Reliability, Maintainability and Risk : Practical Methods for Engineers Including Reliability Centred Maintenance and Safety-Related Systems

by Smith

• ISBN13: 9780750666947
• ISBN10: 0750666943
• Edition: 7th
• Format: Paperback
• Copyright: 2005-05-26
• Publisher: Elsevier Science

Summary

For over 30 years, Reliability, Maintainability and Risk has been recognised as a leading text for reliability and maintenance professionals. Now in its seventh edition, the book has been updated to remain the first choice for professional engineers and students. The seventh edition incorporates new material on important topics including software failure, the latest safety legislation and standards, product liability, integrity of safety-related systems, as well as delivering an up-to-date review of the latest approaches to reliability modelling, including cutsec ranking. It is also supported by new detailed case studies on reliability and risk in practice. * The leading reliability reference for over 30 years * Covers all key aspects of reliability and maintenance management in an accessible way with minimal mathematics - ideal for hands-on applications * Four new chapters covering software failure, safety legislation, safety systems and new case studies on reliability and risk in practice

Table of Contents

Preface	xi
Acknowledgements	xiii
Part One Understanding Reliability Parameters and Costs	1	(34)
The history of reliability and safety technology	3	(8)
Failure data	3	(1)
Hazardous failures	4	(1)
Reliability and risk prediction	5	(2)
Achieving reliability and safety-integrity	7	(1)
The RAMS-cycle	8	(2)
Contractual pressures	10	(1)
Understanding terms and jargon	11	(13)
Defining failure and failure modes	11	(1)
Failure Rate and Mean Time Between Failures	12	(3)
Interrelationships of terms	15	(2)
The Bathtub Distribution	17	(1)
Down Time and Repair Time	18	(3)
Availability, Unavailability and Probability of Failure on Demand	21	(1)
Hazard and risk-related terms	21	(1)
Choosing the appropriate parameter	22	(2)
Exercises	23	(1)
A cost-effective approach to quality, reliability and safety	24	(11)
Reliability and cost	24	(3)
Costs and safety	27	(3)
The cost of quality	30	(5)
Part Two Interpreting Failure Rates	35	(38)
Realistic failure rates and prediction confidence	37	(13)
Data accuracy	37	(2)
Sources of data	39	(4)
Data ranges	43	(3)
Confidence limits of prediction	46	(3)
Overall conclusions	49	(1)
Interpreting data and demonstrating reliability	50	(11)
The four cases	50	(1)
Inference and confidence levels	50	(1)
The Chi-square Test	51	(2)
Double-sided confidence limits	53	(1)
Summarizing the Chi-square Test	54	(1)
Reliability demonstration	54	(3)
Sequential testing	57	(2)
Setting up demonstration tests	59	(2)
Exercises	60	(1)
Variable failure rates and probability plotting	61	(12)
The Weibull Distribution	61	(2)
Using the Weibull Method	63	(6)
More complex cases of the Weibull Distribution	69	(1)
Continuous processes	70	(3)
Exercises	71	(2)
Part Three Predicting Reliability and Risk	73	(70)
Basic reliability prediction theory	75	(14)
Why predict RAMS?	75	(1)
Probability theory	75	(3)
Reliability of series systems	78	(1)
Redundancy rules	79	(6)
General features of redundancy	85	(4)
Exercises	88	(1)
Methods of modelling	89	(24)
Block Diagrams and Repairable Systems	89	(7)
Common cause (dependent) failure	96	(5)
Fault Tree Analysis	101	(8)
Event Tree Diagrams	109	(4)
Quantifying the reliability models	113	(17)
The reliability prediction method	113	(1)
Allowing for diagnostic intervals	114	(2)
FMEA (Failure Mode and Effect Analysis)	116	(2)
Human factors	118	(5)
Simulation	123	(5)
Comparing predictions with targets	128	(2)
Exercises	129	(1)
Risk assessment (QRA)	130	(13)
Frequency and consequence	130	(1)
