Maintenance Concept

Assignment 2

Submitted by Bisketi, Victor 20786 Class B

(A). The goal of RCM is basically to: Avoid or reduce failure consequences Not necessarily to avoid failure

While failure consequence is referred to as the effects of failure on : Personal and equipment Environmental health and or compliance Operations Economics

(B).According to the SAE JA1011 standard, which describes the minimum criteria that a process must comply with to be called "RCM," a Reliability Centered Maintenance Process answers the following seven questions: 1. What are the functions and associated desired standards of performance of the asset in its present operating context (functions)? 2. In what ways can it fail to fulfill its functions (functional failures)? 3. What causes each functional failure (failure modes)? 4. What happens when each failure occurs (failure effects)? 5. In what way does each failure matter (failure consequences)? 6. What should be done to predict or prevent each failure (proactive tasks and task intervals)? 7. What should be done if a suitable proactive task cannot be found (default actions)?

(C). Failure Analysis involves Systematic Identification of all the functional components of an equipment and their failure characteristics Explain with relevant examples Failure analysis of a system involves: 1. Identifying the function of each piece of equipment in the system. 2. Identifying the causes of failure in the system. This represent the specific cause of functional failure as determine based on engineering judgments. 3. Recording the failure characteristics of the different functional equipment. 4. Identify and Evaluate (Categorize) the Effects of Failure equipment part with regards to the overall failure modes. These logic structures often differentiate evident vs. hidden effects and whether the issue has safety, environmental, operational and/or economic consequences. A typical example of failure analysis that involves systematic identification of all the functional components of equipment and their failure characteristics is as shown in the diagram below

COMPONENTS FUNCTION S/n 1 2 3 4 5 6 7 8 9 10 11 12 components Flow transducer (FE) Flow Controller (FC) Flow Switch (FS) functions detect flow rate of oil from circulating pump sends control signal to open or close the flow control valve actuate the solenoid valve to release air pressure in the pneumatic into TCV Failure Alarm (FAL) Alerts the operator to take appropriate action Flow control Valve (FCV) Re-circulates heating oil back to pump Manual Bypass Valve Manual Alternative to FCV (MBV) Solenoid Valve(SV) Release air pressure in the pneumatic line to TCV Temperature Transducer Monitor the temperature control system (TE) Temperature Controller Sends control signal to operate the TCV (TC) High temperature Switch Detects excessive Temperature due to failure (TSH) Gas Isolation Valve (GIV) Release Gas into the heater tank Temperature Control Valve Closes under spring pressure due to high temperature (TCV)

CAUSES OF FAILURE 1. Zero or low oil flow caused by: Pump failure Flow control system failure Large leak of oil Partial or full blockage of pipeline Valve closed 2. Excess gas flow (e.g. at a time of low oil flow) such as: Gas flow control system failure

FAILURE EFFECT ASSESSMENT The heater coils will burn out if both the pump fails AND the protective response fails. The protective response fails if both the automatic response fails AND the manual response fails. The automatic response fails if either FE fails OR FS fails OR SV fails OR TCV fails. The manual response fails if either FE fails OR FS fails OR the operator fails OR GIV fails.

CONSTRUCTING THE FAULT-TREE