1、 Guide for Surveys Based on Machinery Reliability and Maintenance Techniques GUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES APRIL 2016 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2016 American Bureau of Shipping
2、ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA ii ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 Foreword Foreword The mission of the American Bureau of Shipping (ABS) is to serve the public interest, as well as the needs of its clients, by promoting the
3、 security of life, property, and the natural environment. This is primarily accomplished through the development and verification of standards for the design, construction and operational maintenance of marine and offshore facilities. These standards or Rules are established from principles of naval
4、 architecture, marine engineering and other engineering principles that have been proven satisfactory by service experience and systematic analysis. Marine and offshore operators are striving towards improved operational effectiveness and efficiency. To achieve this end requires a focus on maximizin
5、g uptime, establishing quantitative condition assessment, and improving the overall safety, planning, operations, maintenance and repair processes. This is accomplished with a lifecycle process executing operations and maintenance in a continuous improvement cycle. This cycle aims at improving asset
6、 operations with a balanced criticality and risk-based approach. The Guidelines presented herein offer ABS clients methodologies for achieving classification notations applied to machinery reliability and maintenance management programs. This Guide describes the process and responsibilities for ABS
7、review of design submittals, analysis processes, and resulting maintenance plans as applicable throughout lifecycle stages. The methodology presented relies heavily on risk and reliability assessment techniques as a way to better understand and anticipate machinery and operational issues related to
8、these concepts. 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 Preventative Maintenance Techniques with subsequent updates in 1985, 1987, 1995 and then inclusion in the ABS Rules for
9、 Survey After Construction (Part 7) in mid 2002. Machinery systems continue to become larger and more complex, requiring skilled operators with specialized knowledge of the machinery and systems onboard. This Guide supersedes the ABS Guide for Surveys Based on Reliability-Centered Maintenance (2014)
10、. This Guide updates Reliability Centered Maintenance (RCM) and includes two new reliability processes: Design for Reliability (DFR) utilizes reliability/risk analyses to improve reliability-related performance to a predetermined value. It also provides a structure for applying these reliability/ris
11、k analysis tools throughout the design process to provide the information needed by the designer to make more informed design or procurement decisions. Reliability Based Maintenance (RBM) is an alternative reliability process to Reliability Centered Maintenance (RCM). RBM utilizes risk and criticali
12、ty of systems and equipment to determine the level of analysis needed for maintenance development. A machinery system is selected for evaluation, then the criticality or risk ranking of the equipment and components is determined. The maintenance task selection processes are then chosen based on this
13、 criticality. The final result is a suite of reliability processes that support a comprehensive preventative maintenance plan as defined in Appendix 7-A-14 of the ABS Rules for Survey after Construction (Part 7). This Guide becomes effective on the first day of the month of publication. Users are ad
