Reliability engineering : a life cycle approach

390 Pages·2017·25.966 MB·English

by  Bradley, Edgar

R E L I A B I L I T Y
E N G I N E E R I N G
A Life Cycle Approach

R E L I A B I L I T Y
E N G I N E E R I N G
A Life Cycle Approach
EDGAR BRADLEY
Boca Raton London New York
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Library of Congress Cataloging‑in‑Publication Data
Names: Bradley, Edgar, author.
Title: Reliability engineering : a life cycle approach / by Edgar Bradley.
Description: Boca Raton : Taylor & Francis, a CRC title, part of the Taylor &
Francis imprint, a member of the Taylor & Francis Group, the academic
division of T&F Informa, plc, [2017] | Includes bibliographical references
and index.
Identifiers: LCCN 2016016155 | ISBN 9781498765367
Subjects: LCSH: Reliability (Engineering) | Systems availability.
Classification: LCC TA169 .B73 2017 | DDC 620/.00452--dc23
LC record available at https://lccn.loc.gov/2016016155
Visit the Taylor & Francis Web site at
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Contents
Foreword ......................................................................................................................................xiii
Preface .............................................................................................................................................xv
Introduction .................................................................................................................................xix
About the Author ........................................................................................................................xxi
1. Reliability Fundamentals I: Component Reliability ......................................................1
Introduction ..............................................................................................................................1
The Importance of Reliability ...........................................................................................1
History .......................................................................................................................................1
Definitions.................................................................................................................................2
Reliability .............................................................................................................................2
Maintainability ....................................................................................................................2
Availability ...........................................................................................................................2
Unreliability .........................................................................................................................3
Unavailability ......................................................................................................................3
Component ...........................................................................................................................3
Correlation Coefficient .......................................................................................................3
System ...................................................................................................................................3
Failure ...................................................................................................................................3
Failure Rate ..........................................................................................................................4
Failure Probability Density Function ...............................................................................4
Sample...................................................................................................................................4
Population ............................................................................................................................4
Acronyms ..................................................................................................................................4
Basic Statistics ...........................................................................................................................4
Probability ............................................................................................................................5
Assignment ..........................................................................................................................6
The Failure Probability Density Function .......................................................................6
Three Common Failure Patterns ......................................................................................7
The Negative Exponential Distribution ...........................................................................8
The Mathematics of Randomness .....................................................................................9
The Normal Distribution .................................................................................................10
The Weibull Distribution .................................................................................................11
The Bathtub Curve ............................................................................................................12
Weibull Analysis ...............................................................................................................13
Problems with Weibull .....................................................................................................16
Weibull Cautions ...............................................................................................................17
Using Weibull When Very Little Data Are Available ..................................................17
Assignments ...........................................................................................................................19
Assignment 1.1: Weibull Familiarisation .......................................................................19
Assignment 1.2: Weibull Problem ...................................................................................19
Assignment 1.3: Another Weibull Problem ...................................................................20
Assignment 1.4: Spring Design .......................................................................................20
Assignment 1.5: Weibull Analysis of Rolling Element Bearings ...............................20
v
vi Contents
Assignment 1.6: New Era Fertilizer Plant .....................................................................21
Assignment 1.7: The Life History of a Hillman Vogue Sedan....................................24
2. Reliability Fundamentals II: System Reliability ...........................................................29
A Note of Caution ..................................................................................................................29
System Configurations ..........................................................................................................32
Redundancy .......................................................................................................................32
M-out-of-N Redundancy ..................................................................................................33
System Reliability Prediction ..........................................................................................35
Availability and Maintainability ....................................................................................37
The Maintainability Equation .........................................................................................38
The Equations for System Availability...........................................................................38
Storage Capacity ................................................................................................................39
Reduced Capacity States ..................................................................................................40
Other Forms of System Reliability Analysis ......................................................................41
Method 1: Deconstruction Method ................................................................................41
Method 2: Cut Sets ............................................................................................................41
Monte Carlo Simulation ........................................................................................................42
Markov Simulation ................................................................................................................43
Interconnections .....................................................................................................................44
Laplace Analysis ....................................................................................................................45
Failure Modes and Effects Analysis (FMEA) and Failure Modes and Effects
Criticality Analysis (FMECA) ..............................................................................................47
History ................................................................................................................................47
Flavours of FMEA/FMECA .............................................................................................47
Process versus Design or Product FMEA/FMECA .....................................................48
Design FMECA ..................................................................................................................50
Which Templates to Use? .................................................................................................50
Basic Analysis Procedure for an FMEA or FMECA .....................................................51
