Applied

Reliability-Centered
Maintenance

by Jim August, PE
front matter i-xxiv.qxd 3/3/00 2:28 PM Page i

Applied
Reliability-Centered
Maintenance
front matter i-xxiv.qxd 3/3/00 2:28 PM Page ii
front matter i-xxiv.qxd 3/3/00 2:29 PM Page iii

Applied
Reliability-Centered
Maintenance

by Jim August, PE
OME, Inc.
front matter i-xxiv.qxd 3/3/00 2:29 PM Page iv

Copyright © 1999 by
PennWell
1421 S. Sheridan/P.O. Box 1260
Tulsa, Oklahoma 74101

Library of Congress Cataloging-in-Publication Data

August, Jim
Applied reliability centered maintenance / by Jim August.
p.cm.
ISBN 0-87814-746-2
1. Plant maintenance. 2. Reliability (Engineering) 3. Maintainability
(Engineering)
I.Title.

TS192 .A94 1999

658.2’02--dc21
99-050100

All rights reserved. No part of this book may be reproduced, stored in a

retrieval system, or transcribed in any form or by any means, electronic or
mechanical, including photocopying and recording, without the prior written
permission of the publisher.

Cover Design: Shanon Garvin and Brian Firth

Layout: Brian Firth

Printed in the United States of America

03 02 01 00 99 1 2 3 4 5
Table of Contents
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xix
Chapter 1 Applied RCM: An Overview . . . . . . . . . . . . . . . . . . . . . . . .1
Chapter 2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Chapter 3 RCM Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Chapter 4 Plant Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Chapter 5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Chapter 6 Lessons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Chapter 7 Fast Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Chapter 8 Maintenance Software . . . . . . . . . . . . . . . . . . . . . . . . . . .301
Chapter 9 Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
Chapter 10 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Further Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
RCM Software Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481

v
front matter i-xxiv.qxd 3/3/00 2:29 PM Page vi
front matter i-xxiv.qxd 3/3/00 2:29 PM Page vii

Figures

1-1 Idarado Bar and Rod Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1-2 Failure Distributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1-3 Maintenance Terms Map . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2-1 Maintenance Continuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
2-2 Practical PM Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
2-3 Maintenance Electromagnetic Spectrum Analogy . . . . . . . . . .28
2-4 Fossil Unit Forced Outage Rate . . . . . . . . . . . . . . . . . . . . . . .31
2-5 Boiling Water Reactor Air Operator Valve "Failures" . . . . . . . .34
2-6 Change! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2-7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2-8 Specific Maintenance Processes . . . . . . . . . . . . . . . . . . . . . . .40
2-9 Condition-based Maintenance . . . . . . . . . . . . . . . . . . . . . . . .42
2-10 Engineering (Design)-Limited Failure Aging . . . . . . . . . . . . . .44
2-11 Time Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2-12 PM Performance "Triggers" . . . . . . . . . . . . . . . . . . . . . . . . . .54
2-13 Coal Mill Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . .69
3-1 Modern Blending Coal-fired Power Plant . . . . . . . . . . . . . . . .72
3-2 "Critical" Streamlined RCM/PMO Approach . . . . . . . . . . . . . .78
3-3 Equipment Maintenance Standard . . . . . . . . . . . . . . . . . . . . .80
3-4 System Component Hierarchy . . . . . . . . . . . . . . . . . . . . . . . .82
3-5 “Blocking” Tasks Reduces Outage Duration . . . . . . . . . . . . . .89
3-6 Coal Belt Assembly Functional Failures . . . . . . . . . . . . . . . . .93
3-7 Equipment Failure Hierarchy FMEA . . . . . . . . . . . . . . . . . . . .94
3-8 Ishikawa Fishbone Example . . . . . . . . . . . . . . . . . . . . . . . . . .97
3-9 Fault Tree: Loss of Cooling . . . . . . . . . . . . . . . . . . . . . . . . .106
3-10 Random Limit Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

vii
front matter i-xxiv.qxd 3/3/00 2:29 PM Page viii

3-11 Fault Tree: Loss of Cooling . . . . . . . . . . . . . . . . . . . . . . . . .108

