Reliability, maintainability and risk. Practical methods for engineers

✍ Scribed by Smith D.J

• Publisher: Elsevier
• Year: 2011
• Tongue: English
• Leaves: 463
• Edition: 8
• Category: Library

✦ Table of Contents

Reliability, Maintainabilityand Risk......Page 4
copyright......Page 5
Contents......Page 6
Preface......Page 20
Acknowledgements......Page 22
Part 1 - Understanding ReliabilityParameters and Costs......Page 24
1.1 - Failure Data......Page 26
1.3 - Reliability and Risk Prediction......Page 28
1.4 - Achieving Reliability and Safety-Integrity......Page 31
1.5 - The RAMS Cycle......Page 32
1.6 - Contractual and Legal Pressures......Page 34
2.1 - Defining Failure and Failure Modes......Page 36
2.2 - Failure Rate and Mean Time Between Failures......Page 38
2.3 - Interrelationships of Terms......Page 40
2.4 - The Bathtub Distribution......Page 43
2.5 - Down Time and Repair Time......Page 45
2.6 - Availability, Unavailability and Probability of Failure on Demand......Page 47
2.7 - Hazard and Risk-Related Terms......Page 48
2.8 - Choosing the Appropriate Parameter......Page 49
Exercises......Page 50
3.1 - Reliability and Optimum Cost......Page 52
3.2 - Costs and Safety......Page 56
3.3 - The Cost of Quality......Page 57
Part 2 - Interpreting Failure Rates......Page 62
4.1 - Data Accuracy......Page 64
4.2 - Sources of Data......Page 66
4.3 - Data Ranges......Page 71
4.4 - Confidence Limits of Prediction......Page 75
4.5 - Manufacturers’ Data......Page 77
4.6 - Overall Conclusions......Page 78
5.2 - Inference and Confidence Levels......Page 80
5.3 - The Chi-Square Test......Page 82
5.4 - Understanding the Method in More Detail......Page 85
5.6 - Reliability Demonstration......Page 86
5.7 - Sequential Testing......Page 91
5.8 - Setting Up Demonstration Tests......Page 92
Exercises......Page 93
6.1 - The Weibull Distribution......Page 94
6.2 - Using the Weibull Method......Page 96
6.3 - More Complex Cases of the Weibull Distribution......Page 104
6.4 - Continuous Processes......Page 105
Exercises......Page 106
Part 3 - Predicting Reliability and Risk......Page 108
7.1 - Why Predict RAMS?......Page 110
7.2 - Probability Theory......Page 111
7.3 - Reliability of Series Systems......Page 114
7.4 - Redundancy Rules......Page 115
7.5 - General Features of Redundancy......Page 121
Exercises......Page 124
8.1 - Block Diagrams and Repairable Systems......Page 126
8.2 - Common Cause (Dependent) Failure......Page 134
8.3 - Fault Tree Analysis......Page 141
8.4 - Event Tree Diagrams......Page 149
9.1 - The Reliability Prediction Method......Page 156
9.2 - Allowing for Diagnostic Intervals......Page 158
9.3 - FMEA (Failure Mode and Effect Analysis)......Page 160
9.4 - Human Factors......Page 163
9.5 - Simulation......Page 170
9.6 - Comparing Predictions with Targets......Page 176
10.1 Frequency and Consequence......Page 178
10.2 Perception of Risk, ALARP and Cost per Life Saved......Page 179
10.3 Hazard Identification......Page 187
10.4 Factors to Quantify......Page 192
Part 4 - Achieving Reliabilityand Maintainability......Page 200
Chapter 11 - Design and Assurance Techniques......Page 202
11.3 Environmental Stress Protection......Page 207
11.4 Failure Mechanisms......Page 208
11.5 Complexity and Parts......Page 210
11.6 Burn-In and Screening......Page 212
11.7 Maintenance Strategies......Page 213
12.1 Review Techniques......Page 214
12.2 Categories of Testing......Page 215
12.3 Reliability Growth Modeling......Page 222
13.2 Information and Difficulties......Page 228
13.3 Times to Failure......Page 230
13.4 Spreadsheets and Databases......Page 231
13.5 Best Practice and Recommendations......Page 233
13.6 Analysis and Presentation of Results......Page 234
13.7 Manufacturers’ data......Page 235
