Reliability, maintainability, and risk : practical methods for engineers / David J. Smith.

Format:

Book

Author/Creator:

Smith, David J. (David John), 1943 June 22-

Language:

English

Subjects (All):

Reliability (Engineering).

Maintainability (Engineering).

Engineering design.

Physical Description:

xii, 335 pages : illustrations, map ; 25 cm

Edition:

Sixth edition.

Place of Publication:

Oxford ; Boston : Butterworth-Heinemann, 2001.

Summary:

This 6th edition incorporates brand new material on the accuracy of reliability prediction and common cause failure based on the author's PhD research work. David J. Smith approaches these subjects from an entirely original and unique viewpoint, emphasising that the need to demonstrate that safety-related systems have been assessed against target integrity levels is now commonplace in most industries, and the material contained in this book will address these growing needs.

Reliability, Maintainability and Risk has now been established for over 20 years. It deals with all aspects of reliability, maintainability and safety-related failures in a simple and straightforward style, explaining technical terms and jargon and handling the imitations of reliability parameters. It pre-supposes no prior knowledge of the subject-the author deals with numerical data making realistic predictions using the minimum of mathematics.

Contents:

Part 1 Understanding Reliability Parameters and Costs 1

1 The history of reliability and safety technology 3

1.1 Failure data 3

1.2 Hazardous failures 4

1.3 Reliability and risk prediction 5

1.4 Achieving reliability and safety-integrity 6

1.5 The RAMS-cycle 7

1.6 Contractual pressures 9

2 Understanding terms and jargon 11

2.1 Defining failure and failure modes 11

2.2 Failure Rate and Mean Time Between Failures 12

2.3 Interrelationships of terms 14

2.4 The Bathtub Distribution 16

2.5 Down Time and Repair Time 17

2.6 Availability 20

2.7 Hazard and risk-related terms 20

2.8 Choosing the appropriate parameter 21

3 A cost-effective approach to quality, reliability and safety 23

3.1 The cost of quality 23

3.2 Reliability and cost 26

3.3 Costs and safety 29

Part 2 Interpreting Failure Rates 33

4 Realistic failure rates and prediction confidence 35

4.1 Data accuracy 35

4.2 Sources of data 37

4.3 Data ranges 41

4.4 Confidence limits of prediction 44

4.5 Overall conclusions 46

5 Interpreting data and demonstrating reliability 47

5.1 The four cases 47

5.2 Inference and confidence levels 47

5.3 The Chi-square Test 49

5.4 Double-sided confidence limits 50

5.5 Summarizing the Chi-square Test 51

5.6 Reliability demonstration 52

5.7 Sequential testing 56

5.8 Setting up demonstration tests 57

6 Variable failure rates and probability plotting 58

6.1 The Weibull Distribution 58

6.2 Using the Weibull Method 60

6.3 More complex cases of the Weibull Distribution 67

6.4 Continuous processes 68

Part 3 Predicting Reliability and Risk 71

7 Essential reliability theory 73

7.1 Why predict RAMS? 73

7.2 Probability theory 73

7.3 Reliability of series systems 76

7.4 Redundancy rules 77

7.5 General features of redundancy 83

8 Methods of modelling 87

8.1 Block Diagram and Markov Analysis 87

8.2 Common cause (dependent) failure 98

8.3 Fault Tree Analysis 103

8.4 Event Tree Diagrams 110

9 Quantifying the reliability models 114

9.1 The reliability prediction method 114

9.2 Allowing for diagnostic intervals 115

9.3 FMEA (Failure Mode and Effect Analysis) 117

9.4 Human factors 118

9.5 Simulation 123

9.6 Comparing predictions with targets 126

10 Risk assessment (QRA) 128

10.1 Frequency and consequence 128

10.2 Perception of risk and ALARP 129

10.3 Hazard identification 130

10.4 Factors to quantify 135

Part 4 Achieving Reliability and Maintainability 140

11 Design and assurance techniques 142

11.1 Specifying and allocating the requirement 142

11.2 Stress analysis 145

11.3 Environmental stress protection 148

11.4 Failure mechanisms 148

11.5 Complexity and parts 150

11.6 Burn-in and screening 153

11.7 Maintenance strategies 154

12 Design review and test 155

12.1 Review techniques 155

12.2 Categories of testing 156

12.3 Reliability growth modelling 160

13 Field data collection and feedback 164

13.1 Reasons for data collection 164

13.2 Information and difficulties 164

13.3 Times to failure 165

13.4 Spreadsheets and databases 166

13.5 Best practice and recommendations 168

13.6 Analysis and presentation of results 169

13.7 Examples of failure report forms 170

14 Factors influencing down time 173

14.1 Key design areas 173

14.2 Maintenance strategies and handbooks 180

15 Predicting and demonstrating repair times 193

15.1 Prediction methods 193

15.2 Demonstration plans 201

16 Quantified reliability centred maintenance 205

16.1 What is QRCM? 205

16.2 The QRCM decision process 206

16.3 Optimum replacement (discard) 207

16.4 Optimum spares 209

16.5 Optimum proof-test 210

16.6 Condition monitoring 211

17 Software quality/reliability 213

17.1 Programmable devices 213

17.2 Software failures 214

17.3 Software failure modelling 215

17.4 Software quality assurance 217

17.5 Modern/formal methods 223

17.6 Software checklists 226

Part 5 Legal, Management and Safety Considerations 231

18 Project management 233

18.1 Setting objectives and specifications 233

18.2 Planning, feasibility and allocation 234

18.3 Programme activities 234

18.4 Responsibilities 237

18.5 Standards and guidance documents 237

19 Contract clauses and their pitfalls 238

19.1 Essential areas 238

19.2 Other areas 241

19.3 Pitfalls 242

19.4 Penalties 244

19.5 Subcontracted reliability assessments 246

20 Product liability and safety legislation 248

20.2 Strict liability 249

20.3 The Consumer Protection Act 1987 250

20.4 Health and Safety at Work Act 1974 251

20.5 Insurance and product recall 252

21 Major incident legislation 254

21.1 History of major incidents 254

21.2 Development of major incident legislation 255

21.3 CIMAH safety reports 256

21.4 Offshore safety cases 259

21.5 Problem areas 261

21.6 The COMAH directive (1999) 262

22 Integrity of safety-related systems 263

22.1 Safety-related or safety-critical? 263

22.2 Safety-integrity levels (SILs) 264

22.3 Programmable electronic systems (PESs) 266

22.4 Current guidance 268

22.5 Accreditation and conformity of assessment 272

23 A case study: The Datamet Project 273

23.2 The DATAMET Concept 273

23.3 Formation of the project group 277

23.4 Reliability requirements 278

23.5 First design review 279

23.6 Design and development 281

23.7 Syndicate study 282

23.8 Hints 282

Appendix 2 Percentage points of the Chi-square distribution 292

Appendix 3 Microelectronics failure rates 296

Appendix 4 General failure rates 298

Appendix 5 Failure mode percentages 305

Appendix 6 Human error rates 308

Appendix 7 Fatality rates 310

Appendix 10 Scoring criteria for BETAPLUS common cause model 320

Appendix 11 Example of HAZOP 327

Appendix 12 HAZID checklist 330.

Notes:

Includes bibliographical references (pages [316]-319) and index.

ISBN:

0750651687

OCLC:

187510764