3-12 "Run-in" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
3-13 Turbine Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
3-14 Cumulative Turbine Failures . . . . . . . . . . . . . . . . . . . . . . . .111
4-1 Pareto Chart of System Loses . . . . . . . . . . . . . . . . . . . . . . . .117
4-2 PM Performance Process . . . . . . . . . . . . . . . . . . . . . . . . . . .126
4-3 IR Sootblower Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
4-4a Nuclear 4160V Breaker Failures . . . . . . . . . . . . . . . . . . . . .139
4-4b Fossil 4160V Breaker Failures . . . . . . . . . . . . . . . . . . . . . . .139
4-5 System "Black Box" Model . . . . . . . . . . . . . . . . . . . . . . . . . .156
4-6 Two Sides of Failure Management . . . . . . . . . . . . . . . . . . . .157
4-7 Boiler Feedpump in a 50% Redundant Train . . . . . . . . . . . . .158
4-8 Failure Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
4-9 System Part Functional Relationships . . . . . . . . . . . . . . . . . .160
4-10 Failure Progression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
5-1 Failure Curves for 93% of Equipment Components . . . . . . . .179
6-1 Best Value? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
6-2 Breaker Failure Summaries . . . . . . . . . . . . . . . . . . . . . . . . .222
7-1 Maintenance Terms "Map" . . . . . . . . . . . . . . . . . . . . . . . . . .257
7-2 Failure Progression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
7-3 Traditional PM Development . . . . . . . . . . . . . . . . . . . . . . . .270
7-4 Backlog Maintenance Timing . . . . . . . . . . . . . . . . . . . . . . . .281
7-5 Plant Instrument Air/Service Air Equipment Group . . . . . . . .288
7-6 Modified Work Control Process Flow . . . . . . . . . . . . . . . . . .289
7-7 Residual Heat Removal Equipment Group Register . . . . . . . .291
7-8 Can It be Worked On-line? . . . . . . . . . . . . . . . . . . . . . . . . .293
7-9 Modified Maintenance Process . . . . . . . . . . . . . . . . . . . . . .297
8-1 CMMS Hierarchy of Equipment . . . . . . . . . . . . . . . . . . . . . .302
8-2a Sootblowing Air Compressors: Task Summary . . . . . . . . . . . .308
8-2b Compressors Loaded (Round) . . . . . . . . . . . . . . . . . . . . . . .309

viii
front matter i-xxiv.qxd 3/3/00 2:29 PM Page ix

9-1 Process Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321

9-2 Maintenance Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
9-3 Maintenance Work Cost . . . . . . . . . . . . . . . . . . . . . . . . . . .336
10-1 Fort. St. Vrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
10-2 Maintenance Strategy Map . . . . . . . . . . . . . . . . . . . . . . . . .345

ix
front matter i-xxiv.qxd 3/3/00 2:29 PM Page x

Tables
1-1 Common Outage Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2-1 Example of Time Base Intervals . . . . . . . . . . . . . . . . . . . . . . . . . .49
3-1 Equipment for “Standard” Templates . . . . . . . . . . . . . . . . . . . . . .81
3-2 Strategy Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
4-1 Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
4-2 PM Basis Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
4-3 PM vs. CM and WO classes . . . . . . . . . . . . . . . . . . . . . . . . . . .154
4-4 Component, Function, Part Failure . . . . . . . . . . . . . . . . . . . . . . .156
6-1 Tick Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
6-2 Critical Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
7-1 Areas Not Worked On-Line . . . . . . . . . . . . . . . . . . . . . . . . . . . .292

x
front matter i-xxiv.qxd 3/3/00 2:29 PM Page xi

Acronyms List

AB A or B (with respect to train, or piece of equipment)

A-E Architect-engineer
ALARA As low as reasonably achievable
ANI American Nuclear Insurers
ANSI American National Standards Institute
ARCM Applied reliability centered maintenance
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASQC American Society for Quality Control
B/C Benefit/cost
BFP Boiler feed pump
BPV Boiler and pressure vessel
B&W Babcock and Wilcox
BWR Boiling water reactor
Cal. Calibration
CBM Condition-based maintenance
CC Channel checks
CCF Common cause failure
CDM Condition-directed maintenance
CDM (FF) Condition-directed maintenance (failure finding)
CE Combustion Engineering
CEM Continuous emissions monitor
CFR Code of federal regulations
CIC Component identification codes
CM Corrective maintenance
CNMM Condition-monitoring (based) maintenance
CMMS (Legacy) Computerized maintenance management systems
CNM Condition monitoring
CO Conditional overhaul
CRT Cathode ray tube
CT Combustion turbine
CWP Circulating water pump
CWT Circulating water tower
DC Design change
DCS Distributed-control system
DOE Department of Energy

xi
front matter i-xxiv.qxd 3/3/00 2:29 PM Page xii

DOT Department of Transportation

DP Differential pressure
E Emergency
EEI Edison Electric Institute
EFOR Equivalent forced outage rate
EG Equipment group
“E” MWR Emergency maintenance work request
EO Equipment operator
EPA Environmental Protection Agency
EPRI Electric Power Research Institute
EQ Environmentally qualified
FAA Federal Aviation Administration
FAI Failed as is
FC Fails closed
FD Forced draft
FERC Federal Energy Regulatory Commission
FF Functional failure
FMEA Failure modes and effects analysis
FMECA Failure modes and effects criticality analysis
FO Fails open
FOR Forced outage rate
FT Functional tests
FTA Fault tree analysis
FTM Fixed-time maintenance
GADS Generation availability data system
GE General Electric
GPA Grade point average
GUI Graphical user interface
HEU Hydraulic equipment units
HP Horse power
HRSG Heat recovery steam generator
HTGR High temperature gas reactor
I&C Instrumentation and control
IA Instrument air
ID Induction draft
IEEE Institute of Electrical and Electronic Engineers
INPO Institute of Nuclear Plant Operations
IPP Independent power producer
KISS Keep it simple, stupid!
LAN Local area network
LCM Life-cycle maintenance

