Reliability, Maintainability and Risk

Part 1: Understanding Reliability Parameters and Costs

Chapter 1: The History of Reliability and Safety Technology

• Abstract
• 1.1. Failure Data
• 1.2. Hazardous Failures
• 1.3. Predicting Reliability and Risk
• 1.4. Achieving Reliability and Safety-Integrity
• 1.5. The RAMS-Cycle
• 1.6. Contractual and Legal Pressures
• 1.7. Reliability versus Functional Safety

Chapter 2: Understanding Terms and Jargon

• Abstract
• 2.1. Defining Failure and Failure Modes
• 2.2. Failure Rate and Mean Time Between Failures
• 2.3. Interrelationships of Terms
• 2.4. The Bathtub Distribution
• 2.5. Down Time and Repair Time
• 2.6. Availability, Unavailability and Probability of Failure on Demand
• 2.7. Hazard and Risk-Related Terms
• 2.8. Choosing the Appropriate Parameter

Chapter 3: A Cost-Effective Approach to Quality, Reliability and Safety

• Abstract
• 3.1. Reliability and Optimum Cost
• 3.2. Costs and Safety
• 3.3. The Cost of Quality

Part 2: Interpreting Failure Rates

Chapter 4: Realistic Failure Rates and Prediction Confidence

• Abstract
• 4.1. Data Accuracy
• 4.2. Sources of Data
• 4.3. Data Ranges
• 4.4. Confidence Limits of Prediction
• 4.5. Manufacturers’ Data (Warranty Claims)
• 4.6. Overall Conclusions

Chapter 5: Interpreting Data and Demonstrating Reliability

• Abstract
• 5.1. The Four Cases
• 5.2. Inference and Confidence Levels
• 5.3. The Chi-Square Test
• 5.4. Understanding the Method in More Detail
• 5.5. Double-Sided Confidence Limits
• 5.6. Reliability Demonstration
• 5.7. Sequential Testing
• 5.8. Setting Up Demonstration Tests

Chapter 6: Variable Failure Rates and Probability Plotting

• Abstract
• 6.1. The Weibull Distribution
• 6.2. Using the Weibull Method
• 6.3. More Complex Cases of the Weibull Distribution
• 6.4. Continuous Processes

Part 3: Predicting Reliability and Risk

Chapter 7: Basic Reliability Prediction Theory

• Abstract
• 7.1. Why Predict RAMS?
• 7.2. Probability Theory
• 7.3. Reliability of Series Systems
• 7.4. Redundancy Rules
• 7.5. General Features of Redundancy
• Exercises

Chapter 8: Methods of Modeling

• Abstract
• 8.1. Block Diagrams and Repairable Systems
• 8.2. Common Cause (Dependent) Failure
• 8.3. Fault Tree Analysis
• 8.4. Event Tree Diagrams

Chapter 9: Quantifying the Reliability Models

• Abstract
• 9.1. The Reliability Prediction Method
• 9.2. Allowing for Diagnostic Intervals
• 9.3. FMEDA (Failure Mode and Diagnostic Analysis)
• 9.4. Human Factors
• 9.5. Simulation
• 9.6. Comparing Predictions with Targets

Chapter 10: Risk Assessment (QRA)

• Abstract
• 10.1. Frequency and Consequence
• 10.2. Perception of Risk, ALARP and Cost per Life Saved
• 10.3. Hazard Identification
• 10.4. Factors to Quantify

Part 4: Achieving Reliability and Maintainability

Chapter 11: Design and Assurance Techniques

• Abstract
• 11.1. Specifying and Allocating the Requirement
• 11.2. Stress Analysis
• 11.3. Environmental Stress Protection
• 11.4. Failure Mechanisms
• 11.5. Complexity and Parts
• 11.6. Burn-In and Screening
• 11.7. Maintenance Strategies

Chapter 12: Design Review, Test and Reliability Growth

• Abstract
• 12.1. Review Techniques
• 12.2. Categories of Testing
• 12.3. Reliability Growth Modeling

Chapter 13: Field Data Collection and Feedback

• Abstract
• 13.1. Reasons for Data Collection
• 13.2. Information and Difficulties
• 13.3. Times to Failure
• 13.4. Spreadsheets and Databases
• 13.5. Best Practice and Recommendations
• 13.6. Analysis and Presentation of Results
• 13.7. Manufacturers’ data
• 13.8. Anecdotal Data
• 13.9. Examples of Failure Report Forms
• 13.10. No-Fault-Found (NFF)

