ABS-132-2004.pdf
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1、 GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE JULY 2004 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2004 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Copyright American Bureau of Shipping Provided
2、by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co
3、/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE . 2004 iii Foreword In recent years, there has been an increase in the use of proactive maintenance techniques by Owners fo
4、r repair and maintenance of machinery onboard vessels and offshore structures. The resulting preventative maintenance programs developed as a result of applying these techniques are being used by the vessels crew and shore-based repair personnel. There have been numerous advances in condition monito
5、ring technology, trending, and increasingly more powerful planned maintenance software as a result of increased business competition. Since 1978, ABS has cooperated with Owners on developing and implementing preventative maintenance programs. In 1984, ABS issued its first Guide for Survey Based on P
6、reventative Maintenance Techniques with subsequent updates in 1985, 1987, 1995 and then inclusion in the Rule Requirements for Survey After Construction Part 7 in mid-2002. However, machinery systems have continued to become larger and more complex, requiring skilled operators with specialized knowl
7、edge of the machinery and systems onboard. The Guide for Survey Based on Reliability-centered Maintenance was issued in December 2003 to provide vessel and other marine structure Owners, managers and operators requirements for the development of a maintenance program using techniques applied in othe
8、r industries for machinery systems within a maintenance philosophy referred to as Reliability-centered Maintenance (RCM). With the application of RCM principles, maintenance is evaluated and applied in a rational manner that provides the most value to a vessels Owner/manager/operator. Accordingly, i
9、mproved equipment and system reliability onboard vessels and other marine structures can be expected by the application of this philosophy. The purpose of these Guidance Notes is to provide supplementary information for application of the requirements of the Guide for Survey Based on Reliability-cen
10、tered Maintenance. Information related to equipment failure, maintenance strategies, risk considerations, conducting and documenting an RCM analysis and sustaining an RCM program is provided in the main section of these Guidance Notes. An Appendix providing an overview of various condition monitorin
11、g techniques is included. A brief example RCM analysis for three propulsion engine components is provided to demonstrate the procedure. ABS welcomes comments and suggestions for improvement of this Guide. Comments or suggestions can be sent electronically to rddeagle.org. Copyright American Bureau o
12、f Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with AB
13、S Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE . 2004 v GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE CONTENTS SECTION 1 General1 1 Objective1 2
14、Application .1 3 Defining Reliability-centered Maintenance 1 4 Definitions 2 SECTION 2 Equipment Failure7 1 Equipment Failure7 2 Equipment Failure Rate and Patterns8 3 Failure Management Strategy .12 3.1 Proactive Maintenance Tasks.13 3.2 Run-to-failure 14 3.3 One-time Changes14 3.4 Servicing and Ro
15、utine Inspection15 TABLE 1 Examples of Dominant Physical Failure Mechanisms for Hardware 8 TABLE 2 Six Classic Failure Rate Patterns 11 FIGURE 1 Normal, Exponential and Weibull Failure Distributions .10 FIGURE 2 Equipment Life Periods12 SECTION 3 Planned Maintenance 17 1 Introduction17 2 Age-To-Fail
16、ure Relationship17 3 Planned-maintenance Task Applicability and Effectiveness18 4 Determining Planned-maintenance Task Interval19 FIGURE 1 Classic Failure Profile Used for Planned Maintenance.17 FIGURE 2 Failure Profile Illustrating the Effect of Performing a Planned Task.18 Copyright American Burea
17、u of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from IHS -,-,- vi ABS GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE . 2004 FIGURE 3 Safe Life Limit 19 FIGURE 4 Econo
18、mic Life Limit19 SECTION 4 Condition Monitoring (Predictive) Maintenance .21 1 Potential Failure (P-F) Diagram.21 2 The P-F Interval.22 3 Condition-monitoring Maintenance Task Applicability and Effectiveness22 4 Determining Condition-monitoring Maintenance Task Intervals23 4.1 Condition-monitoring T
19、ask Interval23 4.2 Initial Condition-monitoring Task Intervals.23 4.3 Improving the Understanding of P-F Intervals.23 5 Establishing Condition-monitoring Maintenance Task Action Limits.24 FIGURE 1 P-F Diagram.21 SECTION 5 Failure Finding Maintenance 25 1 Introduction 25 2 Statistical View of Hidden
20、Failures 25 3 Failure-finding Task Applicability and Effectiveness26 4 Determining Failure-finding Maintenance Task Interval27 4.1 Mathematical Determination of Failure-finding Task Interval.27 4.2 Using Guidelines to Determine the Failure-finding Task Interval.28 TABLE 1 Example of Failure-finding
21、Task Interval Rules.28 TABLE 2 Example of Failure-finding Task Intervals Based on MTTF28 FIGURE 1 Effect of a Failure-finding Task26 SECTION 6 Consideration of Risks29 1 Risks In General 29 2 Vessels and Their Risks 30 3 Risk Characterization.31 TABLE 1 Example Consequence (Severity) Categories.34 F
22、IGURE 1 The General Risk Model30 FIGURE 2 Example Risk Model 32 FIGURE 3 Sample Risk Matrix33 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 20:45:57 MDTNo reproduction or networking permitted without license from
23、 IHS -,-,- ABS GUIDANCE NOTES ON RELIABILITY-CENTERED MAINTENANCE . 2004 vii SECTION 7 Conducting and Documenting an RCM Analysis35 1 Introduction35 2 Defining Systems.35 2.1 Defining Ship Operating Characteristics .35 2.2 Partitioning Systems .40 3 Defining Functions and Functional Failures 43 3.1
24、Identifying Functions for a Functional Group.44 3.2 Identifying Functional Failures for a Functional Group46 4 Conducting an FMECA47 4.1 Identifying Failure Modes and Effects with an FMECA .47 4.2 Considerations in Identifying Failure Modes and Failure Effects with an FMECA .51 4.3 End Effect Consid
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