What is Reliability Centered Maintenance?
Reliability-Centered Maintenance (RCM) is the process of determining the most effective maintenance approach. The RCM philosophy employs Preventive Maintenance (PM), Predictive Maintenance (PdM), Real-time Monitoring (RTM), Run-to-Failure (RTF- also called reactive maintenance) and Proactive Maintenance techniques in an integrated manner to increase the probability that a machine or component will function in the required manner over its design life cycle with a minimum of maintenance.
The goal of the philosophy is to provide the stated function of the facility, with the required reliability and availability at the lowest cost. RCM requires that maintenance decisions be based on maintenance requirements supported by sound, technical, and economic justification.
A Brief History of RCM
RCM originated in the Airline industry in the 1960s. By the late 1950s, the cost of maintenance activities in this industry had become high enough to warrant a special investigation into the effectiveness of those activities. Accordingly, in 1960, a task force was formed consisting of representatives of both the airlines and the Federal Aviation Administration (FAA) to investigate the capabilities of preventive maintenance.
The establishment of this task force subsequently led to the development of a series of guidelines for airlines and aircraft manufacturers to use, when establishing maintenance schedules for their aircraft.
This led to the 747 Maintenance Steering Group (MSG) document MSG-1; Handbook: Maintenance Evaluation and Program Development from the Air Transport Association in 1968. MSG-1 was used to develop the maintenance program for the Boeing 747 aircraft, the first maintenance program to apply RCM concepts. MSG-2, the next revision, was used to develop the maintenance programs for the Lockheed L 1011 and the Douglas DC-10.
The success of this program is demonstrated by comparing maintenance requirements of a DC-8 aircraft, maintained using standard maintenance techniques, and the DC-10 aircraft, maintained using MSG-2 guidelines. The DC-8 aircraft has 339 items that require an overhaul, verses only seven items on a DC-10.
Using another example, the original Boeing 747 required 66,000 labor hours on major structural inspections before a major heavy inspection at 20,000 operating hours. In comparison, the DC-8 - a smaller and less sophisticated aircraft using standard maintenance programs of the day required more than 4 million labor hours before reaching 20,000 operating hours.
In 1974 the U.S. Department of Defense commissioned United Airlines to write a report on the processes used in the civil aviation industry for the development of maintenance programs for aircraft. This report, written by Stan Nowlan and Howard Heap and published in 1978, was entitled Reliability Centered Maintenance,5 and has become the report upon which all subsequent Reliability Centered Maintenance approaches have been based.
What Nowlan and Heap found was that many types of failures could not be prevented no matter how intensive the maintenance activities were. Additionally it was discovered that for many items the probability of failure did not increase with age. Consequently, a maintenance program based on age will have little, if any effect on the failure rate.
THE SAFETY-RELATED CASE FOR ELECTRICAL MAINTENANCE
The relationship between safety and preventive maintenance is not a difficult one to establish. Properly designed equipment that is properly installed is well capable of doing its job when it is new.
As equipment ages however, several factors begin to take their toll on electrical equipment.
● Dust, dirt, and other contaminants collect on equipment causing the equipment to overheat and bearings and other moving parts to bind.
● Vibration causes hardware to loosen. Subsequent operations of equipment can cause joints and equipment to fail explosively.
● Heat and age can cause insulation to fail, resulting in shock hazards to personnel.
● Increased loads, motor starting surges, and power quality issues such as harmonics combine to increase the aging process and set the stage for equipment failure.
Unfortunately, the ultimate failure of unmaintained equipment usually occurs when the equipment is needed the most—during electrical faults. Such failures result in arc and blast events that can and do harm workers in the area.
They also result in significant downtime, loss of equipment, and construction cost incurred in rebuilding the equipment. The only way to ensure that electrical equipment continues to operate in an optimal manner is to maintain it so that it stays in factory-new-operating condition.
Regulatory
As discussed above and in previous chapters, the catastrophic failure of electrical equipment creates severe hazards for personnel working in the area. Recognizing this the
Standard for Electrical Safety in the Workplace (NFPA 70E)3 requires that electrical equipment be properly maintained to minimize the possibility of failure.
Relationship of Improperly Maintained Electrical Equipment to the Hazards of Electricity
Improperly maintained equipment may expose workers to any of the three electrical hazards. For example:
1. Improperly maintained tools or flexible cord sets (extension cords) can have frayed insulation which exposes the energized conductors and allows them to contact the worker or the metallic tool the worker is using. The result is an electric shock.
2. Improperly maintained protective devices, such as circuit breakers or fuses, can fail when interrupting an overcurrent. Such a failure is likely to be explosive; consequently, the worker is exposed to electrical arc and electrical blast.
3. Improperly maintained connections can overheat resulting in any of the following:
a. melted insulation, exposed conductors, and the attendant electrical shock hazard
b. fire
c. failed connections resulting in electrical arc and blast
4. Improperly maintained switchgear, motor control centers, or panelboards can fail explosively when an arc occurs internally. This exposes workers to the effects of electrical blast and possibly electrical arc.
As equipment ages however, several factors begin to take their toll on electrical equipment.
● Dust, dirt, and other contaminants collect on equipment causing the equipment to overheat and bearings and other moving parts to bind.
● Vibration causes hardware to loosen. Subsequent operations of equipment can cause joints and equipment to fail explosively.
● Heat and age can cause insulation to fail, resulting in shock hazards to personnel.
