Reliability centered maintenance (RCM): implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis]
Gespeichert in:
| 1. Verfasser: | |
|---|---|
| Format: | Buch |
| Sprache: | English |
| Veröffentlicht: |
New York, NY [u.a.]
McGraw-Hill
2006
|
| Schlagworte: | |
| Online-Zugang: | kostenfrei kostenfrei Inhaltsverzeichnis Inhaltsverzeichnis Inhaltsverzeichnis |
| Beschreibung: | XX, 291 S. Ill., graph. Darst. 24 cm |
| ISBN: | 0071460691 |
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| 245 | 1 | 0 | |a Reliability centered maintenance (RCM) |b implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] |c Neil Bloom |
| 264 | 1 | |a New York, NY [u.a.] |b McGraw-Hill |c 2006 | |
| 300 | |a XX, 291 S. |b Ill., graph. Darst. |c 24 cm | ||
| 336 | |b txt |2 rdacontent | ||
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Datensatz im Suchindex
| _version_ | 1804140651619549184 |
|---|---|
| adam_text | Contents
Preface xiii
Acknowledgments xix
Chapter 1 Introduction to RCM 1
1.1 Uncovering the Fuzziness and Mystique of RCM 4
1.2 The Background of RCM g
1.3 A No-Nonsense Approach to RCM 11
1.4 RCM as a Major Factor in the Bottom Line 12
Chapter 2 Why RCM Has Historically Been So Difficult to Implement 15
2.1 Consultants 15
2.2 A White Elephant 16
2.3 Reasons for Failure 18
2.3.1 Loss of In-House Control 18
2.3.2 An Incorrect Mix of Personnel Performing the Analysis 19
2.3.3 Unnecessary and Costly Administrative Burdens 20
2.3.4 Fundamental RCM Concepts Not Understood 21
2.3.5 Confusion Determining System Functions 21
2.3.6 Confusion Concerning System Boundaries and Interfaces 21
2.3.7 Divergent Expectations 23
2.3.8 Confusion Regarding Convention 24
2.3.9 Misunderstanding Hidden Failures and Redundancy 24
2.3.10 Misunderstanding Run-to-Failure 25
2.3.11 Inappropriate Component Classifications 25
2.3.12 Instruments Were Not Included as Part of the RCM Analysis 26
Chapter 3 Fundamental RCM Concepts Explained,
Some for the Very First Time: The Next Plateau 27
3.1 The Three Phases of an RCM-Based Preventive Maintenance Program 30
3.2 The Three Cornerstones of RCM 32
3.3 Hidden Failures, Redundancy, and Critical Components 34
3.4 Testing Hidden Systems 45
vii
viii Contents
3.5 The Missing Link: Potentially Critical Components 46
3.6 Commitment Components 50
3.7 Economic Components 51
3.8 The Canon Law of Run-to-Failure Components 52
3.9 The Integration of Preventive and Corrective Maintenance and the
Distinction Between Potentially Critical and Run-to-Failure
Components 57
3.9.1 An RTF CM versus a Critical CM: Which Takes Priority
for Getting Worked First? 59
3.10 The Anatomy of a Disaster 61
3.11 A Deeper Look at Critical Components, Potentially Critical
Components, and Hidden Failures—How They All Fit Together 65
3.12 Finding the Anomalies 68
3.13 Failures Found During Operator Rounds 70
3.14 Redundant, Standby, and Backup Functions 70
3.15 Typical Examples of Component Classifications 73
3.16 Component Classification Hierarchy 73
3.17 The Defensive Strategies of a PM Program 75
3.18 Eliminating the Requirement for Identifying Boundaries
and Interfaces 75
3.19 Functions and Functional Failures Are Identified
at the Component Level, Not the System and Subsystem Level 77
3.20 The Quest for the Consequence of Failure 79
3.21 The COFA versus the FMEA 81
3.22 How Do You Know When Your Plant Is Reliable? 83
3.23 Chapter Summary 85
Chapter 4 RCM Implementation: Preparation and Tools 89
4.1 Preparation 90
4.2 The Sequential Elements Needed for the Analysis 91
4.2.1 A Simple but Comprehensive Alphanumeric
Equipment I.D. Database 91
4.2.2 Informational Resources 93
4.2.3 Establishing Convention 94
4.2.4 Specialized Workstations and Software 94
4.2.5 The COFA Excel Spreadsheet versus the FMEA 95
4.2.6 The PM Task Worksheet 100
4.2.7 The Economic Evaluation Worksheet 102
4.3 Chapter Summary 105
Chapter 5 RCM Made Simple: Implementation Process 107
5.1 Define Your Asset Reliability Strategy 109
5.2 Understanding the RCM COFA Logic Tree, the Potentially
Critical Guideline, and the Economically Significant Guideline 112
5.3 Completing the COFA Worksheet in Conjunction with the
COFA Logic Tree, the Potentially Critical Guideline,
and the Economically Significant Guideline 120
5.3.1 Describe the Component Functions 121
Contents ix
5.3.2 Describe the Functional Failures 123
5.3.3 Describe the Dominant Component Failure Modes
for Each Functional Failure 124
5.3.4 Is the Occurrence of the Failure Mode Evident? 124
5.3.5 Describe the System Effect for Each Failure Mode 126
