|p





  
| 
| 

p

 

  
|   

‡ Present the steps of RCM
‡ Demonstrate the steps clearly
‡ At the end each participant should
± Understand the basics of RCM
± Initiate an RCM project
± Participate effectively in teams
implementing RCM.
  p 

| ë
 RCM pilot study At FP & L¶s Turkey
Point Nuclear plant provided evidence that
RCM could impact O & M costs
| Survey conducted by Electric Power
Research Institute provided more evidence
that RCM has impact on Cost.
 p 
| Plant trip reduction
| Documented Basis For PM
| Efficient PM Planning
| Decrease in corrective maintenance
| More accurate spare parts identification
| Increase plant availability
 p

| System selection and data collection

| System boundary definition

| System description and Functional Block

Diagram
p    
| Systems function and functional failures

| Failure mode and effect analysis

| Logic tree analysis (LTA)

| Task selection
 ^ 
p
 
| Part

| Component---Assembly

| System

| Plant
  
  




| Basis of system selection

| What data and information to collect

 


 

| ë- Systems with high PM tasks

| 2- Systems with high breakdown

maintenance

| 3- Systems with large contributions to

full or partial outages.
 




| - Systems with high cost of CM actions
| 5- Systems with high content of concern with
respect to safety and environmental issues
| 6- Combinations of the Above

| In a Typical selection process at Florida Power &

Light Fossil Power Generation 5 is used coupled
with Parato chart.
  
 


| System piping and information diagram
| System schematic block diagram
| Vendor manual
| Equipment history file
| System operation manual
| System design specification and data
description
 
  
 
  
| It provides knowledge of what hs or has not
been included
| The boundary determines what comes into
and what leave the system ( in and out)
| Boundary definitions must be clearly stated
and documented
 Ñ 
  

  

| Refer To Transparencies --- Figure 5.

| System boundary details --- Figure 5.5 and

Figure 5.6
   
  
  

 !


| System description
| Functional block diagram
| In/out interfaces
| System work breakdown structure
| Equipment history
   


| Tangible benefit of system description

‡ Account and document baseline definition of
system as existed
‡ Ensure comprehensive understanding of the
system
‡ Aid in identifying critical parameters that
contribute to degradation and loss of function
  
  —
| Elements of System Description

‡ Functional description/ key parameters

‡ Redundancy features
‡ Protection features
‡ Key instrumentation features
‡ See figure 5.7 in transparences
  

 !

"#

| The FBD is a top-level representation of the

major functions the system performs
| It consists of functions no equipment
appear. labeled functional subsystems
| In/out interfaces shown
| See figure 5.

 $

 % 

 
"$#
| Carryover from Ministry of Defense Terminology
| Compilation of the equipment lists in each
functional subsystems shown in the fbd
| Include all components within system boundary
| list all instrumentation components
| See figure 5.ë and 5.ëë for equipment history file
    
  



| List all functions
| In essence every out interface should be
captured into a function statement
| Two additional sources for functions
‡ Internal out interfaces between functional
subsystems
‡ Passive functions
‡ List all functional failures
 

 &


    
| Provide ë5 psi safety relief valves(w)
| Provide for pressure relief above ë5 psi
| Provide a ë5 gpm centrifugal pump on
the discharge side of header 26 (w)
| Maintain a flow of ë5 gpm at the outlet of
header 26.
 

 &


    
| Provide alarm to control room if block
valves are <  percent open (w)
| Provide alarm to control room if flow rate is
<  percent of rated flow
| Provide water-cooled heat exchanger for
pump lube oil (w)
| Maintain lube oil ? ë3 o F.
   



| The focus on loss of functions not loss of

equipment
| Absolutely necessary to distinguish between
function loss conditions
‡ Most functions have more than one loss
condition
‡ Distinction in loss condition usually leads to
different failure modes
   



| Function: provide for pressure relief above
ë5 psi
| Functional failure
‡ (a) Pressure relief occurs above ë65 psi
‡ (b) Pressure relief occurs prematurely ( below
ë5psi)
 Ñ 


  



| Function : Maintain a flow of ë5 gpm at

the outlet of header 26
| Functional failures
‡ (a) Flow exceeds ë5 gpm
‡ (b) Flow is less than ë5 but greater than ë
gpm
‡ ( c ) Flow is less than ë gpm
‡ Function ad functional failure are recorded on
figure 5.ë2
 

  Ñ 
 
"Ñ-

| Functional failure and equipment matrix

| This matrix address which system
equipment could play a role in the creation
of functional failures. this is done by
completing the matrix in figure 5.ë3.
 

    
 
"Ñ#
| Record The following on figure 5.ë
‡ Component
‡ Failure Mode --- Figure 5.ë5 provides typical
description for failure modes
‡ Failure cause
‡ Failure effect
‡ Local
‡ System
‡ Plant
 p   '

p

| If redundancy prevent loss of function then
a failure shielded by redundancy should be
given different priority than a failure mode
that can singly defeat a necessary function.
| If multiple independent failure in a
redundant situation is possible the we
identified a design issue
 ^! (
 
"^(#
| The purpose of this step is further
prioritize failure modes that survive
step 5. the prioritization is done
qualitatively using the logic tree
diagram in figure 5.ë6 and form 5.ë7
Œ



| In this step the appropriate

maintenance task is selected to prevent
the loss of function.
| The task selection road map in figure
5.ë
is used for this purpose with form
5.ë
  

| The purpose of this check is to review
critically all components failures that
are treated run to failure to see if this
decision is optimal.
| Explain form 5.2ë
 (
  

| marginal effectiveness : it is not clear that
the rtf costs are significantly less than the
current pm costs
| High-cost failure : while there is no loss of
critical function, the failure mode is likely
to cause extensive damage to the
component that should be avoided.
Œ




| Secondary damage: similar to 2, except that
there is a high probability extensive damage
in neighboring components.
| OEM conflict : The original manufacturer
recommends a PM task that is not supported
by RCM. It is very sensitive of warranty
conditions are involved.
 (
  

| Internal conflict : Maintenance or
operation feel strongly about the PM
task that is not supported by RCM.
| Regulatory conflict : regulatory body
established the PM, such as EPA.
| Insurance conflict : similar to the
above two.
 
  % p
  !   !
| RCM-based and current tasks are
identical
| Current PM tasks exist, but need to be
modified to meet RCM-findings.
| RCM-based PM tasks are
recommended where no current tasks
exist.
| Current PM tasks exist where no RCM
tasks-based task recommended-
candidates for deletion