xii
front matter i-xxiv.qxd 3/3/00 2:29 PM Page xiii

LCO Limiting conditions for operations

LTA Logic tree analysis
LWR Light water reactor
MIS Maintenance information system
MORT Management oversight risk tree
MOV Motor operated valve
MPFF Maintenance preventable functional failure
mREM One thousandth of a REM
MS Microsoft
MSG-3 Maintenance Steering Group-3
MTBF Mean time between failures
MTTR Mean time to repair
MW Megawatt
MWO Maintenance work order
MWR Maintenance work request
NCE New century energies
NDE Non-destructive examination
NEC National electric code
NERC North American Electric Reliability Council
NFPA National Fire Protection Association
NPM No planned maintenance
NPPD Nebraska Public Power District (utility)
NRC Nuclear Regulatory Commission
NSM No scheduled maintenance
O&M Operation and maintenance
OCM On-condition maintenance
OCMFF On-condition maintenance (failure-finding)
OEM Original equipment manufacturer
OOS Out-of-service
OM Operator manual
OSHA Occupational Safety and Health Administration
OTF Operate to failure
P&ID Process and instrumentation drawings
PA Primary air
PC Primary containment
PCRV Pre-stressed concrete reactor vessel
PdM Predictive maintenance
PG&E Pacific Gas & Electric
PM Preventive maintenance
PMO Preventive maintenance optimization
PRB Powder River Basin

xiii
front matter i-xxiv.qxd 3/3/00 2:29 PM Page xiv

PUC Public utility commissions

PV Present value
PWR Pressurized water reactors
R Reliability
RAM Reliability, availability and maintainability
RCA Root cause analysis
RCFA Root cause failure analysis
RCM Reliability centered maintenance
RD Response-driven
REM Roentgen equivalent, man
RL Random limit
RO Reverse osmosis
RPS Reactor protective system
RTF Run to failure
SAE Society of Automotive Engineers
SBAC Soot-blowing air compressor
SL Straight line
SNAFU Situation normal all fouled up
SOA Society of Actuaries
SP Surveillance programs
SPC Statistical process control
SRCM Streamlined reliability centered maintenance
SSC Structures, systems and components
SWOT Strength weakness opportunity threat (analysis)
TBM Time-based maintenance
TC Thermocouple
TMI Three Mile Island
TPM Total productive maintenance
TQM Total quality management
TRCM Traditional reliability centered maintenance
UAL United Airlines
VAR Volt amp reactive
VM Vibration monitoring
VOM Volt ohm meter
VWO Valves wide open
WO Work order
WSSC Western States Coordinating Council
Y2K Year 2000

xiv
front matter i-xxiv.qxd 3/14/00 5:07 PM Page xv

Acknowledgements
...a chaise breaks down, but doesn’t wear out

-Oliver Wendell Holmes, “The Deacon’s Masterpiece”

(with credit to Stan Nolan & Howard Heap)

Elements of reliability centered maintenance (RCM) aren’t new;

time based maintenance, make-or-buy, re-work, performance testing
and corrective maintenance (CM) have been terms used traditionally
to describe aspects of scheduled maintenance programs. On another
level, RCM brought order to a confused and complex subject. Like
Inuit (Eskimo) language’s many terms for snow, maintenance has many
descriptions. The beauty of RCM is the order that it brings to these
terms in the context of a strategy.
Strategy is an underlying theme of RCM. As in chess or war, strat-
egy requires supporting tactics. These are mastered as preliminaries.
Without appreciating the tactics of maintenance, the need and value
for strategy can be missed. Even with a strategy, tactical battles can be
lost. Yet with a strategy comes a comprehensive vision for managing
short, intermediate, and long-term maintenance. A strategy provides a
resource map that uniquely identifies the multiple roles that must be
played by various work groups.
Experts come into play in several ways: (1) developing the strate-
gy and supporting tactics for the existing plant, (2) identifying the
paths to future goals, and (3) managing the emerging maintenance
requirements of the plant. By whatever name it’s given, understanding
on-condition/condition-directed maintenance complementary tasks is
the general lesson of RCM. Too often in my experience, failures
weren’t recognized because limits weren’t defined. Redundancy or
sheer nerve were adequate support decision-making. At some point,
otherwise failed equipment can be operated. Perhaps not economical-
ly, but operated.

xv