13.9 Examples of Failure Report Forms......Page 236
14.1 Key Design Areas......Page 240
14.2 Maintenance Strategies and Handbooks......Page 248
15.1 Prediction Methods......Page 264
15.2 Demonstration Plans......Page 273
16.1 What is QRCM?......Page 278
16.3 Optimum Replacement (Discard)......Page 279
16.4 Optimum Spares......Page 282
16.5 Optimum Proof Test......Page 283
16.6 Condition Monitoring......Page 285
17.1 Programable Devices......Page 286
17.2 Software-related Failures......Page 288
17.3 Software Failure Modeling......Page 290
17.4 Software Quality Assurance (Life Cycle Activities)......Page 291
17.5 Modern/Formal Methods......Page 298
17.6 Software Checklists......Page 302
Part 5 - Legal, Management and Safety Considerations......Page 308
18.1 Setting Objectives and Making Specifications......Page 310
18.2 Planning, Feasibility and Allocation......Page 311
18.3 Program Activities......Page 312
18.4 Responsibilities and Competence......Page 314
18.5 Functional Safety Capability......Page 317
18.6 Standards and Guidance Documents......Page 318
19.1 Essential Areas......Page 320
19.1.2 Environment......Page 322
19.2 Other Areas......Page 325
19.3 Pitfalls......Page 327
19.4 Penalties......Page 328
19.5 Subcontracted Reliability Assessments......Page 331
20.1 The General Situation......Page 334
20.2 Strict Liability......Page 336
20.3 The Consumer Protection Act 1987......Page 337
20.4 Health and Safety at Work Act 1974......Page 338
20.5 Insurance and Product Recall......Page 339
21.1 - History of Major Incidents......Page 342
21.2 - Development of major incident legislation......Page 343
21.3 - CIMAH safety reports......Page 345
21.4 - Offshore Safety Cases......Page 347
21.5 - Problem Areas......Page 350
21.7 - Rail......Page 351
21.8 - Corporate Manslaughter and Corporate Homicide......Page 352
22.1 - Safety-Related or Safety-Critical?......Page 354
22.2 - Safety-Integrity Levels (SILs)......Page 355
22.4 - Current guidance......Page 361
22.5 - Framework for Certification......Page 364
23.2 - The Datamet Concept......Page 366
23.3 - The Contract......Page 369
23.4 - Detailed Design......Page 370
23.6 - Hints......Page 371
24.1 - Safety-Integrity Target......Page 372
24.2 - Random Hardware Failures......Page 373
24.4 - Architectures......Page 375
24.6 - Functional Safety Capability......Page 376
25.1 - The Unprotected System......Page 378
25.2 - Protection System......Page 379
25.4 - Reliability Block Diagram......Page 380
25.6 - Quantifying the Model......Page 381
25.8 - Modeling Common Cause Failure (Pressure Transmitters)......Page 382
25.9 - Quantifying the Revised Model......Page 383
25.11 - Architectural Constraints......Page 384
A1.1 Terms Related to Failure......Page 386
A1.2 Reliability Terms......Page 387
A1.3 Maintainability Terms......Page 388
A1.4 Terms Associated with Software......Page 389
A1.5 Terms Related to Safety......Page 391
A1.6 General Terms......Page 392
Appendix 2 - Percentage Points of theChi-Square Distribution......Page 396
Appendix 3 - Microelectronics Failure Rates......Page 404
Appendix 4 - General Failure Rates......Page 406
Appendix 5 - Failure mode percentages......Page 414
Appendix 6 - Human Error Probabilities......Page 418
Appendix 7 - Fatality rates......Page 422
Chapter 5......Page 424
Chapter 7......Page 425
Chapter 9......Page 426
Chapter 12......Page 428
Chapter 25......Page 429
Bibliography......Page 434
A10.1 Checklist and Scoring for Equipment Containing Programable Electronics......Page 436
A10.2 Checklist and Scoring for Non-Programable Equipment......Page 438
For Sensors and Actuators......Page 440
A11.3 Potential Consequences......Page 442
Worksheet......Page 444
Appendix 12 - HAZID Checklist......Page 446
Appendix 13 - Markov Analysis of Redundant Systems......Page 450