Reliability Centered Maintenance (RCM): Implementation Made Simple

314 Pages·2005·2.207 MB·English

by  Neil Bloom

Reliability Centered
Maintenance (RCM)
This page intentionally left blank
Reliability Centered
Maintenance (RCM)
Implementation Made Simple
Neil Bloom
McGraw-Hill,Inc.
New York Chicago San Francisco Lisbon London
Madrid Mexico City Milan New Delhi San Juan
Seoul Singapore Sydney Toronto
Copyright © 2006 by the McGraw-Hill Companies. All rights reserved. Manufactured in the United
States of America. Except as permitted under the United States Copyright Act of 1976, no part of this
publication may be reproduced or distributed in any form or by any means, or stored in a
database or retrieval system, without the prior written permission of the publisher.
0-07-158918-X
The material in this eBook also appears in the print version of this title: 0-07-146069-1.
All trademarks are trademarks of their respective owners. Rather than put a trademark symbol after
every occurrence of a trademarked name, we use names in an editorial fashion only, and to the
benefit of the trademark owner, with no intention of infringement of the trademark. Where such
designations appear in this book, they have been printed with initial caps.
McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales
promotions, or for use in corporate training programs. For more information, please contact George
Hoare, Special Sales, at [email protected] or [phone].
TERMS OF USE
This is a copyrighted work and The McGraw-Hill Companies, Inc. (“McGraw-Hill”) and its licensors
reserve all rights in and to the work. Use of this work is subject to these terms. Except as permitted
under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not
decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon,
transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without
McGraw-Hill’s prior consent. You may use the work for your own noncommercial and personal use;
any other use of the work is strictly prohibited. Your right to use the work may be terminated if you
fail to comply with these terms.
THE WORK IS PROVIDED “AS IS.” McGRAW-HILL AND ITS LICENSORS MAKE NO
GUARANTEES OR WARRANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETE-
NESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY
INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR
OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. McGraw-Hill and its licensors do not warrant or guar-
antee that the functions contained in the work will meet your requirements or that its operation will be
uninterrupted or error free. Neither McGraw-Hill nor its licensors shall be liable to you or anyone else
for any inaccuracy, error or omission, regardless of cause, in the work or for any damages resulting
therefrom. McGraw-Hill has no responsibility for the content of any information accessed through the
work. Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, inci-
dental, special, punitive, consequential or similar damages that result from the use of or inability to
use the work, even if any of them has been advised of the possibility of such damages. This limitation
of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract,
tort or otherwise.
DOI: 10.1036/0071460691
Professional
Want to learn more?
We hope you enjoy this
McGraw-Hill eBook! If
you’d like more information about this book,
its author, or related books and websites,
please click here.
To my wife,friend,partner,and soul mate,
Bernadette,who is indeed a saint
This page intentionally left blank
For more information about this title, click here
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 9
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