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Reliability, Maintainability and Risk

Practical Methods for Engineers

10th Edition - December 4, 2021

Author: David J. Smith

Paperback ISBN:

9 7 8 - 0 - 3 2 3 - 9 1 2 6 1 - 7

eBook ISBN:

9 7 8 - 0 - 3 2 3 - 9 1 2 6 2 - 4

Reliability, Maintainability and Risk: Practical Methods for Engineers, Tenth Edition has taught reliability and safety engineers techniques to minimize process design, operation… Read more

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Reliability, Maintainability and Risk: Practical Methods for Engineers, Tenth Edition has taught reliability and safety engineers techniques to minimize process design, operation defects and failures for over 40 years. For beginners, the book provides tactics on how to avoid pitfalls in this complex and wide field. For experts in the field, well-described, realistic and illustrative examples and case studies add new insights and assistance. The author uses his more than 40 years of experience to create a comprehensive and detailed guide to the field, while also providing an excellent description of reliability and risk computation concepts.

The book is organized into many parts, covering reliability parameters and costs, the history of reliability and safety technology, a cost-effective approach to quality, reliability and safety, how to interpret failure rates, a focus on the prediction of reliability and risk, a discussion of design and assurance techniques, and much more.

Cover image
Title page
Table of Contents
Also by the same author
Copyright
Preface
Acknowledgments
Part 1. Understanding Reliability Parameters and Costs
Chapter 1. The History of Reliability and Safety Technology
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
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
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
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. Soft Errors/Failures
4.7. Overall Conclusions
Chapter 5. Interpreting Data and Demonstrating Reliability
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
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
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
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
9.1. The Reliability Prediction Method
9.2. Allowing for Diagnostics and Proof Tests
9.3. FMEDA (Failure Mode, Effects and Diagnostic Analysis)
9.4. Human Factors
9.5. Simulation
9.6. Comparing Predictions with Targets
Chapter 10. Risk Assessment (QRA)
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
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
12.1. Review Techniques
12.2. Categories of Testing
12.3. Reliability Growth Modeling
Chapter 13. Field Data Collection and Feedback
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. No-Fault-Found
Chapter 14. Factors Influencing Down Time
14.1. Key Design Areas
14.2. Maintenance Strategies and Handbooks
Chapter 15. Predicting and Demonstrating Repair Times
15.1. Prediction Methods
15.2. Demonstration Plans
Chapter 16. Quantified Reliability Centered Maintenance
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
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. Cyber Security
17.7. Software Checklists
Part 5. Legal, Management and Safety Considerations
Chapter 18. Project Management and Competence
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 (Management)
Chapter 19. Contract Clauses and Their Pitfalls
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
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
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
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
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
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
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
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
Appendix 15. A Suggested “Standard” for Achieving Functional Safety
Index
Appendix 16