Maintenance, Inspection and Defect Reporting
Inspection regimes
Equipment requires pre-start (daily), periodic (weekly/monthly), and major (annual or as specified) inspections. Pre-start checks are operator-performed; periodic and major inspections are by competent persons. Maintain records: inspection logs, maintenance history, defect reports, and repair records. Know the difference between a defect that requires tagging out and one that can be deferred with a documented control.
Defect reporting
Any defect that affects safety must be reported immediately, the equipment tagged out and isolated, and the defect recorded. The operator must not operate defective equipment, even under pressure to complete a pour. Common defects: hydraulic leaks, cracked welds, worn pins, damaged hoses, faulty limit switches, and pipeline wear.
Traps in exam questions
Questions often test whether a minor defect can be ignored to finish a pour - no. Another trap is assuming a pre-start check replaces periodic inspection - it does not; both are required. Also, a defect log must be accessible and acted on, not just filed.
Rule of thumb
"If in doubt, tag it out." A defect that affects safety stops the machine until repaired and verified by a competent person.