Reliability, Maintainability and Risk
Practical Methods for Engineers including Reliability Centred Maintenance and Safety-Related Systems
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Reliability, Maintainability and Risk: Practical Methods for Engineers, Eighth Edition, discusses tools and techniques for reliable and safe engineering, and for optimizing maintenance strategies. It emphasizes the importance of using reliability techniques to identify and eliminate potential failures early in the design cycle. The focus is on techniques known as RAMS (reliability, availability, maintainability, and safety-integrity). The book is organized into five parts. Part 1 on reliability parameters and costs traces the history of reliability and safety technology and presents a cost-effective approach to quality, reliability, and safety. Part 2 deals with the interpretation of failure rates, while Part 3 focuses on the prediction of reliability and risk. Part 4 discusses design and assurance techniques; review and testing techniques; reliability growth modeling; field data collection and feedback; predicting and demonstrating repair times; quantified reliability maintenance; and systematic failures. Part 5 deals with legal, management and safety issues, such as project management, product liability, and safety legislation.
Key Features
- 8th edition of this core reference for engineers who deal with the design or operation of any safety critical systems, processes or operations
- Answers the question: how can a defect that costs less than $1000 dollars to identify at the process design stage be prevented from escalating to a $100,000 field defect, or a $1m+ catastrophe
- Revised throughout, with new examples, and standards, including must have material on the new edition of global functional safety standard IEC 61508, which launches in 2010
