Reliability Centered Maintenance (RCM)

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Reliability Centered Maintenance (RCM)

Reliability Centered Maintenance (RCM)

Authors: Neil Bloom

Published: December 2005

eISBN: 9780071589185 007158918X | ISBN: 9780071460699

Contents

Preface

Acknowledgments

Chapter 1 Introduction to RCM

1.1 Uncovering the Fuzziness and Mystique of RCM

1.2 The Background of RCM

1.3 A No-Nonsense Approach to RCM

1.4 RCM as a Major Factor in the Bottom Line

Chapter 2 Why RCM Has Historically Been So Difficult to Implement

2.1 Consultants

2.2 A White Elephant

2.3 Reasons for Failure

2.3.1 Loss of In-House Control

2.3.2 An Incorrect Mix of Personnel Performing the Analysis

2.3.3 Unnecessary and Costly Administrative Burdens

2.3.4 Fundamental RCM Concepts Not Understood

2.3.5 Confusion Determining System Functions

2.3.6 Confusion Concerning System Boundaries and Interfaces

2.3.7 Divergent Expectations

2.3.8 Confusion Regarding Convention

2.3.9 Misunderstanding “Hidden” Failures and Redundancy

2.3.10 Misunderstanding Run-to-Failure

2.3.11 Inappropriate Component Classifications

2.3.12 Instruments Were Not Included as Part of the RCM Analysis

Chapter 3 Fundamental RCM Concepts Explained, Some for the Very First Time: The Next Plateau

3.1 The Three Phases of an RCM-Based Preventive Maintenance Program

3.2 The Three Cornerstones of RCM

3.3 Hidden Failures, Redundancy, and Critical Components

3.4 Testing Hidden Systems

3.5 The Missing Link: Potentially Critical Components

3.6 Commitment Components

3.7 Economic Components

3.8 The “Canon Law” of Run-to-Failure Components

3.9 The Integration of Preventive and Corrective Maintenance and the Distinction Between Potentially Critical and Run-to-Failure Components

3.9.1 An RTF CM versus a Critical CM: Which Takes Priority for Getting Worked First?

3.10 The Anatomy of a Disaster

3.11 A Deeper Look at Critical Components, Potentially Critical Components, and Hidden Failures—How They All Fit Together

3.12 Finding the Anomalies

3.13 Failures Found During Operator Rounds

3.14 Redundant, Standby, and Backup Functions

3.15 Typical Examples of Component Classifications

3.16 Component Classification Hierarchy

3.17 The Defensive Strategies of a PM Program

3.18 Eliminating the Requirement for Identifying Boundaries and Interfaces

3.19 Functions and Functional Failures Are Identified at the Component Level, Not the System and Subsystem Level

3.20 The Quest for the Consequence of Failure

3.21 The COFA versus the FMEA

3.22 How Do You Know When Your Plant Is Reliable?

3.23 Chapter Summary

Chapter 4 RCM Implementation: Preparation and Tools

4.1 Preparation

4.2 The Sequential Elements Needed for the Analysis

4.2.1 A Simple but Comprehensive Alphanumeric Equipment I.D. Database

4.2.2 Informational Resources

4.2.3 Establishing Convention

4.2.4 Specialized Workstations and Software

4.2.5 The COFA Excel Spreadsheet versus the FMEA

4.2.6 The PM Task Worksheet

4.2.7 The Economic Evaluation Worksheet

4.3 Chapter Summary

Chapter 5 RCM Made Simple: Implementation Process

5.1 Define Your Asset Reliability Strategy

5.2 Understanding the RCM COFA Logic Tree, the Potentially Critical Guideline, and the Economically Significant Guideline

5.3 Completing the COFA Worksheet in Conjunction with the COFA Logic Tree, the Potentially Critical Guideline, and the Economically Significant Guideline