Chapter 14: Factors Influencing Down Time

• Abstract
• 14.1. Key Design Areas
• 14.2. Maintenance Strategies and Handbooks

Chapter 15: Predicting and Demonstrating Repair Times

• Abstract
• 15.1. Prediction Methods
• 15.2. Demonstration Plans

Chapter 16: Quantified Reliability Centered Maintenance

• Abstract
• 16.1. What is QRCM?
• 16.2. The QRCM Decision Process
• 16.3. Optimum Replacement (Discard)
• 16.4. Optimum Spares
• 16.5. Optimum Proof Test
• 16.6. Condition Monitoring

Chapter 17: Systematic Failures, Especially Software

• Abstract
• 17.1. Random versus Systematic Failures
• 17.2. Software-related Failures
• 17.3. Software Failure Modeling
• 17.4. Software Quality Assurance (Life Cycle Activities)
• 17.5. Modern/Formal Methods
• 17.6. Software Checklists

Part 5: Legal, Management and Safety Considerations

Chapter 18: Project Management and Competence

• Abstract
• 18.1. Setting Objectives and Making Specifications
• 18.2. Planning, Feasibility and Allocation
• 18.3. Program Activities
• 18.4. Responsibilities and Competence
• 18.5. Functional Safety Capability
• 18.6. Standards and Guidance Documents

Chapter 19: Contract Clauses and Their Pitfalls

• Abstract
• 19.1. Essential Areas
• 19.2. Other Areas
• 19.3. Pitfalls
• 19.4. Penalties
• 19.5. Subcontracted Reliability Assessments

Chapter 20: Product Liability and Safety Legislation

• Abstract
• 20.1. The General Situation
• 20.2. Strict Liability
• 20.3. The Consumer Protection Act 1987
• 20.4. Health and Safety at Work Act 1974
• 20.5. Insurance and Product Recall

Chapter 21: Major Incident Legislation

• Abstract
• 21.1. History of Major Incidents
• 21.2. Development of major incident legislation
• 21.3. Safety reports
• 21.4. Offshore Safety Cases
• 21.5. Problem Areas
• 21.6. Rail
• 21.7. Corporate Manslaughter and Corporate Homicide

Chapter 22: Integrity of Safety-Related Systems

• Abstract
• 22.1. Safety-Related or Safety-Critical?
• 22.2. Safety-Integrity Levels (SILs)
• 22.3. Programable electronic systems (PESs)
• 22.4. Current guidance
• 22.5. Framework for Certification

Chapter 23: A Case Study: The Datamet Project

• Abstract
• 23.1. Introduction
• 23.2. The Datamet Concept
• 23.3. The Contract
• 23.4. Detailed Design
• 23.5. Syndicate Study
• 23.6. Hints

Chapter 24: A Case Study: Gas Detection System

• Abstract
• 24.1. Safety-Integrity Target
• 24.2. Random Hardware Failures
• 24.3. ALARP
• 24.4. Architectures
• 24.5. Life-Cycle Activities
• 24.6. Functional Safety Capability

Chapter 25: A Case Study: Pressure Control System

• Abstract
• 25.1. The Unprotected System
• 25.2. Protection System
• 25.3. Assumptions
• 25.4. Reliability Block Diagram
• 25.5. Failure Rate Data
• 25.6. Quantifying the Model
• 25.7. Proposed Design and Maintenance Modifications
• 25.8. Modeling Common Cause Failure (Pressure Transmitters)
• 25.9. Quantifying the Revised Model
• 25.10. ALARP
• 25.11. Architectural Constraints

Chapter 26: Helicopter Incidents and Risk Assessment

• Abstract
• 26.1. Helicopter Incidents
• 26.2. Risk Assessment - Floatation Equipment
• 26.3. Effect of Pilot Experience on Incident Rate

Appendix 1: Glossary

Appendix 2: Percentage Points of the Chi-Square Distribution

Appendix 3: Microelectronic Failure Rates

Appendix 4: General Failure Rates

Appendix 5: Failure Mode Percentages

Appendix 6: Human Error Probabilities

Appendix 7: Fatality Rates

Appendix 8: Answers to Exercises

Appendix 9: Bibliography

Appendix 10: Scoring Criteria for BETAPLUS Common Cause Model

Appendix 11: Example of HAZOP

Appendix 12: HAZID Checklist

Appendix 13: Markov Analysis of Redundant Systems

Appendix 14: Calculating the GDF