Readership
Chemical, Process, Plant, Oil & Gas and related systems safety engineers
Table of Contents
Preface
Acknowledgements
Part 1 Understanding Reliability Parameters and Costs
Chapter 1: The History of Reliability and Safety Technology
1.1 Failure Data
1.2 Hazardous Failures
1.3 Reliability and Risk Prediction
1.4 Achieving Reliability and Safety-Integrity
1.5 The RAMS Cycle
1.6 Contractual and Legal Pressures
Chapter 2: Understanding Terms and Jargon
2.1 Defining Failure and Failure Modes
2.2 Failure Rate and Mean Time Between Failures
2.3 Interrelationships of Terms
2.4 The Bathtub Distribution
2.5 Down Time and Repair Time
2.6 Availability, Unavailability and Probability of Failure on Demand
2.7 Hazard and Risk-Related Terms
2.8 Choosing the Appropriate Parameter
Chapter 3: A Cost-Effective Approach to Quality, Reliability and Safety
3.1 Reliability and Optimum Cost
3.2 Costs and Safety
3.3 The Cost of Quality
Part 2 Interpreting Failure Rates
Chapter 4: Realistic Failure Rates and Prediction Confidence
4.1 Data Accuracy
4.2 Sources of Data
4.3 Data Ranges
4.4 Confidence Limits of Prediction
4.5 Manufacturers’ Data
4.6 Overall Conclusions
Chapter 5: Interpreting Data and Demonstrating Reliability
5.1 The Four Cases
5.2 Inference and Confidence Levels
5.3 The Chi-Square Test
5.4 Understanding the Method in More Detail
5.5 Double-Sided Confidence Limits
5.6 Reliability Demonstration
5.7 Sequential Testing
5.8 Setting Up Demonstration Tests
Exercises
Chapter 6: Variable Failure Rates and Probability Plotting
6.1 The Weibull Distribution
6.2 Using the Weibull Method
6.3 More Complex Cases of the Weibull Distribution
6.4 Continuous Processes
Exercises
Part 3 Predicting Reliability and Risk
Chapter 7: Basic Reliability Prediction Theory
7.1 Why Predict RAMS?
7.2 Probability Theory
7.3 Reliability of Series Systems
7.4 Redundancy Rules
7.5 General Features of Redundancy
Exercises
Chapter 8: Methods of Modeling
8.1 Block Diagrams and Repairable Systems
8.2 Common Cause (Dependent) Failure
8.3 Fault Tree Analysis
8.4 Event Tree Diagrams
Chapter 9: Quantifying the Reliability Models
9.1 The Reliability Prediction Method
9.2 Allowing for Diagnostic Intervals
9.3 FMEA (Failure Mode and Effect Analysis)
9.4 Human Factors
9.5 Simulation
9.6 Comparing Predictions with Targets
Exercises
Chapter 10: Risk Assessment (QRA)