14、vised to check periodically on the ABS website www.eagle.org to verify that this version of these Guidance Notes is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to 0Hrsdeagle.org. Table of Contents GUIDE FOR SURVEYS BASED ON MACHINERY RELIAB
15、ILITY AND MAINTENANCE TECHNIQUES CONTENTS SECTION 1 General 1 1 Application 1 2 Objective . 2 3 Definitions . 2 4 Program Conditions and Administration . 6 4.1 Engineering Review 6 4.2 Implementation Survey 7 4.3 Spares Holding 7 4.4 Sustainment 7 4.5 Annual Confirmation Survey 7 4.6 Cancellation of
16、 Program 7 4.7 Overhauls and Damage Repairs . 7 5 Application of Risk and Criticality in Decision Making 8 6 Reliability Assessment Team Requirements 8 6.1 Client Activities and ABS Participation 9 7 Coordination with Lifecycle Activities 9 8 Classification Notations . 10 8.1 Program Enrollment Opti
17、ons for Asset, System, or Equipment . 10 8.2 Machinery Status Indicators 12 8.3 Equipment Certification . 12 9 Sample Program Workflows . 12 TABLE 1 Risk Matrix Example Format . 8 TABLE 2 Program Definitions and Notations . 11 TABLE 3 Machinery Status Indicators 12 FIGURE 1 Class Alignment with Clie
18、nt Programs 10 FIGURE 2 Design for Reliability Process Workflow . 13 FIGURE 3 Reliability Based Maintenance Process Workflow 14 FIGURE 4 RCM Process Workflow 15 FIGURE 5 PMP Process Workflow 16 ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 iii SECTION 2 Design
19、for Reliability 17 1 Principles of Design for Reliability 17 1.1 Age Requirements for DFR . 17 1.2 Limitations . 17 2 Analysis Requirements . 17 2.1 Design for Reliability Overview 17 2.2 Reliability Team . 17 2.3 Procedures 17 3 Plans and Data to be Submitted . 18 3.1 For All Machinery Items to be
20、Included 18 3.2 As Applicable for Each Item . 19 TABLE 1 Reliability Objectives in Design . 18 SECTION 3 Reliability Based Maintenance 20 1 Principles of Reliability Analysis 20 1.1 Definition 20 1.2 Tools and Expertise Employed to Perform RBM Analyses 20 1.3 Process Documentation and Implementation
21、 20 2 RBM Process Requirements . 20 2.1 Overview 20 2.2 Reliability Team . 20 2.3 Procedures 20 3 Plans and Data to be Submitted . 22 3.1 Items Selected for Analysis . 22 3.2 Risk and Reliability Analysis 22 3.3 Maintenance Plan 23 3.4 Critical Spares Holding 23 3.5 Sustainment Plan. 23 TABLE 1 Crit
22、icality Based Maintenance Alignment 21 SECTION 4 Reliability Centered Maintenance . 24 1 Principles of Reliability Centered Maintenance 24 1.1 Definition 24 1.2 Objective 24 1.3 Tools and Expertise . 24 1.4 Reliability Centered Maintenance Overview 25 2 Process Requirements 25 2.1 Overview 25 2.2 Re
23、liability Team . 25 2.3 Procedures 25 3 Plans and Data to be Submitted . 26 3.1 RCM Analysis Documentation . 26 3.2 Maintenance Plan 28 iv ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 SECTION 5 In-Service Application and Operations 29 1 Principles of Maintenan
24、ce and Sustainment. 29 2 Onboard Documentation . 29 2.1 All Programs 29 2.2 Condition Monitoring . 29 2.3 Planned Maintenance 29 2.4 Any Other Applicable and Effective Tasks . 29 2.5 Spares Holding 29 2.6 Sustainment 29 3 Preventative Maintenance Program . 30 4 Sustainment Activities . 30 4.1 Sustai
25、nment Documentation Requirements 30 5 Annual Reporting Requirements . 31 5.1 Annual Reliability Programs Report . 31 SECTION 6 Surveys . 32 1 Implementation Survey . 32 1.1 Reliability Implementation Surveys 32 1.2 Preventative Maintenance Requirements 32 2 Annual Requirements . 33 2.1 Annual Confir
