Professional Documents
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DRAFT
National Aeronautics and Space Administration
FINAL
September 2008
TABLE OF CONTENTS
1.0 Preface .......................................................................................1-1
1.1 RCM and NASA .............................................................................. 1-1 1.2 Applicability and Use of this Guide ..................................................... 1-4
NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT 6.8 Non-Destructive Testing ................................................................ 6-31 6.9 Photography .............................................................................. 6-42
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NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT 12.5 Metric Selection ........................................................................ 12-5 12.6 Benchmarking Background ............................................................ 12-5 12.7 Benchmark Section ..................................................................... 12-6 12.8 Utilization of KPIs ...................................................................... 12-7 12.9 Examples of Benchmarks .............................................................. 12-7 12.10 Planning and Scheduling KPIs ....................................................... 12-9 12.11 RCM KPIs ............................................................................... 12-10
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LIST OF FIGURES
Figure 2-1. Bearing Life Scatter ......................................................................... 2-2 Figure 3-1. Components of an RCM Program .......................................................... 3-1 Figure 3-2. NASA RCM Logic Tree........................................................................ 3-5 Figure 3-3. RCM Analysis Considerations ............................................................... 3-8 Figure 3-4. Effect on Maintenance and Repair Costs................................................. 3-9 Figure 3-5. Cost of Maintenance Programs by Type ................................................ 3-10 Figure 3-6. Life-Cycle Cost Commitment ............................................................ 3-12 Figure 4-1. System Performance Curve ................................................................ 4-1 Figure 4-2. P-F Curve (Modified) ........................................................................ 4-2 Figure 4-3. Conceptual Degradation Detection Graph ............................................... 4-3 Figure 4-4. System Functional Boundaries ............................................................. 4-4 Figure 4-5. Conditional Probability of Failure Curves................................................ 4-7 Figure 4-6. Preventing Failure ........................................................................... 4-9 Figure 4-7. FMEA Worksheet ........................................................................... 4-10 Figure 4-8. General HVAC System with Test Points ................................................ 4-13 Figure 5-1. Monitoring Intervals ......................................................................... 5-6 Figure 5-2. Sample HVAC System........................................................................ 5-9 Figure 5-3. Effects of Misalignment on Roller Bearings............................................ 5-16 Figure 5-4. Determining Network Reliability ........................................................ 5-22 Figure 5-5. Failure Analysis Form ..................................................................... 5-27 Figure 5-6. Generic Parametric Model................................................................ 5-30 Figure 5-7. Sample of Relationship between Classification Codes and DM Category Codes . 5-31 Figure 6-1. Sound Disc Diagram.......................................................................... 6-5 Figure 6-2. Lubrication Analysis Chart................................................................ 6-21 Figure 6-3. Power Factor Current/Voltage Relationship .......................................... 6-23 Figure 6-4. Non-Destructive Testing Selection Process ............................................ 6-32 Figure 6-5. Shielded Radiography Enclosure......................................................... 6-33 Figure 6-6. Magnetic Particle Testing ................................................................ 6-35 Figure 6-7. Inspection Program Development ....................................................... 6-39 Figure 7-1. Conceptual Wear Particle Size and Equipment Condition............................. 7-4 Figure 9-1. Seven Steps for Performing a Pareto Analysis........................................... 9-2 Figure 9-2. Sample Control Sequence .................................................................. 9-5 Figure 9-3. Sample of RH Control ....................................................................... 9-6
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NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT Figure 9-4. Design Improvements through Maintenance Feedback .............................. 9-10 Figure 10-1. Transducer Response .................................................................... 10-5 Figure 12-1. Presentation and Use of KPIs ........................................................... 12-1 Figure 13-1. The Retrocommissioning Process ...................................................... 13-3 Figure 13-2. Functional Performance Test Process................................................ 13-11 Figure 14-1. Reliability and Maintainability Matrix................................................. 14-7
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LIST OF TABLES
Table 3-1. RCM Facility Life-Cycle Implications .................................................... 3-13 Table 4-1. Criticality/Severity Categories ........................................................... 4-11 Table 4-2. Probability of Occurrence Categories ................................................... 4-12 Table 4-3. Chilled Water System Analysis ........................................................... 4-14 Table 4-4. Electric Motor Component Analysis...................................................... 4-14 Table 4-5. Cause of Motor Bearing Failure........................................................... 4-15 Table 5-1. Maintenance Priority Levels ................................................................ 5-2 Table 5-2. Reactive Maintenance/Trouble Call Priorities ........................................... 5-4 Table 5-3. Recommended Coupled Alignment Tolerances (General Motors, 1993) ........... 5-14 Table 5-4. Alignment Related Tolerances (General Motors, 1993) .............................. 5-14 Table 5-5. Limitations on Rolling Bearing Misalignment (Harris, 1984) ......................... 5-15 Table 5-6. Example of Failure Times ................................................................. 5-20 Table 5-7. Example of Total Operating Hours Based on Failure Times.......................... 5-20 Table 5-8. DM Category Facility System CRV Percentages ........................................ 5-32 Table 5-9. Condition Rating Criteria .................................................................. 5-33 Table 5-10. System Condition CRV Percentage versus Condition Code ......................... 5-34 Table 6-1. PT&I Applications............................................................................. 6-2 Table 6-2. Estimated Steam Loss...................................................................... 6-10 Table 6-3. Recommended Maximum Inspection Intervals (API 570) ............................. 