Reliability Centered Maintenance
Page 2
1.,,,. Mode Component, Sub-system, System, System. Reliability Centered Maintenance :, program? Mechanism Page 3
Page 4. Mode Mode () () (FMEA) (FTA) (LTA) System Sub System Equipment Component Part
2. 1942 : 2 U-1. 1950 : 1957 : 1960 : 1970 : 1980 :,, 1985 : Page 5
3.,,,,., (Bath Tube Curve) TBM, CBM,. (1),. (2) Process. Page 6
BATH TUB Page 7
6??????,,,, Page 8
4. 1. 2. 3. 4. 5. 6. 7. Page 9
( ) Helicopter Turbine Engine 1 rotor seal 176.8 2 roller brg 176.8 3 brg 176.8 0 100 200 4 rotor brg seal 176.8 5 impellar 176.8 6 rotor disc 176.8 7 rotor plate 176.8 8 176.8 9 brg 176.8 10~41 32 176.8 42~90 54 176.8 9 32 54 95 9 CR = P(Xi) P(Fxi) Page 10
mode On con 1. seal 2. ( )Brg 3. Brg 4. Brg seal 5. impellar 6. Gas, 7. Vane 8. Vane @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ 9. Brg @ @ @ @ Page 11
Helicopter Engine (CR) @ Xi -, () P(Fxi) - P(Xi) @ CR = P(Xi) P(Fxi) @ ModeData. Page 12
5. TPM Item, Staff + 0, 0 +,, TPM., Operator Plant Item PM Item, Process Page 13
TPM system system. :, system : Item : system Item,,. Page 14
TPM R C M Page 15
ITEM ( ) (SYSTEM SUB) (ASSEMBLY ) ( ) ( )) SYSTEM SUB SUB SYSTEM ASSEM SUB SUB ASSEM COMPONENT PART SYSTEM LEVEL ASSEMBLY LEVEL LEVEL LEVEL Page 16
STEP 1 STEP 2 STEP Model Data (Block flow sheet, functional block chart,,, ) 3 STEP Component, list up 4 STEP Functional Failure Analysis FTA(Fault Tree Analysis) FMECA(Function Failure Mode Effects Analysis 3STEP FMECA FTA,, (2TA). 5 STEP (Logic Tree Analysis) 6 STEP 7 STEP Page 17
6. 1. 2. 3. 4. 5. Page 18
6-1., :,,,, Page 19
6-2. 1).,. 2),,.,. 3),. 4), Life Cycle. Life Cycle. 5), Trouble,. Page 20
6-3. (1).,.. ( ) ( ) (2).... (Maintainability). (3). ( ) (Availability). (3) = (1) + (2) = Page 21
,,,,, ( ). 1) 2),? 3)? 4)?,,,,,,,. 1)~3) MakerUser. Page 22
:,,,,.,.,,.... 3 1),, 2), ( ) 3),.,..,,. Page 23
6-4. reliability,,..,. Plant 1. (,,,,,, ),,,.. R(t), F(t) R(t) + F(t) = 1 - (1) (t), t =0. R(t), t = 0 1, R(0) = 1. R(t) 1.0 0 (t) 1-5-1 Page 24
1-5-2. NO.150 1 F(t) = 1 = 0.02 1 Probability 50 R(t) = 50-1 = 0.98 49 normalprobability, = (Credible) curve 50 R(t) = 1 F(t) = 1 0.02 = 0.98. Page 25
df(t) dt = f(t) = d[1r(t)]dt = dr(t)dt (2) F, R Function t F(t) = t 0 f(t)dt f(t) dt f(t)dt tt + dt. Ex) f(t)dt ~! ( = 0 ) Page 26
Page 27 1.5.2 No. t F(t) R(t) 1 2 3 4 5 6 7 8 9 10 11 12 3 4 6 7 8 9 10 11 11 12 12 13 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.24 0.98 0.96 0.94 0.92 0.90 0.88 0.86 0.76 13 14 15 16 17 18 19 20 21 22 23 24 14 15 15 16 16 16 17 17 17 17 18 18 0.26 0.36 0.44 0.74 0.64 0.56 25 26 27 28 29 30 31 32 33 34 19 20 21 22 22 22 23 24 25 26 0.50 0.52 0.24 0.62 0.64 0.66 0.68 0.50 0.48 0.46 0.38 0.36 0.34 0.32 No. t F(t) R(t) No. t F(t) R(t) 0.16 0.22 0.82 0.78 0.30 0.70 0.48 0.52 0.60 0.40