26、mation Surveys 33 2.2 Shore Office-Sustainment Program Audit 33 SECTION 7 Information, Offices . 34 1 Information 34 1.1 Program Entry and Fees . 34 1.2 External Specialist . 34 2 ABS Offices Responsible for Machinery Reliability and Maintenance Programs . 34 APPENDIX 1 Guidance on Lifecycle Reliabi
27、lity Principles . 36 1 General . 36 2 Detailed Lifecycle Reliability . 36 3 Design for Reliability and Procurement Strategies . 36 3.1 Overview of Design for Reliability 36 3.2 Design Phases 37 3.3 Design For Reliability (DFR) Approaches 39 4 Principles of Reliability and Integrity Analysis. 43 5 Re
28、liability Based Maintenance 44 5.1 Overview . 44 5.2 Machinery List Development . 44 5.3 Operating Modes and Context . 44 5.4 Criticality Ranking Execution . 45 5.5 Maintenance Development Strategy . 45 5.6 Critical Spare Part Identification 46 ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND
29、 MAINTENANCE TECHNIQUES .2016 v 6 Reliability Centered Maintenance . 46 6.1 Overview 46 6.2 Operating Modes and Context . 46 6.3 System Definition . 47 6.4 System Block Diagrams and Functions . 48 6.5 Identification of Functional Failures . 49 6.6 Failure Mode Effects and Criticality Analysis (FMECA
30、) . 49 6.7 Selection of the Failure Management Tasks 52 6.8 Spares Holding Determination . 52 6.9 Spares Holding Decisions 53 6.10 Sustainment Plan. 53 7 Maintenance Alignment 53 7.1 Condition Based Maintenance . 54 7.2 Planned Maintenance 54 7.3 Run-to-Failure Maintenance 54 8 Principles of In-serv
31、ice Application and Sustainment . 55 8.1 Examples of In-service Application and Sustainment 56 9 Reference Tables and Figures . 57 TABLE 1 Reliability Objectives in Design . 39 TABLE 2 Example Operating Modes and Operating Context 58 TABLE 3 Example Function and Functional Failure List 59 TABLE 4 Ex
32、ample Bottom-up FMECA Worksheet. 60 TABLE 5 Example Consequence/Severity Level Definition Format. 61 TABLE 6 Probability of Failure (i.e., Frequency, Likelihood) Criteria Example Format 62 TABLE 7 Risk Matrix Example Format . 62 TABLE 8 Failure Characteristic and Suggested Failure Management Tasks .
33、 62 TABLE 9 Example Maintenance Task Selection Worksheet . 63 TABLE 10 Summary of Maintenance Tasks 64 TABLE 11 Summary of Spares Holding Determination . 65 FIGURE 1 Lifecycle Maintenance Management Activities . 36 FIGURE 2 Design for Reliability Process . 37 FIGURE 3 Asset Lifecycle Design Phase 38
34、 FIGURE 4 Application of DFR in Design Phases . 39 FIGURE 5 Simple RBM Process 44 FIGURE 6 Maintenance Alignment 54 FIGURE 7 Sustainment Learning Loop 55 FIGURE 8 Example Partitioning of Functional Groups 66 FIGURE 9 Example System Block Diagram . 67 FIGURE 10 RCM Task Selection Flow Diagram 68 FIGU
35、RE 11 Spares Holding Decision Flow Diagram . 70 vi ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 APPENDIX 2 Reliability Tools and Techniques . 71 1 Equipment Criticality Assessment 71 2 Reliability, Availability, Maintainability Study (RAM) . 71 3 Reliability D
36、ata Management (Bad Actor Analysis) 71 4 Failure Modes and Effects Analysis (FMEA) 72 5 Hazard Identification Study (HAZID, HAZOP) 73 6 Preventative Maintenance Optimization (PMO) . 73 7 Applications of Predictive Technologies . 74 8 Inventory and Part Stocking Management 74 9 Continuous Improvement
37、 Process 75 10 Structured Root Cause Failure Analysis . 75 10.1 RCFA Approach 75 11 Control Charting 75 12 Pareto Analysis . 76 13 Cause and Effects Analysis 76 14 Trend Analysis 77 15 Maintenance Requirements Document Reviews 77 16 Task Packaging 77 17 Age Exploration Tasks 77 18 Failure Management
38、 . 77 19 Relative Ranking Analysis 77 FIGURE 1 FMEA Process 72 FIGURE 2 PM Optimization 73 FIGURE 3 Maintenance Strategy . 74 FIGURE 4 Sample Control Chart . 75 FIGURE 5 Sample Pareto Charts . 76 FIGURE 6 Sample Cause and Effect Fishbone Diagram . 76 APPENDIX 3 Additional Resources 78 1 Related Stan
