05 December 2007 Revision 5
RCM2 Case StudyProject Plan Cooling Fan Systemhttp://maintenanceforums.com (topic link)
Content
• Introduction
• Why this study
• Output
• Team
• Planning
• System boundaries
• Functional Block diagram & Major Equipment
• Key information
• Let’s get started
Introduction
From within the Maintenance Forum the initiative was born to conduct a “Virtual RCM” study to learn and share knowledge in an interactive way.
A Case & Operating Context is defined for the Company Ollie’s Olefins based on business impact/criticality.
There are a lot of methods which are called RCM
In this study the RCM2 methodology of John Moubray will be applied
Acrobat Document
Goal and output
Make a maintenance plan which preserve the functions of the chosen Cooling Fan System throughout the
technologically useful live by selecting and applying the most cost effective technique for managing
failures and their consequences
Output:
- Maintenance schema
- Operator Care Instruction
- Modifications (can also be operational procedure)
Team
Team Forum Alias
Rogier de Mulder RogierSteve Turner Steve TurnerYoussef X Abbaoui ?Johnny W Campbell Johnny W. CampbellBruno S Santos bsbsantosSteven van Els savanelsTrevor Sullivan TrevorsMike W Ward Mike66
Planning
• The project kick-off is in week 41 after publishing project plan on forum
• Minimum 1 session a week depending on input
• A live chat or telecom can be organised to discuss different views if necessary
• Estimated time needed is 11 sessions, completion date end 2007 (new estimatedis febr. 2008)
• Participant are assumed to have basic RCM knowledge starting the study
Session Content
Kick off – Setup project and team 1 session (WK 42)
Functions and performance standards 1 sessions
Functional Failures & Failure Modes 2 sessions
Failure Effects 2 sessions
Failure Consequences 2 sessions
The RCM Task Selection Process 3 sessions
Spare 2 sessions
Finalizing report by facilitator 1 week
System Selection (Boundary)
Arflow i.e.minimum 200 RPN
Cooling Fan System
(Audible) Alarm
Electricity380 V 3 fase
- Ambient tempeture -5 – 35 deg. Celcius- Salt sea moisture
Funct. Block diagram & Major Equipement
Arflow i.e.minimum 200 RPN
Drive Convey Displace Air
Electricity380 V 3 fase
Control & Monitor
Signal (Audible) Alarm
Stop signal
E- Motor (4 bolts connected)3 thermistors
CouplingGearbox (4 bolts connected)Drive belt & pulleysShaftBearings
FAN (locking device)
On/of switchManual Emergency off switchTachometerVibrating sensorDoor switch (Protective mesh)Alarm (lamp/buzzer)
Key information
• Plant located on island near to sea
• Operation 24h/7 days a week /365 day’s a year
• It can sell all product it can make
• 30 equal systems in production unit
• System supplies ambient air to refrigeration system
• Performance indicator: If fan < 200 RPM audible alarm sounds in control room
• Revenue loss of $5000 per hour if one system down for > 30 min
• System cost a lot of maintenance hours due to breakdown disturbing the process (how much cost / failure history?)
Let’s get started
-Who is willing to be part of the team?
-let share email addresses within the team, mail me your email address please?
-When the team is complete I will setup a platform to share / add remark or something to be able to give your input when it suits your agenda
-We are in different time zone's I think, so live discussion can be a problem, Can we make an overview of possibilities when to discuss /chat live?
-To share learning's everyone get’s read rights on chosen platform and only team member write rights
•All information needed for study will documented and posted
-Final Result per session will be post on maintenanceforum to share learning
-English is not everyone’s native language so can give misunderstanding, treat everyone with respect, lets focus on the big picture and not argue about minor language details.
Step 1 functions
-Step 1 – Describing FunctionsWe have enough information to start with defining the function
A function statement should consist of a verb,
an object and a desired standard of performance
If we miss relevant information it will be an action point for someone to retrieve of we make a decision as a group
We can use the template supplied by Rolly12
Other steps will be added during the study
Microsoft Excel Worksheet
Step 1 functions
Primary functions: What's the main reason the asset exist?
Secondary functions: Asset is expected to fulfill one ore more functions in addition to their primary function
To help none of these functions is overlooked they are diveided in 7 categories (ESCAPES):
- Environmental integrity
- Safety/structural integrity
- Control/containment/comfort
- Appearance
- Protection
- Economy/Efficiency
- Superfluous functions
One of the most mistakes in the RCM process is carrying out the analysis on too low level in the equipment hierarchy.
Step 2 Functional Failures
Step 2 – Describing Functional Failures
A functional failure is defined as the inability of any asset
to fulfil a function to a standard of performance
which is acceptable to the user
Functional Failures can be placed under the following headings:
• partial and total failure
• Upper and lower limits
• Gauges and indicators
• The operating context
Step 2 Functional Failures
Who shoulls set the standard?
Step 3 Failure Modes
A failure mode is any event which causes a functional failure
A failure mode description should at the very least consist of a noun and a verb
i.e. Bearing seizes
A list of reasonably likely failure modes should include:
• failures which have occurred before
• failure modes which are already the subject of proactive maintenance routines
• any other failure mode which have not yet occurred but which are considered to be real possibilities
Step 3 Failure Modes
• How much detail?
failure modes should be defined in enough detail for it
to be possible to select a suitable failure management policy
Step 4 Failure Effect
failure effect describes what happens when a failure mode occurs
The level of describing the failure effect depends whether it includes all information needed to support the evaluation of the consequences of the failure (decision diagram).
The effect of the failure should be described as if nothing was being done to prevent it.
Step 4 Failure Effect
• The following should be recorded:
• What evidence (if any) that the failure has occurred
• In what ways (if any) it poses a threat to safety or environment
• In what (if any) it affects production or operations
• What physical damage (if any) is caused by the failure
• What must be done to repair the failure