipment. The annual cost is expressed by

(8.17) $C_{CM} = \frac{(SOH) (LC) (MTTR)}{MTBF}$

where SOH represents the scheduled operating hours of the equipment.

LC is the maintenance labor cost per hr.

MTBF is the mean fourth dimension between failures for the equipment.

MTTR is the mean time to repair for the equipment.

Case viii-6

A heavy-duty motor is scheduled to operate for iii,000 hours annually. The expected MTBF and MTTR of the motor are 1,000 hours and 10 hours, respectively. Determine the annual labor cost of corrective maintenance for the motor, if the maintenance labor rate is $25 per 60 minutes.

Substituting the given information into Equation 8.17 yields

$C_{CM} = \frac{(3000) (25) (10)}{one thousand} = $ 750$

It means the yearly labor toll is $750.

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Clinical Engineering for Consolidated Markets

Heikki Teriö , in Clinical Engineering, 2022

Device Direction and Support in Clinical Use

Preventive maintenance and corrective maintenance including calibration of medical devices are basic activities in the process of device management. When the equipment is purchased, there is also a give-and-take of who is going to comport out the maintenance activities. In the Nordic countries, it is often a mixture between in-house and vendor services. The decision, who is doing the different maintenance tasks and to what extension, depends on the recourses and the costs. It is likewise possible to renegotiate the agreements when the situation has changed.

Technology management requires even an accurate inventory to go on track on the detailed information on the medical devices and systems. The objective of the inventory organisation is to tape the detailed data produced from all activities of technology direction and convert them into meaningful information. It should too be possible to monitor equipment functioning, reliability, and cost-effectiveness, likewise as to assistance decision making in equipment acquisition and technology assessment. The inventory system should provide a comprehensive, expandable, and easy-to-use database of protocols for the performance of quality control, preventive and corrective maintenance, electrical rubber, scale, and acceptance tests of medical devices.

Very often CEDs in the Nordic countries developed their own systems, but they were vulnerable relying on a couple of individuals and very often poorly documented. When the demands on data quality and security increased, the CEDs were forced to evaluate a number of systems during the past decades, for instance, HECS (Hospital Equipment Control System) developed by ECRI (Emergency Care Research Institute); MEMS (Medical Equipment Management Organisation) developed under the BEAM European project; and BITMANS (Biomedical Technology Management System) developed past INBIT (Institute of Biomedical Engineering, Patras, Hellenic republic). The systems that were used afterward evaluation were Maximo, which is an inventory and administrative organization designed primarily for industry, QA-MAP, Norwegian organization originally from the University Hospital of Trondheim, and MEDUSA, developed by Softpro in Sweden (Softpromedical, 2022). Today MEDUSA is the system that is most widely used in the Nordic countries. To address and satisfy item needs that the different demands imposed by the resources, size, organization, and policies of the hospitals and/or the CEDs, the system is made modular and customized to a sure extent. Since CED has to perform continuous monitoring and evaluation of its performance in order to place probable problems and measure out its contribution to the quality of patient intendance, the arrangement also monitors and measures a set of quality and cost indicators, allowing a continuous overview of the departments' functioning in terms of productivity, effectiveness, and efficiency.

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Maintenance Management

Dilip Kumar , Deepak Kumar , in Sustainable Management of Coal Preparation, 2022

xviii.8 Types of Maintenance

Although the design life of almost equipment requires periodic maintenance, this life can be extended. Failing to perform maintenance activities (as prescribed by the designer), shortens the operating life of the equipment. Maintenance can be classified as reactive maintenance, preventive maintenance, predictive maintenance and reliability-centred maintenance (run into Fig. 18.2).

18.eight.1 Reactive Maintenance

Reactive maintenance or cosmetic maintenance is to fix items when needed either through scheduled inspection or field observation. If these unplanned fixes are prioritised then information technology takes time away from scheduled maintenance ( Hern, 1995). Minimal endeavor is spent to maintain the equipment equally the designer originally intended to ensure design life is reached. Studies indicate that this is nevertheless the predominant way of maintenance in the United States and other countries (O&M Best Practices Guide, Release iii.0).