39、dards 78 2 Related Publications . 78 3 Condition Monitoring and Dynamic Monitoring Standards . 78 APPENDIX 4 Suggested Failure Modes for Marine Machinery Equipment and Components . 80 TABLE 1 Electrical Equipment . 81 TABLE 2 Mechanical Equipment 82 TABLE 3 Piping Equipment 86 TABLE 4 Control Equipm
40、ent 89 TABLE 5 Lifting Equipment 90 TABLE 6 Electrical Components 91 TABLE 7 Mechanical Components 92 TABLE 8 Piping Components . 96 ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 vii TABLE 9 Structural Components . 98 TABLE 10 Rigging Components. 99 APPENDIX 5
41、Failure-finding Maintenance Task Interval . 100 1 Introduction . 100 2 Statistical View of Hidden Failures . 100 3 Failure-finding Task Applicability and Effectiveness . 101 4 Determining Failure-finding Maintenance Task Interval . 101 4.1 Mathematical Determination of Failure-finding Task Interval
42、. 102 4.2 Using Guidelines to Determine Failure-finding Task Interval . 103 5 Failure-finding Maintenance Task Intervals 103 TABLE 1 Example of Failure-finding Task Interval Rules 103 TABLE 2 Example of Failure-finding Task Intervals Based on MTTF . 103 TABLE 3 Failure-finding Maintenance Task Inter
43、val Estimates . 104 FIGURE 1 Effect of a Failure-finding Task . 101 APPENDIX 6 Overview of Condition-monitoring Techniques and Potential-Failure Interval Data . 105 1 Introduction . 105 2 Condition Monitoring Categories 105 2.1 Corrosion Monitoring . 106 2.2 Thermography . 106 2.3 Dynamic Monitoring
44、 . 106 2.4 Oil Analysis and Tribology . 106 2.5 Nondestructive Testing 106 2.6 Electrical Condition Monitoring 106 2.7 Performance Monitoring 106 2.8 Tabular Listing of Techniques 107 3 Guidance for Condition-monitoring Interval Determination . 107 3.1 Introduction 107 3.2 Condition-monitoring Maint
45、enance Task Applicability and Effectiveness . 107 3.3 Determining Condition-monitoring Maintenance Task Intervals . 108 TABLE 1 Condition Monitoring Categories . 105 TABLE 2 Corrosion Monitoring . 109 TABLE 3 Thermography . 110 TABLE 4 Dynamic Monitoring 111 TABLE 5 Oil Analysis and Tribology 112 TA
46、BLE 6 Nondestructive Testing . 114 TABLE 7 Electrical Condition Monitoring . 116 TABLE 8 Performance Monitoring 117 viii ABSGUIDE FOR SURVEYS BASED ON MACHINERY RELIABILITY AND MAINTENANCE TECHNIQUES .2016 Section 1: General SECTION 1 General 1 Application This Guide provides techniques for owners a
47、nd operators to leverage reliability principles into machinery design, maintenance plan development, and sustainment activities. Owners and operators maintaining their marine or offshore assets with advanced machinery maintenance practices may increase their reliability and/or operational availabili
48、ty. Additionally, the processes found in this Guide and the resulting preventative maintenance plan may provide an alternative for crediting of Special Periodical Survey of Machinery. Early in the lifecycle, the reliability of components, systems, or combinative processes can be improved by selectin
49、g appropriate reliability-enhancing design strategies. These strategies focus on: Improving equipment and configuration reliability through their arrangements, Designing to simplify manufacturing and assembly, Forecasting the design needs anticipated for operations, maintenance, Generating a testing and evaluation plan to confirm and validate the changes in design. These processes enable optimized design, integrated features, and/or technology that will support minimizing operational disruption from component failure, maintenance, inspection, and survey of equipment. Design c