5.3.1 Describe the Component Functions

5.3.2 Describe the Functional Failures

5.3.3 Describe the Dominant Component Failure Modes for Each Functional Failure

5.3.4 Is the Occurrence of the Failure Mode Evident?

5.3.5 Describe the System Effect for Each Failure Mode

5.3.6 Describe the Consequence of Failure Based on the Asset Reliability Criteria You Selected

5.3.7 Define the Component Classification

5.4 RCM Serves as a Translation of the Design Objectives

5.5 Companion Equipment

5.6 The SAE Standard: Document JA1011

5.7 A Real-Life Analysis: Averting a Potentially Devastating Plant Consequence

5.8 Why Streamlined RCM Methods Are Not Recommended

5.8.1 Total Productive Maintenance (TPM)

5.8.2 Reliability-Based Maintenance (RBM)

5.8.3 Probabilistic Safety Analysis (PSA) Based Maintenance

5.8.4 80/20 Rule

5.9 Chapter Summary

5.10 RCM Made “Difficult”

5.10.1 Determine System Boundaries

5.10.2 Determine Subsystem Boundaries

5.10.3 Determine Interfaces

5.10.4 Determine Functions

5.10.5 Determine the Functional Failures

5.10.6 Determine Which Equipment Is Responsible for the Functional Failures

Chapter 6 The PM Task Selection Process

6.1 Understanding Preventive Maintenance Task Terminology

6.2 Condition-Directed, Time-Directed, and Failure-Finding Tasks

6.3 The PM Task Worksheet

6.4 The PM Task Selection Logic Tree

6.5 Why a Condition-Directed Task Is Preferred

6.6 Determining the PM Task Frequency and Interval

6.6.1 The Optimum Time to Establish a Reliability Program

6.7 Is a Design Change Recommended?

6.8 Completing a Typical PM Task Worksheet

6.9 Institute Technical Restraints

6.10 A Sampling Strategy

6.11 Common Mode Failures

6.12 Different Predictive Maintenance (PdM) Techniques

6.12.1 Vibration Monitoring and Analysis

6.12.2 Acoustic Monitoring

6.12.3 Thermography or Infrared Monitoring

6.12.4 Oil Sampling and Analysis

6.12.5 X-ray or Radiography Inspection

6.12.6 Magnetic Particle Inspection

6.12.7 Eddy Current Testing

6.12.8 Ultrasonic Testing

6.12.9 Liquid Penetrant

6.12.10 Motor Current Signature Analysis (MCSA)

6.12.11 Boroscope Inspections

6.12.12 Diagnostics for Motor-Operated Valves

6.12.13 Diagnostics for Air-Operated Valves

6.13 Chapter Summary

Chapter 7 RCM for Instruments

7.1 Instrument Categories

7.2 Instrument Design Tolerance Criteria

7.3 The Instrument Logic Tree

7.3.1 Block 1: Is the Instrument a Functional Instrument?

7.3.2 Block 2: Instrument Is Analyzed in the COFA Worksheet and the PM Task Selection Worksheet.

7.3.3 Block 3: Can the Instrument Reading Result in an Operator Having to Initiate Some Kind of Action?

7.3.4 Block 4: A PM Is Required. Calibration Criteria and Periodicity Guidance Are as Follows.

7.3.5 Block 5: Were the Last Three Successive Calibrations Within Vendor Tolerance Criteria?

7.3.6 Block 6: Periodicity Extension Is Allowed.

7.3.7 Block 7: Reduce Periodicity or Implement a Design Change.

7.3.8 Block 8: Is the Instrument Redundant?

7.3.9 Block 9: Is an Indication Comparison Applicable?

7.3.10 Block 10: Is the Consequence of Excessive Drift (to the Point of Instrument Failure) Acceptable?

7.3.11 Block 11: A Calibration PM Is Optional.

7.3.12 Block 12: A PM Is Required. Calibration Criteria and Periodicity Guidance Are as Follows.

7.3.13 Block 13: Were the Last Two Successive Calibrations Within a +/–2.5 Percent Accuracy Tolerance?

7.3.14 Block 14: Periodicity Extension Is Allowed.

7.3.15 Block 15: Were the Last Two Successive Calibrations Within a +/–5.0 Percent Accuracy Tolerance?

7.3.16 Block 16: Periodicity Extension Is Not Allowed.

7.3.17 Block 17: Reduce Periodicity or Implement a Design Change.

7.4 Chapter Summary

Chapter 8 The RCM Living Program

8.1 A Model for an RCM Living Program

8.1.1 The Craft Feedback Evaluation Element

8.1.2 The Corrective Maintenance (CM) Evaluation Element

8.1.3 The “Other Inputs” Element

8.1.4 Monitoring and Trending

8.1.5 The RCM Analysis Element

8.1.6 Equipment Database

8.1.7 The PM Audit

8.2 Chapter Summary

Chapter 9 An RCM Monitoring and Trending Strategy

9.1 What Is Reliability and How Do You Measure It?

9.2 Monitoring Reliability Is Like Monitoring the Human Body

9.3 Caution: Avoid Analysis Paralysis Performance Monitoring

9.4 The Aggregate Metrics

9.4.1 Unplanned Plant or Facility Trips

9.4.2 Capacity Factor

9.4.3 Unplanned Operator Actions

9.4.4 Unplanned Power Reductions

9.4.5 Production Delays

9.4.6 Enforcement Actions

9.4.7 Litigation Occurrences

9.4.8 Citations and Violations

9.4.9 Root-Cause Evaluations

9.4.10 Injuries

9.4.11 Rate of Written CMs

9.4.12 Overdue CM Backlog

9.4.13 Overdue PM Backlog

9.5 Weighting Factors

9.6 Performance Calculations

9.7 Performance Graph

9.8 Performance Graph by System

9.9 A Final Caution

9.10 Benchmarking

9.11 More About Expected Performance Rates

9.12 Avoid Reliability Complacency

9.13 How to Maintain Your Reliability Performance

9.14 Chapter Summary

Chapter 10 RCM Implementation Made Simple—Epilogue

10.1 RCM as a Plant Culture

10.2 A Step-by-Step Review of the Process

10.2.1 Select an RCM Point of Contact

10.2.2 Review the Reasons for RCM Program Failures

10.2.3 Understand the Concepts

10.2.4 Define Your Asset Reliability Criteria

10.2.5 Establish Your Alphanumeric Equipment Database

10.2.6 Analyze Each Component Function in the COFA Logic Tree

10.2.7 Analyze Each Component Function in the Potentially Critical Guideline

10.2.8 Analyze Each Component Function in the Economically Significant Guideline

10.2.9 Enter All Data in the COFA Worksheet

10.2.10 Classify Each Component

10.2.11 Analyze All Classified Components Except Run-to-Failure Components in the PM Task Selection Logic Tree

10.2.12 Document All Tasks and Periodicities on the PM Task Worksheet

10.2.13 Analyze Instruments in the Instrument Logic Tree

10.2.14 Develop Your RCM Living Program

10.2.15 Establish Monitoring and Trending Program Metrics

10.2.16 Establish Your Expected Performance Rate

10.2.17 Establish Your Actual Performance Rate

10.2.18 Establish Your Trend Graphs

10.2.19 Maintain Continued Vigilance Over Your Program

10.3 Taking Command of Your Own Ship

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Bibliography

Index