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E-grāmata: Reliability Centered Maintenance - Reengineered: Practical Optimization of the RCM Process with RCM-R(R)

  • Formāts: 367 pages
  • Izdošanas datums: 25-May-2017
  • Izdevniecība: Productivity Press
  • Valoda: eng
  • ISBN-13: 9781498785198
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  • Formāts: 367 pages
  • Izdošanas datums: 25-May-2017
  • Izdevniecība: Productivity Press
  • Valoda: eng
  • ISBN-13: 9781498785198

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Reliability Centered Maintenance Reengineered: Practical Optimization of the RCM Process with RCM-R® provides an optimized approach to a well-established and highly successful method used for determining failure management policies for physical assets. It makes the original method that was developed to enhance flight safety far more useful in a broad range of industries where asset criticality ranges from high to low. RCM-R® is focused on the science of failures and what must be done to enable long-term sustainably reliable operations. If used correctly, RCM-R® is the first step in delivering fewer breakdowns, more productive capacity, lower costs, safer operations and improved environmental performance. Maintenance has a huge impact on most businesses whether its presence is felt or not. RCM-R® ensures that the right work is done to guarantee there are as few nasty surprises as possible that can harm the business in any way.

RCM-R® was developed to leverage on RCMs original success at delivering that effectiveness while addressing the concerns of the industrial market. RCM-R® addresses the RCM method and shortfalls in its application -- It modifies the method to consider asset and even failure mode criticality so that rigor is applied only where it is truly needed. It removes (within reason) the sources of concern about RCM being overly rigorous and too labor intensive without compromising on its ability to deliver a tailored failure management program for physical assets sensitive to their operational context and application. RCM-R® also provides its practitioners with standard based guidance for determining meaningful failure modes and causes facilitating their analysis for optimum outcome.











Includes extensive review of the well proven RCM method and what is needed to make it successful in the industrial environment





Links important elements of the RCM method with relevant International Standards for risk management and failure management





Enhances RCM with increased emphasis on statistical analysis, bringing it squarely into the realm of Evidence Based Asset Management