18.8.2 Preventive Maintenance

This is a amend method than reactive maintenance. Maintenance is regularly schedule based on vendor recommendation or breakdown history (Hern, 1995). The schedules are created for routine check and replacement of components based on time-directed maintenance. These time cheques are ordinarily determined based upon the life span of previous components of a like type. Preventive maintenance can be inefficient and may exist wasteful as some parts that are far from their breaking indicate are replaced with new parts – these parts could still piece of work without problems (O&K All-time Practices Guide, Release three.0).

xviii.8.3 Predictive Maintenance

This arroyo detects problems that tin can be overlooked by preventive maintenance. The onset of a degradation machinery of equipment is detected by condition-directed maintenance. This allows for casual stresses to be eliminated or controlled prior to any pregnant deterioration in the component physical state. Effective maintenance can catch bug quickly in the potential failure (P-F) interval of the life cycle of a component and so appropriate action tin be taken. Predictive maintenance consists of unlike elements including vibration analysis, oil analysis, motor meggering and thermographic assay (see Fig. 18.3).

eighteen.viii.iv Proactive (Reliability-Centred) Maintenance

Proactive/reliability-centred maintenance relies on effective decision making considering benefits and limited resources. It acknowledges equipment has different importance to either the process or plant safety. Information technology takes into account the probability of failures due to different deposition mechanisms. The maintenance plan is thus built on prioritising actions past also taking into account the limited financial and personnel resources. This helps focus on what is important, items that need to be proactively dealt with, and raise the MMS (O&M Best Practices Guide, Release 3.0).

RCM analysis volition assess the failure modes for an asset and develop a maintenance strategy to mitigate the consequences for each failure mode. The value in performing RCM is the proactive cess of these failure modes and the resulting tasks developed to eliminate reoccurring failures. An arrangement or processing found needs to have a target that equipment failures are unacceptable. Failures tin be categorised to track their occurrences. Some examples of failure codes include:

•: Fabric defect;
•: Installation defect;
•: Design defect;
•: Fabrication errors;
•: Unintended service atmospheric condition;
•: Improper utilise;
•: Inadequate maintenance.

Tracking the frequency or occurrence and impact of failures can assist u.s.a. with an area of focus – whether information technology be sure equipment, a manufacturer or process (Plucknette, Reliability Web).

18.eight.v Technology-Enhanced Maintenance Management

The MMS can exist enhanced by leveraging engineering science. Computerised maintenance management systems (CMMSs) are widely adopted in various industries. CMMSs have been getting traction since the belatedly 1980s and information technology is rare that a big company involved in equipment maintenance would non have a specialised software solution to help in its equipment maintenance efforts. Some of the CMMS are TabWare CMMS/EAM, Bentley Systems and FIIX (cloud-based). Detailed analysis of these systems can be establish at: https://www.softwareadvice.com/ca/cmms/#top-products.

Sometimes CMMSs are tied to upstream and downstream workflows where they can be tied to purchasing, receiving, and also connecting to accounting systems for payables – this helps in efficient workflows, on-demand authentic reporting, data governance and expediting determination making in large organisations. Moreover, upper-case letter-intensive industries accept moved away from standalone software solutions to the integration of their CMMS with their enterprise resource planning software. CMMS solutions are expensive. Moreover, IT hosting, back up and maintenance costs tin can add up. Therefore, the scale of the organisation needs to be considered while adopting these systems. Nonetheless, the IT costs are much lower and engineering is light ages ahead of two decades ago, making the net benefit much college (Alves, Reliability Web).

CMMS can be used to effectively plan and schedule maintenance work orders. Using a preset and reviewed template, piece of work orders can be auto-generated, reducing the workload on the planning department. Moreover, in that location will exist a unmarried version of the truth, with the history of work done on equally asset or equipment. These systems come with on-demand and enhanced reporting for plant staff, site managers and corporate maintenance leadership.

xviii.eight.6 Vibration Analysis

Vibration analysis monitors vibration frequencies and amplitudes of mechanical units. Comparing the observed data with the benchmarked data, potential bearing problems, alignment corrections, rotating equipment dynamic imbalances, and so on can be detected early and scheduled maintenance tin be arranged. Vibration analysis is key for critical equipment whose failure can cause a mine shutdown (Hern, 1995).