● Increased loads, motor starting surges, and power quality issues such as harmonics combine to increase the aging process and set the stage for equipment failure.
Unfortunately, the ultimate failure of unmaintained equipment usually occurs when the equipment is needed the most—during electrical faults. Such failures result in arc and blast events that can and do harm workers in the area.
They also result in significant downtime, loss of equipment, and construction cost incurred in rebuilding the equipment. The only way to ensure that electrical equipment continues to operate in an optimal manner is to maintain it so that it stays in factory-new-operating condition.
Regulatory
As discussed above and in previous chapters, the catastrophic failure of electrical equipment creates severe hazards for personnel working in the area. Recognizing this the
Standard for Electrical Safety in the Workplace (NFPA 70E)3 requires that electrical equipment be properly maintained to minimize the possibility of failure.
Relationship of Improperly Maintained Electrical Equipment to the Hazards of Electricity
Improperly maintained equipment may expose workers to any of the three electrical hazards. For example:
1. Improperly maintained tools or flexible cord sets (extension cords) can have frayed insulation which exposes the energized conductors and allows them to contact the worker or the metallic tool the worker is using. The result is an electric shock.
2. Improperly maintained protective devices, such as circuit breakers or fuses, can fail when interrupting an overcurrent. Such a failure is likely to be explosive; consequently, the worker is exposed to electrical arc and electrical blast.
3. Improperly maintained connections can overheat resulting in any of the following:
a. melted insulation, exposed conductors, and the attendant electrical shock hazard
b. fire
c. failed connections resulting in electrical arc and blast
4. Improperly maintained switchgear, motor control centers, or panelboards can fail explosively when an arc occurs internally. This exposes workers to the effects of electrical blast and possibly electrical arc.
ELECTRICAL EMERGENCIES GUIDE - WHAT TO DO IN CASE OF ELECTRICAL EMERGENCIES?
Strong winds, ice or unintentional contact with equipment may cause trees or tree limbs to fall into powerlines. This may cause wires to break and fall to the ground. Should this happen, notify the electric utility company immediately.
A fallen wire can create hazards for workers and the general public. Objects touched by a fallen wire - fences, vehicles, buildings or even the surrounding ground - must be considered energized and should not be touched.
It is impossible to tell simply by looking whether a downed wire is energized. Consider all downed wires energized and dangerous until the electric utility personnel notify you otherwise.
Where a power line has fallen across a vehicle, occupants should remain within the vehicle. If they must leave the vehicle because of a life-threatening situation, such as fire or potential explosion, they should jump clear of the vehicle without touching either the vehicle or wire and the ground at the same time.
Once clear of the vehicle, they should shuffle away, taking small steps and keeping both feet in contact with the ground.
Remember, electricity can be transmitted from the victim to you. If a switch is accessible, shut off the power immediately. Otherwise, stand on a dry surface and pull the victim away with a dry board or rope. Do not use your hands or anything metal.
Use a C02 or dry chemical extinguisher to put out an electrical fire. Water should be used only by trained firefighting personnel. In an emergency involving power lines or electrical equipment, call the electric utility company immediately.
Training Workers
Ensure that workers assigned to operate cranes and other boomed vehicles are specifically trained in safe operating procedures. Also ensure that workers are trained (1) to understand the limitations of such devices as boom guards, insulated lines, ground rods, nonconductive links, and proximity warning devices, and (2) to recognize that these devices are not substitutes for de-energizing and grounding lines or maintaining safe clearance.
Workers should also be trained to recognize the hazards and use proper techniques when rescuing coworkers or recovering equipment in contact with electrical energy. CSA guidelines list techniques that can be used when equipment contacts energized power lines [CSA 1982]. All employers and workers should be trained in cardiopulmonary resuscitation (CPR).
A fallen wire can create hazards for workers and the general public. Objects touched by a fallen wire - fences, vehicles, buildings or even the surrounding ground - must be considered energized and should not be touched.
It is impossible to tell simply by looking whether a downed wire is energized. Consider all downed wires energized and dangerous until the electric utility personnel notify you otherwise.
Where a power line has fallen across a vehicle, occupants should remain within the vehicle. If they must leave the vehicle because of a life-threatening situation, such as fire or potential explosion, they should jump clear of the vehicle without touching either the vehicle or wire and the ground at the same time.
Once clear of the vehicle, they should shuffle away, taking small steps and keeping both feet in contact with the ground.
Remember, electricity can be transmitted from the victim to you. If a switch is accessible, shut off the power immediately. Otherwise, stand on a dry surface and pull the victim away with a dry board or rope. Do not use your hands or anything metal.
Use a C02 or dry chemical extinguisher to put out an electrical fire. Water should be used only by trained firefighting personnel. In an emergency involving power lines or electrical equipment, call the electric utility company immediately.
Training Workers
Ensure that workers assigned to operate cranes and other boomed vehicles are specifically trained in safe operating procedures. Also ensure that workers are trained (1) to understand the limitations of such devices as boom guards, insulated lines, ground rods, nonconductive links, and proximity warning devices, and (2) to recognize that these devices are not substitutes for de-energizing and grounding lines or maintaining safe clearance.
Workers should also be trained to recognize the hazards and use proper techniques when rescuing coworkers or recovering equipment in contact with electrical energy. CSA guidelines list techniques that can be used when equipment contacts energized power lines [CSA 1982]. All employers and workers should be trained in cardiopulmonary resuscitation (CPR).
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