Includes extensive, experience based advice on implementing and sustaining RCM based failure management programs
Foreword xiii
Introduction xv
Chapter 1 Asset Management 1(12)
References
11(2)
Chapter 2 The History of RCM and Its Relevance in Today's Industry 13(12)
RCM Development
14(9)
References
23(2)
Chapter 3 The RCM-R® Process 25(26)
The SAE JA1011 RCM Standard
25(7)
Operational Context and Functions
26(1)
Functional Failures
27(1)
Failure Modes
28(1)
Failure Effects
29(1)
Failure Consequences
29(1)
Maintenance Strategies Selection
30(2)
Reliability Centered Maintenance-Reengineered (RCM-R®)
32(4)
RCM-R® Project
36(11)
System Description
37(1)
Reliability, Availability, and Maintainability (RAM) Analysis
37(2)
Current Situation Explained
39(1)
Failure Data Analysis at a Glance
40(1)
Introduction to Weibull Distribution and Analysis
41(1)
Optimum Replacement Time Analysis
42(1)
Detailed Failure Data Analysis Using the Weibull Distribution
43(4)
Conclusions
47(1)
The RCM-R® Process Diagram
47(2)
References
49(2)
Chapter 4 RCM-R® Pre-work 51(22)
Ensuring Asset Data Integrity
52(5)
RCM-R® Data
57(1)
Asset Data Registers
58(4)
Work Order Data
62(2)
Asset Criticality Analysis
64(4)
Summary
68(3)
References
71(2)
Chapter 5 Functions and Failures 73(28)
The Operating Context
74(2)
Performance Levels
76(3)
Functional Analysis
79(2)
Primary Functions
81(2)
Secondary Functions
83(1)
Protection
84(1)
Efficiency and Economy
85(1)
Appearance
85(1)
Control, Containment, and Comfort
86(1)
Health and Safety
87(1)
Environmental Integrity
87(1)
Structural Integrity and Superfluous Functions
88(2)
Hidden Functions
90(1)
Functional Block Diagrams
91(3)
Failure Types and Classes
94(1)
Types of Failures: Functional and Potential Failures
94(3)
Classification of Functional Failures
97(1)
Summary
98(3)
Chapter 6 Failure Symptoms and Causes 101(16)
Brainstorming
102(1)
Failure Modes
103(4)
Failure Mode Types
107(3)
Root Causes of Failure Modes
110(1)
How Much Detail?
111(3)
Summary
114(3)
Chapter 7 Quantifying Failure Impacts 117(18)
Guide Questions for Describing Failure Effects
118(1)
How Is the Failure Detected?
119(1)
How Is the Safety of the People around the Failed Asset Affected?
120(1)
How Are Environmental Goals Impacted?
121(1)
How Is Production or Operations Affected by the Failure?
122(1)
What Kind of Physical Damage Is Caused by the Failure? How Costly Is the Failure in Terms of Maintenance and Repair?
123(1)
Is There Any Secondary Damage? What Must Be Done to Restore Operations? How Long Would It Take?
124(1)
Documenting Failure Effects Statements in the RCM-R® Worksheet
125(1)
ISO Standard-Based Failure Effects Risk Analysis
125(4)
RCM-R® Failure Effects Risk Assessment Matrix
129(1)
Summary
129(4)
References
133(2)
Chapter 8 Overview of Maintenance Strategies 135(22)
Overview of Strategies for Managing Failure Consequences
135(1)
Technically Feasible and Worth Doing
136(1)
Preventive Maintenance
137(3)
Predictive Maintenance (PDM)
140(5)
Detective Maintenance (Failure Finding) (DM)
145(6)
Running to Failure (RTF)
151(1)
Nonrecurring Actions (One-Time Changes)
151(3)
Design Change Objectives
154(1)
Timing
154(1)
Describing One-Time Changes
155(1)
Summary
155(2)
Chapter 9 Condition-Based Maintenance Techniques 157(54)
Vibration Analysis
158(5)
Jesus R. Sifonte
Vibration Parameters and Units
158(3)
Vibration Analyses
161(1)
Machine Condition Diagnosis with Vibration Analyses
162(1)
Vibration Analysis Diagnostic Example
162(1)
Infrared Thermography
163(12)
Wayne Ruddock
Introduction and History
163(1)
Basic Infrared Theory
164(2)
Applications of Infrared Thermography in Predictive Maintenance (PdM)
166(1)
Electrical Inspections
167(3)
Mechanical Inspections
170(2)
Process Inspections
172(1)
Facility Inspections
173(2)
Precision Lubrication and Oil Analysis
175(10)
Mark Barnes
Identifying Lubrication-Related Failure Modes
175(2)
Lack of Lubrication
177(1)
Too Much Lubricant (Overlubrication)
178(1)
Wrong Lubricant Selected
178(1)
Wrong Lubricant Added
179(1)
Lubricant Contaminated with Moisture
179(1)
Lubricant Contaminated with Particles
180(1)
Lubricant Degraded
181(1)
Lubricant Too Hot/Cold
181(1)
Additives Depleted
182(1)
Lubricant Contains Foam/Air Entrainment
182(1)
Oil Analysis as a Predictive Tool of Other Problems
182(1)
Sampling Frequency
183(1)
Sampling Location
184(1)
Oil Analysis Test Slate
184(1)
Ultrasound
185(19)
Allan Rienstra
Sound Principles
186(1)
The Basics
187(1)
Frequency (F)
188(1)
Period (T)
189(1)
Measuring Sound
189(3)
Velocity of Sound and Acoustic Impedance
192(1)
Sound Propagation through Air
193(1)
How Ultrasound Detectors Work.