5.3.6 Describe the Consequence of Failure Based
on the Asset Reliability Criteria You Selected 129
5.3.7 Define the Component Classification 129
5.4 RCM Serves as a Translation of the Design Objectives 131
5.5 Companion Equipment 133
5.6 The SAE Standard: Document JA1011 134
5.7 A Real-Life Analysis: Averting a Potentially Devastating Plant
Consequence 135
5.8 Why Streamlined RCM Methods Are Not Recommended 141
5.8.1 Total Productive Maintenance (TPM) 142
5.8.2 Reliability-Based Maintenance (RBM) 142
5.8.3 Probabilistic Safety Analysis (PSA)
Based Maintenance 142
5.8.4 80/20 Rule 142
5.9 Chapter Summary 143
5.10 RCM Made Difficult 147
5.10.1 Determine System Boundaries 148
5.10.2 Determine Subsystem Boundaries 148
5.10.3 Determine Interfaces 149
5.10.4 Determine Functions 149
5.10.5 Determine the Functional Failures 150
5.10.6 Determine Which Equipment Is Responsible
for the Functional Failures 150
Chapter 6 The PMTask Selection Process 153
6.1 Understanding Preventive Maintenance Task Terminology 154
6.2 Condition-Directed, Time-Directed, and Failure-Finding Tasks 154
6.3 The PMTask Worksheet 157
6.4 The PMTask Selection Logic Tree 158
6.5 Why a Condition-Directed Task Is Preferred 161
6.6 Determining the PM Task Frequency and Interval 162
6.6.1 The Optimum Time to Establish a Reliability Program 165
6.7 Is a Design Change Recommended? 166
6.8 Completing a Typical PM Task Worksheet 167
6.9 Institute Technical Restraints 168
6.10 A Sampling Strategy 169
6.11 Common Mode Failures 171
6.12 Different Predictive Maintenance (PdM) Techniques 172
6.12.1 Vibration Monitoring and Analysis 172
6.12.2 Acoustic Monitoring 173
6.12.3 Thermography or Infrared Monitoring 173
6.12.4 Oil Sampling and Analysis 173
6.12.5 X-ray or Radiography Inspection 173
6.12.6 Magnetic Particle Inspection 174
x Contents
6.12.7 Eddy Current Testing 174
6.12.8 Ultrasonic Testing 174
6.12.9 Liquid Penetrant 174
6.12.10 Motor Current Signature Analysis (MCSA) 174
6.12.11 Boroscope Inspections 174
6.12.12 Diagnostics for Motor-Operated Valves 175
6.12.13 Diagnostics for Air-Operated Valves 175
6.13 Chapter Summary 175
Chapter 7 RCM for Instruments 181
7.1 Instrument Categories 182
7.2 Instrument Design Tolerance Criteria 183
7.3 The Instrument Logic Tree 185
7.3.1 Block 1: Is the Instrument a Functional Instrument? 185
7.3.2 Block 2: Instrument Is Analyzed in the COFA Worksheet
and the PM Task Selection Worksheet. 185
7.3.3 Block 3: Can the Instrument Reading Result
in an Operator Having to Initiate Some Kind of Action? 185
7.3.4 Block 4: A PM Is Required. Calibration Criteria
and Periodicity Guidance Are as Follows. 186
7.3.5 Block 5: Were the Last Three Successive Calibrations
Within Vendor Tolerance Criteria? 186
7.3.6 Block 6: Periodicity Extension Is Allowed. 187
7.3.7 Block 7: Reduce Periodicity or Implement a Design Change. 187
7.3.8 Block 8: Is the Instrument Redundant? 187
7.3.9 Block 9: Is an Indication Comparison Applicable? 187
7.3.10 Block 10: Is the Consequence of Excessive Drift
(to the Point of Instrument Failure) Acceptable? 188
7.3.11 Block 11: A Calibration PM Is Optional. 189
7.3.12 Block 12: A PM Is Required. Calibration Criteria
and Periodicity Guidance Are as Follows. 189
7.3.13 Block 13: Were the Last Two Successive Calibrations
Within a +1-2.5 Percent Accuracy Tolerance? 189
7.3.14 Block 14: Periodicity Extension Is Allowed. 189
7.3.15 Block 15: Were the Last Two Successive Calibrations
Within a +/-5.0 Percent Accuracy Tolerance? 189
7.3.16 Block 16: Periodicity Extension Is Not Allowed. 190
7.3.17 Block 17: Reduce Periodicity or Implement a Design Change. 190
7.4 Chapter Summary 190
Chapter 8 The RCM Living Program 193
8.1 A Model for an RCM Living Program 194
8.1.1 The Craft Feedback Evaluation Element 196
8.1.2 The Corrective Maintenance (CM) Evaluation Element 203
8.1.3 The Other Inputs Element 205
8.1.3.1 Root-Cause Evaluations 206
8.1.3.2 Vendor Bulletins 206
8.1.3.3 Regulatory Bulletins 207
8.1.3.4 Industry Failure Data 207
8.1.3.5 Engineering Evaluations 208
Contents xi
8.1.3.6 Plant Design Changes 208
8.1.3.7 New Commitments 208
8.1.4 Monitoring and Trending 209
8.1.5 The RCM Analysis Element 209
8.1.6 Equipment Database 210
8.1.7 The PM Audit 210
8.2 Chapter Summary 212
Chapter 9 An RCM Monitoring and Trending Strategy 217
9.1 What Is Reliability and How Do You Measure It? 218
9.2 Monitoring Reliability Is Like Monitoring the Human Body 220
9.3 Caution: Avoid Analysis Paralysis Performance Monitoring 220
