Reliability Engineering: A Life Cycle Approach

439 Pages·2022·10.058 MB·English

by  Edgar Bradley

Reliability Engineering
Updated throughout for the second edition, Reliability Engineering: A Life Cycle
Approach draws on the author’s global industry experience to demonstrate the
invaluable role reliability engineers play in the entire life cycle of a plant.
Applicable to both high-cost, cutting-edge plants and to plants operating under
serious budget constraints, this textbook uses a practical approach to cover the
theory of reliability engineering, alongside the design, operation, and maintenance
required in a plant. This textbook has been updated to cover the modern standards of
maintenance practice, most notably the ISO 55 000 standards. It also covers linear
programming, failure analysis, fnancial management, and analysis. This textbook refers
to case studies throughout.
This textbook will be of interest to students and engineers in the feld of reliability,
mechanical, manufacturing, and industrial engineering. It will also be relevant to
automotive and aerospace engineers.

Reliability Engineering
A Life Cycle Approach
Second Edition
Dr Edgar Bradley
Second edition published 2023
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487–2742
and by CRC Press
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CRC Press is an imprint of Taylor & Francis Group, LLC
© 2023 Edgar Bradley
First edition published by CRC Press 2017
Reasonable efforts have been made to publish reliable data and information, but the author and
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ISBN: 978-1-032-35337-1 (hbk)
ISBN: 978-1-032-35349-4 (pbk)
ISBN: 978-1-003-32648-9 (ebk)
DOI: 10.1201/9781003326489
Typeset in Times
by Apex CoVantage, LLC
Contents
Foreword to the First Edition .................................................................................xvii
Preface..................................................................................................................... xix
Author ..................................................................................................................... xxi
Introduction ...........................................................................................................xxiii
Chapter 1 Reliability Fundamentals I: Component Reliability ............................ 1
Introduction.......................................................................................... 1
The Importance of Reliability ......................................................... 1
History.................................................................................................. 1
Defnitions............................................................................................ 2
Reliability ........................................................................................ 2
Maintainability ................................................................................ 2
Availability ...................................................................................... 2
Unreliability..................................................................................... 3
Unavailability .................................................................................. 3
Component ...................................................................................... 3
Correlation Coeffcient .................................................................... 3
System ............................................................................................. 3
Failure.............................................................................................. 3
Failure Rate...................................................................................... 4
Failure Probability Density Function .............................................. 4
Sample............................................................................................. 4
Population........................................................................................ 4
Acronyms ............................................................................................. 4
Basic Statistics...................................................................................... 5
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 ............................................................... 10
The Bathtub Curve......................................................................... 13
Weibull Analysis............................................................................ 13
Problems with Weibull................................................................... 17
Weibull Cautions ........................................................................... 19
Using Weibull When Very Little Data Are Available..................... 19
Assignments ....................................................................................... 20
Assignment 1.1: Weibull Familiarisation ...................................... 20
Assignment 1.2: Weibull Problem................................................. 20
v
vi Contents
Assignment 1.3: Another Weibull Problem................................... 20
Assignment 1.4: Spring Design..................................................... 21
Assignment 1.5: Weibull Analysis of Rolling Element
Bearings............................................................................ 21
Assignment 1.6: New Era Fertilizer Plant..................................... 22
Assignment 1.7: The Life History of a Hillman Vogue
Sedan................................................................................ 25
Note .................................................................................................... 30
Chapter 2 Reliability Fundamentals II: System Reliability.................................31
A Note of Caution .............................................................................. 33
System Confgurations ....................................................................... 34
Redundancy ................................................................................... 34
M-Out-of-N Redundancy ................................................................... 35
System Reliability Prediction............................................................. 37
Availability and Maintainability......................................................... 39
The Maintainability Equation............................................................. 40
The Equations for System Availability ............................................... 40
Storage Capacity (Figure 2.10) .......................................................... 41
Reduced-Capacity States.................................................................... 42
Other Forms of System Reliability Analysis...................................... 43
Method 1: Deconstruction Method..................................................... 44
Method 2: Cut Sets............................................................................. 44
Monte Carlo Simulation ..................................................................... 45
Markov Simulation............................................................................. 45
Interconnections ................................................................................. 47
Laplace Analysis................................................................................. 48
Failure Modes and Effects Analysis (FMEA) and Failure Modes
and Effects Criticality Analysis (FMECA).............................. 49
History .......................................................................................... 49
Flavours of FMEA/FMECA ............................................................... 50
Process vs Design or Product FMEA/FMECA.................................. 50
Design FMECA.................................................................................. 53
Which Templates to Use?................................................................... 53
Basic Analysis Procedure for an FMEA or FMECA ......................... 53
Advantages of the FMEA/FMECA Process....................................... 54
Limitations of the FMEA/FMECA Process....................................... 54
FMEA of a Scraper Winch ................................................................. 55
Operation............................................................................................ 55
Common Failures and Recent Improvements .................................... 56
Assignment......................................................................................... 58
Fault Tree Analysis............................................................................. 58
Assignment......................................................................................... 61
Additional Assignments ..................................................................... 62
Assignment 2.1.............................................................................. 62
Contents vii
The V1 ...................................................................................... 62
Assignment 2.2.............................................................................. 62
The Parallel System of Conveyors............................................ 62
Assignment 2.3.............................................................................. 62
Availability Upgrade................................................................. 62
Assignment 2.4.............................................................................. 62
Laplace Calculation .................................................................. 62
Assignment 2.5.............................................................................. 62
A System Availability Prediction.............................................. 62
Abbreviations ..................................................................................... 63
Notes................................................................................................... 64
Chapter 3 Maintenance Optimisation................................................................. 65
Maintenance—Raison D’être............................................................. 65
Know Your Plant, Keep It Good as New............................................ 65
Data Collection................................................................................... 69