Perception of risk and ALARP	130	(2)
Hazard identification	132	(5)
Factors to quantify	137	(6)
Part Four Achieving Reliability and Maintainability	143	(90)
Design and assurance techniques	145	(12)
Specifying and allocating the requirement	145	(2)
Stress analysis	147	(3)
Environmental stress protection	150	(1)
Failure mechanisms	150	(3)
Complexity and parts	153	(2)
Burn in and screening	155	(1)
Maintenance strategies	156	(1)
Design review and test	157	(10)
Review techniques	157	(1)
Categories of testing	158	(5)
Reliability growth modelling	163	(4)
Exercises	166	(1)
Field data collection and feedback	167	(9)
Reasons for data collection	167	(1)
Information and difficulties	167	(1)
Times to failure	168	(1)
Spreadsheets and databases	169	(2)
Best practice and recommendations	171	(1)
Analysis and presentation of results	172	(1)
Examples of failure report forms	173	(3)
Factors influencing down time	176	(20)
Key design areas	176	(7)
Maintenance strategies and handbooks	183	(13)
Predicting and demonstrating repair times	196	(12)
Prediction methods	196	(8)
Demonstration plans	204	(4)
Quantified reliability centred maintenance	208	(7)
What is QRCM?	208	(1)
The QRCM decision process	209	(1)
Optimum replacement (discard)	210	(2)
Optimum spares	212	(1)
Optimum proof test	212	(2)
Condition monitoring	214	(1)
Systematic failures, especially software	215	(18)
Programmable devices	215	(2)
Software-related failures	217	(1)
Software failure modelling	218	(1)
Software quality assurance	219	(6)
Modern/formal methods	225	(3)
Software checklists	228	(5)
Part Five Legal, Management and Safety Considerations	233	(53)
Project management	235	(6)
Setting objectives and specifications	235	(1)
Planning, feasibility and allocation	236	(1)
Programme activities	236	(2)
Responsibilities	238	(1)
Functional safety capability	239	(1)
Standards and guidance documents	240	(1)
Contract clauses and their pitfalls	241	(10)
Essential areas	241	(3)
Other areas	244	(2)
Pitfalls	246	(1)
Penalties	247	(2)
Subcontracted reliability assessments	249	(1)
Examples	250	(1)
Product liability and safety legislation	251	(6)
The general situation	251	(1)
Strict liability	252	(1)
The Consumer Protection Act 1987	253	(1)
Health and Safety at Work Act 1974	253	(2)
Insurance and product recall	255	(2)
Major incident legislation	257	(9)
History of major incidents	257	(1)
Development of major incident legislation	258	(1)
CIMAH safety reports	259	(3)
Offshore safety cases	262	(1)
Problem areas	263	(1)
The COMAH directive (1999)	264	(1)
Rail	265	(1)
Integrity of safety-related systems	266	(10)
Safety-related or safety-critical?	266	(1)
Safety-integrity levels (SILs)	267	(3)
Programmable electronic systems (PESs)	270	(2)
Current guidance	272	(2)
Framework for certification	274	(2)
A case study: The Datamet Project	276	(6)
Introduction	276	(1)
The DATAMET concept	276	(3)
The contract	279	(1)
Detailed design	280	(1)
Syndicate study	280	(1)
Hints	280	(2)
A case study: Gas Detection System	282	(4)
Safety-integrity target	282	(1)
Random hardware failures	283	(2)
ALARP	285	(1)
Architectures	285	(1)
Life-cycle activities	285	(1)
Functional safety capability	285	(1)
Appendix 1 Glossary	286	(8)
Appendix 2 Percentage points of the Chi-square distribution	294	(4)
Appendix 3 Microelectronics failure rates	298	(2)
Appendix 4 General failure rates	300	(7)
Appendix 5 Failure mode percentages	307	(3)
Appendix 6 Human error rates	310	(2)
Appendix 7 Fatality rates	312	(2)
Appendix 8 Answers to exercises	314	(6)
Appendix 9 Bibliography	320	(3)
Appendix 10 Scoring criteria for BETAPLUS common cause model	323	(7)
Appendix 11 Example of HAZOP	330	(4)
Appendix 12 HAZID checklist	334	(3)
Appendix 13 Markov analysis of redundant systems	337	(6)
Index	343