9.4 The Aggregate Metrics 222
9.4.1 Unplanned Plant or Facility Trips 223
9.4.2 Capacity Factor 224
9.4.3 Unplanned Operator Actions 224
9.4.4 Unplanned Power Reductions 225
9.4.5 Production Delays 225
9.4.6 Enforcement Actions 226
9.4.7 Litigation Occurrences 226
9.4.8 Citations and Violations 227
9.4.9 Root-Cause Evaluations 227
9.4.10 Injuries 228
9.4.11 Rate of Written CMs 228
9.4.12 Overdue CM Backlog 229
9.4.13 Overdue PM Backlog 229
9.5 Weighting Factors 230
9.6 Performance Calculations 231
9.7 Performance Graph 235
9.8 Performance Graph by System 237
9.9 A Final Caution 239
9.10 Benchmarking 239
9.11 More About Expected Performance Rates 241
9.12 Avoid Reliability Complacency 241
9.13 How to Maintain Your Reliability Performance 242
9.14 Chapter Summary 246
Chapter 10 RCM Implementation Made Simple—Epilogue 249
10.1 RCM as a Plant Culture 249
10.2 A Step-by-Step Review of the Process 251
10.2.1 Select an RCM Point of Contact 251
10.2.2 Review the Reasons for RCM Program Failures 255
10.2.3 Understand the Concepts 255
10.2.4 Define Your Asset Reliability Criteria 255
10.2.5 Establish Your Alphanumeric Equipment Database 256
10.2.6 Analyze Each Component Function in the COFA Logic Tree 256
10.2.7 Analyze Each Component Function in the
Potentially Critical Guideline 257
xii Contents
10.2.8 Analyze Each Component Function in the
Economically Significant Guideline 257
10.2.9 Enter All Data in the COFA Worksheet 258
10.2.10 Classify Each Component 258
10.2.11 Analyze All Classified Components Except Run-to-Failure
Components in the PM Task Selection Logic Tree 258
10.2.12 Document All Tasks and Periodicities on the PM
Task Worksheet 258
10.2.13 Analyze Instruments in the Instrument Logic Tree 259
10.2.14 Develop Your RCM Living Program 259
10.2.15 Establish Monitoring and Trending Program Metrics 260
10.2.16 Establish Your Expected Performance Rate 260
10.2.17 Establish Your Actual Performance Rate 261
10.2.18 Establish Your Trend Graphs 261
10.2.19 Maintain Continued Vigilance Over Your Program 261
10.3 Taking Command of Your Own Ship 262
Glossary 265
Bibliography 285
Index 287
|
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| indexdate | 2024-07-09T22:03:22Z |
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| isbn | 0071460691 |
| language | English |
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| spelling | Bloom, Neil B. Verfasser aut Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] Neil Bloom New York, NY [u.a.] McGraw-Hill 2006 XX, 291 S. Ill., graph. Darst. 24 cm txt rdacontent n rdamedia nc rdacarrier Instandhaltung (DE-588)4027145-6 gnd rswk-swf Instandhaltung (DE-588)4027145-6 s DE-604 http://www.loc.gov/catdir/enhancements/fy0664/2005054460-b.html Contributor biographical information kostenfrei http://www.loc.gov/catdir/enhancements/fy0664/2005054460-d.html Publisher description kostenfrei http://www.loc.gov/catdir/enhancements/fy0664/2005054460-t.html kostenfrei Inhaltsverzeichnis DE-605 pdf/application http://www.gbv.de/dms/hbz/toc/ht014682280.pdf 2008-11-15 Inhaltsverzeichnis HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=018600301&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Bloom, Neil B. Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] Instandhaltung (DE-588)4027145-6 gnd |
| subject_GND | (DE-588)4027145-6 |
| title | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] |
| title_auth | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] |
| title_exact_search | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] |
| title_full | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] Neil Bloom |
| title_fullStr | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] Neil Bloom |
| title_full_unstemmed | Reliability centered maintenance (RCM) implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] Neil Bloom |
| title_short | Reliability centered maintenance (RCM) |
| title_sort | reliability centered maintenance rcm implementation made simple identify system functions features and consequences hidden failure modes in plant and equipment run to failure components and limitations understanding systems analysis |
| title_sub | implementation made simple ; [identify system functions, features and consequences ; hidden failure modes in plant and equipment ; run-to-failure components and limitations ; understanding systems analysis] |
| topic | Instandhaltung (DE-588)4027145-6 gnd |
| topic_facet | Instandhaltung |
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