1.5.2 1.0 0.9 0.8 R 0.7 (t) 0.6 F 0.5 (t) 0.4 0.3 0.2 0.1 0 2 4 6 8 10 11 12 14 16 18 20 22 24 26 28 t 1,000 Page 28
(2) t R(t) f(t)dt 0 t 0 F(t). (3) f(t)dt. (4) f(t)r(t) (t) dr(t) (t) dt 1 R(t) f(t) R(t) (5) (5) 0 t f(t)dt 0 t H(t) f(t)dt 0 t f(t) R(t) lnr(t) H(t) (7) R(t) e H(t) (8) dt Log R(t) (6) (6) Page 29
e (e,2.71823 ). (t) (9) t (t) ( t ) ( t ) 1.5. 2. NO.1(t) ( 1100) (503) 0.67(%1,000) NO.2(t) ( 1100) 49(4-3) 2.04 (%1,000). Page 30
6-5. Maintainability,,.,.,, 3. 3 0.9 0.9 10.9 = 0.1.. P D Q C M A U U D A : Availability U : Up-time D : Down - time 1.4.1 Page 31
A U ( U+D ). t A(t), (Steady State) ASS( Steady state availability) E(U) ASS E(U) + E(D) (6 1)., ( i) (Mi),. M(t) M(t) = 1e t ( 6-2). MTTR, 1, MTTF. M M(t). Page 32
7... ( ) () (FTA) Mode (FMECA). Block Tree. (, ) ( ) (, ) ( ) Page 33
1.,,, Sequence,, 2. Block Data Process 3., 4.,, Interface Page 34
5. FMEA Mode FMEA Logic Tree Mode Mode Plant (1), (2), (3), FMEA SHEET 6. Logic Tree 4 Logic Tree Page 35
6-1. (1) 6-2. (2) (1) ( Logic Tree Diagram [1] ) A : B : C : D : E : (2) ( Logic Tree Diagram [2] ),.. a : b : Monitoring c : On-condition d : e : f : g : h : PM 4 Logic Tree 3- FMEA 4 Logic Tree Flow. Page 36
/ 7. / / (1) Data (2) (3) Data (4), / 5, Monitoring pump Monitoring 36. 8. Life Cycle Data /. Page 37
8. 1., plant,. 2. level item datd. 3. (LAT) Step. 4. plant system. Page 38
M P Surge tank M P M P F T Page 39
1 2 1 zone 2 zone 3 zone 4 zone Extruder 230 4 K2 4 K4 4 R203 48 4 GRU 244 60 10 R203 48 4 GRU 245 60 10 C102 4 NO 18 19 20 21 22 23 24 25 26 Page 40
Block Diagram ( ) Page 41
A. Pump Valve Valve Header Motor H / Exchanger Header Piping Valve Strainer Loop piping Valve Shaper Surge Tank Page 42
B. Pump Motor Surge tank Coupling Tank Impellar Cable Bearing Air filter Cable Positioner Valve Page 43
Page 44 MODEL Motor Motor Sprocket Sprocket Pulley Pulley Coupling Coupling Chain Chain Belt Belt Sprocket Sprocket Pulley Pulley Rotating shaft Rotating shaft Pinion Pinion Gear Gear Bearing Bearing Bolt Bolt Housing Housing Frame Frame ( ) ( )
LIST 1 Roll 980 ~ 1100mm Roll Lift max 1000mm max 740mm Spindle ( Close pin ) 940 1100 9340mm 2, Hi - Line Upper spindle 6.16 º Bottom spindle 3.07 º Torque 113 ton 211ton Main motor DC 3100kw 2 40 100rpm Page 45
( ) LIST. A Cylinder B Cylinder 115 kgfcm² ~ 120 kgfcm² 115 kgfcm² ~ 120 kgfcm² 115 kgfcm² ~ 120 kgfcm² 3mg 100cc 2 kgfcm² ~ 2.5 kgfcm² 1m³ min 10 2 kgfcm² 1m³ min 10mg / 100cc Roller table Slide Gap 0.05mm m 0.1mm m 0.1mm m 0.08mm Page 46
,? YES NO? YES NO,,? YES NO,,? YES NO? Page 47
STEP 1 Step 2 Step Model Data (Block flow sheet, Functional block chart,,,, ) 3 Step Functional Failure Analysis Component List up 4 Step Mode FTA, FMECA 3 Step FMECA FTA FTA,,, (LTA) 5 Step Logic Tree Analysis 6 Step Sheet 7 Step Page 48