Advantages of the FMEA/FMECA Process ..................................................................51
Limitations of the FMEA/FMECA Process ...................................................................51
FMEA of a Scraper Winch ...............................................................................................51
Operation .......................................................................................................................52
Common Failures and Recent Improvements..........................................................52
Assignment ...................................................................................................................54
Fault Tree Analysis ................................................................................................................56
Assignment ........................................................................................................................58
Additional Assignments ..................................................................................................59
Assignment 2.1: The V1 ...............................................................................................59
Assignment 2.2: The Parallel System of Conveyors ................................................61
Assignment 2.3: Availability Upgrade ......................................................................61
Assignment 2.4: Laplace Calculation .........................................................................61
Assignment 2.5: A System Availability Prediction .................................................61
3. Maintenance Optimisation ................................................................................................63
Maintenance – Raison d’etre ................................................................................................63
Know Your Plant, Keep It Good as New ............................................................................63
Data Collection .......................................................................................................................67
The Big Five.............................................................................................................................68
Contents vii
Maintenance Optimisation ...................................................................................................69
Reliability Centred Maintenance .........................................................................................70
The RCM Process ...................................................................................................................70
The RCM Decision Diagram ................................................................................................72
On-Condition Inspection Task ........................................................................................72
Scheduled Rework ............................................................................................................72
Scheduled Discard ............................................................................................................74
Acronyms ...........................................................................................................................74
The RCM FMEA .....................................................................................................................74
Alternative and Modified Forms of RCM ..........................................................................74
Summary of the RCM Output .............................................................................................76
An RCM Example ..................................................................................................................76
Economic Evaluation .............................................................................................................77
Total Productive Maintenance .............................................................................................77
The Five Pillars Definition of TPM ......................................................................................78
The Six Major Losses (Manufacturing Industry) ..............................................................79
The Eight Major Losses (Process Industry) ........................................................................79
The Primary TPM Metric: OEE ............................................................................................79
The Goals of TPM ..................................................................................................................80
Zero Breakdowns ...................................................................................................................80
Zero Adjustments ..................................................................................................................81
Zero Idling and Zero Minor Stoppages ..............................................................................82
Speed Loss ..............................................................................................................................82
Quality Problems ...................................................................................................................82
Semantics in Maintenance Management: Explanation and Qualification ....................84
ISO 55000 .................................................................................................................................87
Wrench Time ..........................................................................................................................90
Work Sampling .......................................................................................................................90
Estimating Job Times.............................................................................................................92
4. Condition Monitoring .......................................................................................................137
The Four Kinds of Maintenance ........................................................................................137
The Major Types of Condition Monitoring ......................................................................138
Vibration Monitoring ..........................................................................................................139
The Time Domain ...........................................................................................................139
The Frequency Domain ..................................................................................................139
The Measurement of Vibration .....................................................................................139
Positioning of Transducers ............................................................................................142
Detection of Various Vibration Problems ....................................................................142
Resonance .........................................................................................................................142
Unbalance .........................................................................................................................142
Misalignment ...................................................................................................................142
Rolling Element Bearings ..............................................................................................144
Ultrasonics .......................................................................................................................145
Plain Bearings ..................................................................................................................145
Gearboxes .........................................................................................................................147
Sidebands .........................................................................................................................147
Compressors ....................................................................................................................149
Fans ...................................................................................................................................149
viii Contents
Oil Analysis ..........................................................................................................................150
History ..............................................................................................................................150
Requirements for Oil Analysis ......................................................................................150
A Basic Test Programme ................................................................................................151
Viscosity .......................................................................................................................151
Water Content .............................................................................................................152
Acid Number ..............................................................................................................152
Oxidation .....................................................................................................................152
Element Analysis ........................................................................................................152
Additional Oil Analysis Tests .......................................................................................153
Particle Count .............................................................................................................153
Ferrography .................................................................................................................153