194(2)
How Ultrasound Is Collected
196(1)
Airborne Sensors
196(2)
Contact Sensors
198(1)
Why Ultrasound Is an Effective Technology
199(1)
Applications
200(1)
Compressed Air Leak Management
201(1)
Condition Monitoring
201(1)
Slow-Speed Bearings
201(1)
Acoustic Condition-Based Lubrication
202(1)
Electrical Applications
202(1)
Steam System Inspections
202(1)
Pump Cavitation
202(1)
Reciprocating Compressors and Valves
203(1)
Heat Exchanger and Condenser Leaks
203(1)
Ultrasound for Reliability
204(1)
Nondestructive Testing
204(7)
Jeff Smith
Conventional NDT Methods
206(1)
Advanced NDT Methods
207(2)
Conclusion
209(1)
Reference
209(2)
Chapter 10 Selecting Strategies for Managing Failure Consequences 211(26)
Categories of Failure Consequences
212(3)
Failure Consequence Management Policies' Nomenclature and Typical Decisional Diagrams
215(2)
Hidden Failures Consequence Management Tasks
217(1)
Safety and/or Environmental Consequence Management Tasks
217(2)
Production Consequence Management Tasks
219(1)
Maintenance Consequence Management Tasks
220(3)
RCM-R' Failure Consequence Management Decision Diagram
223(7)
Developing Meaningful Maintenance Tasks
230(2)
Summary
232(5)
Chapter 11 Fine-Tuning RCM Analysis 237(20)
The Need for Better Data
238(1)
Reliability, Availability, and Maintainability (RAM) Analysis
238(5)
Failure Data Analysis
243(2)
Weibull Analysis
245(7)
Creating and Interpreting Weibull Data Plots
247(5)
Periodic Tasks Frequency
252(3)
Summary
255(1)
Reference
255(2)
Chapter 12 Implementing RCM-R® 257(28)
The Analysis Team
258(1)
The Facilitator
259(2)
Training and Competency
261(3)
Preparation
264(2)
Estimating the Effort
266(2)
Conducting the Analysis
268(1)
Implementing the Outcomes
269(2)
Implementing C and T Tasks
271(2)
Implementing D Tasks
273(1)
F Outcomes
274(1)
R Decisions
275(1)
Monitoring and Continuous Improvement
276(2)
Monitoring and Improvement Tools
278(4)
Governance for Sustainability
282(3)
Chapter 13 Leveraging RCM-R® 285(20)
Concept
286(1)
Integrated and Iterative?
286(2)
Why Bother?
288(2)
Industrial Life Cycle Support
290(3)
Condition Monitoring Support
293(1)
Time-Based Task Support
294(1)
Detective Maintenance Support
294(1)
Run to Failure (F Tasks)
295(1)
Providing Support
295(2)
Documentation and Records
297(1)
Skills and Capabilities
298(1)
Facilities
299(1)
Spares
300(3)
Neil Montgomery
Summary
303(2)
Appendix A 305(16)
Appendix B 321(16)
Epilogue 337(4)
Index 341
Jesśs R. Sifonte, BSME, MMRE, PE, CMRP is the founder and President of PdMtech of Vega Baja, Puerto Rico, United States if America. He provides business consulting services in the areas of Condition Based Maintenance techniques certification and implementation, RCM and reliability analysis teaching, mentoring and implementation. He is also the director of Puerto Ricos based Condition Monitoring and Maintenance Institute with presence all over Latin America and Spain. He is a licensed Professional Engineer, a certified level III ASNT-TC-1A vibration analysis consultant by Technical Associates of Charlotte, Member of the institute of Asset Management, the American Society of Mechanical Engineers, a Certified Maintenance and Reliability Professional by the Society of Maintenance and Reliability Professionals (USA). Jesus holds a Bachelor Degree in Mechanical Engineering from the University of Puerto Rico and a Master of Maintenance and Reliability Engineering Degree from Monash University at Australia. Jesus has extensive years of hands-on experience in engineering, maintenance management, predictive maintenance, reliability engineering field practice, implementation and consulting.









James V Reyes-Picknell, BASc, CMC., P.Eng., CMRP, CAMA., is the founder and President of Conscious Asset, a Canadian-based consulting and training firm specializing in asset management. He provides business consulting services for our practice in Physical Asset Management in the areas of strategy, process improvement, executive / management coaching, change management and general client advisory. He is a licensed Professional Engineer, certified management consultant (international), certified maintenance and reliability professional (USA),a former RCM2 practitioner, member of the institute of Asset Management and honours graduate of the University of Toronto in Mechanical Engineering. James also studied at the Royal Naval Engineering College in the UK, the Technical University of Nova Scotia and at Dalhousie Universities in Canada. James has extensive years of hands-on experience in engineering, operations, maintenance management, consulting and change management.