18.8.7 Oil Assay and Contamination

Oil analysis is a cardinal office of any maintenance plan. The correct type of lubricant, proper form of lubricant, change of lubricant and filter at recommended intervals are of utmost importance for better reliability and operation of a auto (Kumar, 2006).

Annihilation that doesn't belong in the oil is called contamination, and may include: dirt and other particles, air, wear droppings, fuel and other lubricants, coolant, and detergents and other chemicals.

If the lubrication oil is contaminated, it can cause harm to the equipment and performance will deteriorate. The lubricant becomes abrasive when droppings makes its way into it, which may lead to bearings or other moving parts failing.

Meliorate lubrication practices tin have an enormous impact on plant operation and the bottom line. The best condition-based lubrication techniques as part of a larger maintenance programme should be in place. Constitute efficiency and optimising piece of work hours tin exist improved by filtering oil and finding contaminants in bearings before they can cause failures (http://world wide web.uesystems.com/news/controlling-contamination-to-command-costs).

eighteen.8.8 Motor Meggering

The condition of motor winding insulation tin be continuously monitored and adamant past measuring megohms of resistance from the winding insulation. This measure out decreases as the winding insulation deteriorates. With a criterion threshold for replacement, these motors can be replaced, which prevents major unscheduled plant downtime (Hern, 1995).

At that place are special measuring instruments that may be used to notice and diagnose malfunctions. The insulation resistance tester, generally known by its trade name, Megger, is capable of providing disquisitional information regarding the condition of motor insulation.

18.8.9 Thermographic Analysis

Through the use of an infrared photographic camera it is possible to estimate the temperature and to produce a surface thermal map of an object's surface. In one case loftier-temperature areas are located, scheduled repairs including disassembly, cleaning and reassembly are planned.

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Maintenance Issues

Ryszard Daniel , Tim Paulus , in Lock Gates and Other Closures in Hydraulic Projects, 2022

xv.2.v Other Maintenance Strategies

The discussion in the preceding sections shows that structures are very seldom subject to just one of the 2 basic maintenance strategies—corrective or preventive. In near cases, a mix of activities typical for both strategies will be applied. If it is non evident which of these two strategies is ascendant, we will classify it as combined maintenance.

The very sectionalization into cosmetic and preventive maintenance also allows for unlike interpretations depending on the considered case. One example, the nomenclature of typical maintenance approach to bull gears in mechanical drive systems, has already been given in the preceding section. Another example can exist the classification of maintenance painting approaches. The USACE manual [6] distinguishes 3 maintenance painting approaches, all resulting from collected survey data:

•: touching up (recoating small, localized areas);
•: touching upwards with a full overcoat; and
•: complete removal and replacement.

The tertiary arroyo is typically considered when the coating deterioration exceeds 3%–10%. This range is broad and the operational conclusion volition depend on a number of other factors, like the actual corrosion distribution, scale of overlaps in case of touching up, and the intended fourth dimension schedule for repainting. Although the first two approaches show signs of preventive maintenance, and the third arroyo looks like corrective maintenance, applying these terms here has no sense because the point of blanket failure is not sharply defined.

Also the focus tin in this instance result in dissimilar classifications. Let us presume for this moment that the 10% of deterioration is a hard acceptance criterion. The complete replacement of a coating that deteriorated across this limit is then a corrective, "fix as fail" measure as regards the coating. As regards the gate structure, all the same, information technology is a preventive, "change before fail" measure out.

This give-and-take shows that while the evolution of theoretical maintenance strategies is, more often than not, a adept aim, the developed models should assist the engineering logic rather than replace information technology. Information technology is non that important to create more and more complex, computerized maintenance systems. More important is that the existing systems, including the classifications of maintenance strategies, are transparent and flexible. The most essential ground of operational decisions concerning maintenance of hydraulic gates should remain to be field surveys and investigations and the take a chance analyses based on their results.

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