Flash Point ...................................................................................................................153
Thermography ......................................................................................................................154
5. Incident Investigation or Root Cause Analysis ............................................................155
Introduction ..........................................................................................................................155
Scope of Any Investigation .................................................................................................156
Definitions and Abbreviations ...........................................................................................156
Definitions ........................................................................................................................156
Abbreviations and Acronyms .......................................................................................156
Root Cause Analysis ..................................................................................................157
Incident Investigation Techniques .....................................................................................157
The Five Whys .................................................................................................................157
Kepner-Tregoe and Its Derivatives ...............................................................................158
Step 1: Problem Definition ........................................................................................158
Step 2: The Problem Described in Detail: Identity, Location, Timing,
Magnitude ...................................................................................................................158
Step 3: Where Does the Malfunction NOT Occur? ...............................................158
Step 4: What Differences Could Have Caused the Malfunction? .......................159
Step 5: Analyse the Differences ................................................................................159
Step 6: Verify Proposed Solution..............................................................................159
The ASSET Methodology ...............................................................................................159
Background to the Process ........................................................................................159
The Sequence of Actions in the ASSET Process.....................................................160
Personnel Errors .........................................................................................................160
Contributors to the Identified Errors .......................................................................163
Procedural Errors .......................................................................................................163
Deficiencies in Plant ...................................................................................................165
Proposal of Solutions .................................................................................................166
Tables ............................................................................................................................167
Management of the Incident Investigation Process ..............................................167
Fault Trees ........................................................................................................................167
Introduction ................................................................................................................167
Construction of the Fault Tree ..................................................................................167
Ishikawa Diagrams ....................................................................................................172
Kipling’s Serving Men ...............................................................................................176
Apollo Root Cause Analysis – Dean L Gano .........................................................176
Contents ix
Causal Relationship Methods...................................................................................176
The Nature of Failure ................................................................................................176
6. Other Techniques Essential for Modern Reliability Management: I ......................231
Introduction ..........................................................................................................................231
Configuration Management ...............................................................................................231
Flavours of CM: CMI versus CMII ....................................................................................232
Preventive Maintenance .....................................................................................................233
Predictive Maintenance ......................................................................................................234
Information ...........................................................................................................................234
The Human Factor ...............................................................................................................234
A Case Study of Poor CM ..............................................................................................235
Software for CM ...................................................................................................................235
A Final Note ..........................................................................................................................235
Codification and Coding Systems .....................................................................................236
The History of Coding ...................................................................................................236
Coding Systems ...............................................................................................................236
Linnaeus ...........................................................................................................................236
Dewey Decimal Classification System .........................................................................236
UNSPSC ............................................................................................................................237
Engineering Codification ...............................................................................................237
The History of the NATO Coding System ...................................................................237
Nations Using the Code ............................................................................................239
Standardised Long Description ...............................................................................240
Standardised Short Description ...............................................................................240
Technical Dictionaries ....................................................................................................240
Advantages of the NATO System .................................................................................240
Master Data ......................................................................................................................241
ISO 22745: Standard-Based Exchange of Product Data .............................................242
Non-Military Applications of Master Data .................................................................242
Coding by Colour or Stamping .....................................................................................242
Modern Trends in Codification .....................................................................................242
Lubrication ............................................................................................................................243
Manufacture of Lubricants ............................................................................................243
Tribology ..........................................................................................................................247
The Requisite Qualities of a Lubricant .........................................................................247
Friction ...................................................................................................................................247
Wear .......................................................................................................................................248
Lubrication ............................................................................................................................248
Hydrodynamic Lubrication ...........................................................................................249
Thin-Film or Mixed Lubrication ...................................................................................249
Boundary Lubrication ....................................................................................................249
Elasto-Hydrodynamic Lubrication ...............................................................................250
Lubricant Selection ..............................................................................................................250
Lubricant Properties .......................................................................................................250
Viscosity Measurement ..................................................................................................250
Absolute Viscosity ...........................................................................................................251
Kinematic Viscosity ........................................................................................................251