The Big Five....................................................................................... 70
Maintenance Optimisation ................................................................. 71
RCM................................................................................................... 72
The RCM Process............................................................................... 73
The RCM Decision Diagram.............................................................. 74
On-Condition Inspection Task............................................................ 74
Scheduled Rework.............................................................................. 74
Scheduled Discard.............................................................................. 75
Acronyms ........................................................................................... 75
The RCM Failure Modes and Effects Analysis.................................. 75
Alternative and Modifed Forms of RCM .......................................... 76
Summary of the RCM Output............................................................ 77
An RCM Example.............................................................................. 77
Economic Evaluation ......................................................................... 78
Total Productive Maintenance, TPM.................................................. 78
The Five Pillars Defnition of TPM.................................................... 80
The Six Major Losses (Manufacturing Industry)............................... 80
The Eight Major Losses (Process Industry)....................................... 80
The Primary TPM Metric: OEE......................................................... 80
The Goals of TPM.............................................................................. 81
Zero Breakdowns ............................................................................... 81
Zero Adjustments ............................................................................... 82
Zero Idling and Zero Minor Stoppages.............................................. 83
Speed Loss.......................................................................................... 83
Quality Problems................................................................................ 83
Semantics in Maintenance Management: Explanation
and Qualifcation ..................................................................... 85
ISO 55000 ......................................................................................... 88
Wrench Time...................................................................................... 90
viii Contents
Takeout: Panel—Work Sampling....................................................... 92
Takeout: End of Panel ........................................................................ 92
Estimating Job Times ......................................................................... 94
Note.................................................................................................. 141
Chapter 4 Condition Monitoring........................................................................143
The Four Kinds of Maintenance....................................................... 143
The Major Types of Condition Monitoring...................................... 145
Vibration Monitoring........................................................................ 145
The Time Domain........................................................................ 145
The Frequency Domain ............................................................... 145
The Measurement of Vibration.................................................... 146
Positioning of Transducers .......................................................... 148
Detection of Various Vibration Problems .................................... 148
Resonance.................................................................................... 150
Unbalance.................................................................................... 150
Misalignment............................................................................... 150
Rolling Element Bearings............................................................ 150
Ultrasonics................................................................................... 152
Plain Bearings.............................................................................. 152
Gearboxes.................................................................................... 154
Sidebands..................................................................................... 154
Compressors ................................................................................ 156
Fans.............................................................................................. 157
Oil Analysis...................................................................................... 157
History......................................................................................... 157
Requirements for Oil Analysis .................................................... 158
A Basic Test Programme............................................................. 159
Viscosity ................................................................................. 159
Water Content ......................................................................... 160
Acid Number .......................................................................... 160
Oxidation ................................................................................ 160
Element Analysis .................................................................... 160
Additional Oil Analysis Tests...................................................... 160
Particle Count ......................................................................... 161
Ferrography............................................................................. 161
Flash Point .............................................................................. 161
Thermography .................................................................................. 161
Chapter 5 Incident Investigation or Root Cause Analysis .................................163
Introduction...................................................................................... 163
Scope of Any Investigation............................................................... 164
Defnitions and Abbreviations.......................................................... 164
Defnitions ................................................................................... 164
Contents ix
Root Cause Analysis............................................................... 164
Abbreviations and Acronyms ...................................................... 164
Root Cause Analysis............................................................... 164
Incident Investigation Techniques.................................................... 165
The Five Whys............................................................................. 165
Kepner-Tregoe and Its Derivatives .............................................. 166
Step 1: Problem Defnition ..................................................... 166
Step 2: The Problem Described in Detail: Identity,
Location, Timing, Magnitude ............................................ 166
Step 3: Where Does the Malfunction NOT Occur?................ 166
Step 4: What Differences Could Have Caused the
Malfunction?...................................................................... 166
Step 5: Analyse the Differences.............................................. 167
Step 6: Verify Proposed Solution............................................ 167
The ASSET Methodology ........................................................... 167
Background to the Process...................................................... 167
The Sequence of Actions in the ASSET Process.................... 168
Personnel Errors...................................................................... 168
Reliability at Work............................................................. 169
External Factors ................................................................. 169
Physical Environment ........................................................ 170
Safety Culture .................................................................... 170
Qualifcation to Perform the Task...................................... 170
Training.............................................................................. 170
Educational Background.................................................... 170
Contributors to the Identifed Errors....................................... 170
Procedural Errors.................................................................... 171
Reliability of the Procedures.............................................. 171
Assurance of Currency....................................................... 171
Scope Limitations .............................................................. 171
Adaptation to Working Conditions .................................... 172
Ergonomics ........................................................................ 172
Environmental Adaptation ................................................. 172
Task Qualifcation.............................................................. 172
Adequacy of Content ......................................................... 172
Background Support .......................................................... 172
Contributors ....................................................................... 172
Defciencies in Plant ............................................................... 173
Plant Reliability ................................................................. 173
Endurance .......................................................................... 173
Performance Limitations.................................................... 173
External Infuences............................................................. 173
Physical Environment ........................................................ 173
Operating Practices............................................................ 173
Qualifcation of Function................................................... 173
Manufacture, Storage, and Installation.............................. 173