10.1 Frequency and Consequence
10.2 Perception of Risk, ALARP and Cost per Life Saved
10.3 Hazard Identification
10.4 Factors to Quantify
Part 4 Achieving Reliability and Maintainability
Chapter 11: Design and Assurance Techniques
11.1 Specifying and Allocating the Requirement
11.2 Stress Analysis
11.3 Environmental Stress Protection
11.4 Failure Mechanisms
11.5 Complexity and Parts
11.6 Burn-In and Screening
11.7 Maintenance Strategies
Chapter 12: Design Review, Test and Reliability Growth
12.1 Review Techniques
12.2 Categories of Testing
12.3 Reliability Growth Modeling
Exercises
Chapter 13: Field Data Collection and Feedback
13.1 Reasons for Data Collection
13.2 Information and Difficulties
13.3 Times to Failure
13.4 Spreadsheets and Databases
13.5 Best Practice and Recommendations
13.6 Analysis and Presentation of Results
13.7 Manufacturers’ data
13.8 Anecdotal Data
13.9 Examples of Failure Report Forms
Chapter 14: Factors Influencing Down Time
14.1 Key Design Areas
14.2 Maintenance Strategies and Handbooks
Chapter 15: Predicting and Demonstrating Repair Times
15.1 Prediction Methods
15.2 Demonstration Plans
Chapter 16: Quantified Reliability Centered Maintenance
16.1 What is QRCM?
16.2 The QRCM Decision Process
16.3 Optimum Replacement (Discard)
16.4 Optimum Spares
16.5 Optimum Proof Test
16.6 Condition Monitoring
Chapter 17: Systematic Failures, Especially Software
17.1 Programable Devices
17.2 Software-related Failures
17.3 Software Failure Modeling
17.4 Software Quality Assurance (Life Cycle Activities)
17.5 Modern/Formal Methods
17.6 Software Checklists
Part 5 Legal, Management and Safety Considerations
Chapter 18: Project Management and Competence
18.1 Setting Objectives and Making Specifications
18.2 Planning, Feasibility and Allocation
18.3 Program Activities
18.4 Responsibilities and Competence
18.5 Functional Safety Capability
18.6 Standards and Guidance Documents
Chapter 19: Contract Clauses and Their Pitfalls
19.1 Essential Areas
19.2 Other Areas
19.3 Pitfalls
19.4 Penalties
19.5 Subcontracted Reliability Assessments
Examples
Chapter 20: Product Liability and Safety Legislation
20.1 The General Situation
20.2 Strict Liability
20.3 The Consumer Protection Act 1987
20.4 Health and Safety at Work Act 1974
20.5 Insurance and Product Recall
Chapter 21: Major Incident Legislation
21.1 History of Major Incidents
21.2 Development of major incident legislation
21.3 CIMAH safety reports
21.4 Offshore Safety Cases
21.5 Problem Areas
21.6 The COMAH Directive (1999 and 2005 Amendment)
21.7 Rail
21.8 Corporate Manslaughter and Corporate Homicide
Chapter 22: Integrity of Safety-Related Systems
22.1 Safety-Related or Safety-Critical?
22.2 Safety-Integrity Levels (SILs)
22.3 Programable electronic systems (PESs)
22.4 Current guidance
22.5 Framework for Certification
Chapter 23: A Case Study: The Datamet Project
23.1 Introduction
23.2 The Datamet Concept
23.3 The Contract
23.4 Detailed Design
23.5 Syndicate Study
23.6 Hints
Chapter 24: A case study: gas detection system
24.1 Safety-Integrity Target
24.2 Random Hardware Failures
24.3 ALARP
24.4 Architectures
24.5 Life-Cycle Activities
24.6 Functional Safety Capability
Chapter 25: A Case Study: Pressure Control System
25.1 The Unprotected System
25.2 Protection System
25.3 Assumptions
25.4 Reliability Block Diagram
25.5 Failure Rate Data
25.6 Quantifying the Model
25.7 Proposed Design and Maintenance Modifications
25.8 Modeling Common Cause Failure (Pressure Transmitters)
25.9 Quantifying the Revised Model
25.10 ALARP
25.11 Architectural Constraints
Appendix 1: Glossary
A1.1 Terms Related to Failure
A1.1.1 Failure
A1.1.2 Failure Mode
A1.1.3 Failure Mechanism
A1.1.4 Failure Rate
A1.1.5 Mean Time Between Failures and Mean Time to Fail
A1.1.6 Common Cause Failure
A1.1.7 Common Mode Failure
A1.2 Reliability Terms
A1.2.1 Reliability
A1.2.2 Redundancy
A1.2.3 Diversity
A1.2.4 Failure Mode and Effect Analysis
A1.2.5 Fault Tree Analysis
A1.2.6 Cause Consequence Analysis (Event Trees)
A1.2.7 Reliability Growth
A1.2.8 Reliability Centered Maintenance
A1.3 Maintainability Terms
A1.3.1 Maintainability
A1.3.2 Mean Time to Repair (MTTR)
A1.3.3 Repair Rate
A1.3.4 Repair Time
A1.3.5 Down Time
A1.3.6 Corrective Maintenance
A1.3.7 Preventive Maintenance
A1.3.8 Least Replaceable Assembly (LRA)
A1.3.9 Second-Line Maintenance
A1.4 Terms Associated with Software
A1.4.1 Software
A1.4.2 Programable Device
A1.4.3 High-Level Language
A1.4.4 Assembler
A1.4.5 Compiler
A1.4.6 Diagnostic Software
A1.4.7 Simulation
A1.4.8 Emulation
A1.4.9 Load Test
A1.4.10 Functional Test
A1.4.11 Software Error
A1.4.12 Bit Error Rate
A1.4.13 Automatic Test Equipment (ATE)
A1.4.14 Data Corruption
A1.5 Terms Related to Safety
A1.5.1 Hazard
A1.5.2 Major Hazard
A1.5.3 Hazard Analysis
A1.5.4 HAZOP
A1.5.5 LOPA
A1.5.6 Risk
A1.5.7 Consequence Analysis
A1.5.8 Safe Failure Fraction
A1.5.9 Safety-Integrity
A1.5.10 Safety-Integrity level
A1.6 General Terms
A1.6.1 Availability (Steady State)
A1.6.2 Unavailability (PFD)
A1.6.3 Burn-In
A1.6.4 Confidence Interval
A1.6.5 Consumer’s Risk
A1.6.6 Derating
A1.6.7 Ergonomics
A1.6.8 Mean
A1.6.9 Median
A1.6.10 PFD
A1.6.11 Producer’s Risk
A1.6.12 Quality
A1.6.13 Random
A1.6.14 FRACAS
A1.6.15 RAMS
Appendix 2: Percentage Points of the Chi-Square Distribution
Appendix 3: Microelectronics Failure Rates
Appendix 4: General Failure Rates
Appendix 5: Failure mode percentages
Appendix 6: Human Error Probabilities
Appendix 7: Fatality rates
Appendix 8: Answers to Exercises
Chapter 2
Chapter 5
Chapter 6
Chapter 7
Chapter 9
Notes
Chapter 12
Chapter 25
25.2: Protection System
25.4: Reliability Block Diagram
25.6: Quantifying the Model
25.7 Revised diagrams
25.10 ALARP
25.11 Architectural Constraints
Appendix 9: Bibliography
Appendix 10: Scoring Criteria for BETAPLUS Common Cause Model
A10.1 Checklist and Scoring for Equipment Containing Programable Electronics
A10.2 Checklist and Scoring for Non-Programable Equipment For Programable Electronics For Sensors and Actuators
Appendix 11: Example of HAZOP
A11.1 Equipment Details
A11.2 HAZOP Worksheets
A11.3 Potential Consequences
Worksheet
Appendix 12: HAZID Checklist
Appendix 13: Markov Analysis of Redundant Systems
Index
Product details
- No. of pages: 436
- Language: English
- Copyright: © Butterworth-Heinemann 2011
- Published: June 20, 2011
- Imprint: Butterworth-Heinemann
- eBook ISBN: 9780080969039
About the Author
David Smith
Dr. David J. Smith is the Proprietor of Technis Consultancy. He has written numerous books on Reliability and Safety over the last 40 years. His FARADIP database has become widely used, and his other software packages are also used throughout the profession. His PhD thesis was on the subject of reliability prediction and common cause failure. He contributed to the first drafting of IEC 61508 and chairs the IGEM panel which produces SR/15 (the gas industry safety related guidance). David is past President of the Safety and Reliability Society.
Affiliations and Expertise
Independent Consultant, Technis, Tonbridge, UK
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