6-37 Table 7-1. Actions Required Based on Temperature Rise under Load............................. 7-5 Table 7-2. Temperature Limits for Selected Components .......................................... 7-6 Table 9-1. Maintenance Training ........................................................................ 9-9 Table 10-1. Motor Balance Specifications............................................................ 10-7 Table 10-2. Motor Vibration Criteria.................................................................. 10-8 Table 10-3. Pump Vibration Limits.................................................................... 10-8 Table 10-4. Belt Driver Fan Vibration Limits ........................................................ 10-9 Table 10-5. ISO 10816-1: 1995 (E) Typical Zone Boundary Limits................................ 10-9 Table 10-6. Vibration Acceptance Classes .......................................................... 10-10 Table 10-7. Machine Classifications.................................................................. 10-10 Table 10-8. Lubricant Tests ........................................................................... 10-13 Table 10-9. Sperry Vickers Table of Suggested Acceptable Contamination Levels for Various Hydraulic Systems ...................................................................................... 10-14 Table 10-10. Typical Properties of Transformer Oils.............................................. 10-15
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NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT Table 10-11. RCM Clauses for A&E Contracts....................................................... 10-18 Table 10-12. RCM Clauses for Construction Contracts ............................................ 10-19 Table 10-13. RCM Clauses for Equipment Procurement Contracts.............................. 10-21 Table 10-14. RCM Clauses for M&O Contracts ...................................................... 10-23 Table 11-1. RCM Quality Assurance Planning Considerations ..................................... 11-1 Table 11-2. RCM Quality Assurance Design Considerations ....................................... 11-2 Table 11-3. RCM Quality Assurance Construction Considerations ................................ 11-3 Table 11-4. RCM Quality Assurance Equipment Procurement Considerations.................. 11-4 Table 11-5. RCM Quality Assurance Maintenance and Operations Considerations............. 11-5 Table 12-1. Sample KPIs ................................................................................ 12-3 Table 12-2. Financial Benchmarks .................................................................... 12-7 Table 12-3. Organizational Benchmarks.............................................................. 12-8 Table 12-4. Work Practices Benchmarks ............................................................. 12-8 Table 13-1. Pumps Schedule #M-1 ................................................................... 13-15 Table 14-1. Maintainability Metrics ................................................................... 14-6 Table 14-2. First Principles of Maintainability Design ............................................ 14-12 Table 14-3. Access Dimensions ....................................................................... 14-18 Table 14-4. Examples of Accessibility Issues ....................................................... 14-23
TABLE OF APPENDICES
APPENDIX A: Glossary .....................................................................................A-1 APPENDIX B: Abbreviations and Acronyms .............................................................B-1 APPENDIX C: Bibliography ................................................................................C-1 APPENDIX D: Sources of PT&I Equipment, Services, and Training .................................D-1 APPENDIX E: Vibration Criteria ..........................................................................E-1 APPENDIX F: PT&I Technologies Correlation Relationships ......................................... F-1 APPENDIX G: Alignment Standard ...................................................................... G-1 APPENDIX H: Balance Standard ......................................................................... H-1 APPENDIX I: Maintenance Procedures .................................................................. I-1 APPENDIX J: Generic FMEAs Worksheets ............................................................... J-1 APPENDIX K: Items Recommended for Further Discussion ..........................................K-1
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1.0
PREFACE
Reliability-Centered Maintenance (RCM) and variations thereof are employed by thousands of public and private organizations world-wide to address a host of reliability issues in order to improve Overall Equipment Effectiveness (OEE) while controlling the Life-Cycle Cost (LCC) inherent with Asset Management and Facility Stewardship. With each new RCM practitioner, new ideas and applications for RCM are discovered, which in turn improves the RCM process. Professional organizations have formed or expanded as the number of RCM practitioners has grown. The role of RCM in organizations has expanded past the development of maintenance tasks based on Failure Modes and Effects Analysis (FMEA) to include the following: Sustainability Energy Efficiency Commissioning, Recommissioning, and Retrocommissioning Maintainability Age Exploration Reliability Analysis
1.1
National Aeronautics and Space Administration (NASA) holds a policy to continuously improve the institutional management of capital assets by maintaining the NASA-owned and NASAoperated facilities in safe, environmentally sound, and affordable condition. Facilities and equipment owned by NASA shall be maintained in the most cost efficient fashion to create a hazard-free working environment while protecting and preserving capital investments and their capability. It is the policy of the United States to promote the efficient and economical use of America's real property assets and to assure management accountability for implementing Federal real property management reforms. Based on this policy, executive branch departments and agencies shall recognize the importance of real property resources through increased management attention, the establishment of clear goals and objectives, improved policies and levels of accountability, and other appropriate action. 1 Since the NASA RCM Guide for Facilities and Collateral Equipment was implemented in 1996, the uses and capabilities of RCM principles and techniques have increased significantly. NASA applies the NASA-created Reliability-Centered Maintenance (RCM) Guide to successfully employ diverse asset maintenance strategies, varying from run to failure to streamlined
Executive Order 13327, Federal Real Property Asset Management: February 4, 2004.
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NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT failure mode and effect analysis (FMEA), combined with Predictive Testing and Inspection (PT&I). Specifically, NASA believes the RCM approach can be a valuable tool in the effort to meet the goals of the Energy Policy Act of 2005. The Secretary, in consultation with the Administrator of General Services, shall establish an Advanced Building Efficiency Testbed program for the development, testing, and demonstration of advanced engineering systems, components, and materials to enable innovations in building technologies. The program shall evaluate efficiency concepts for government and industry buildings, and demonstrate the ability of next generation buildings to support individual and organizational productivity and health (including by improving indoor air quality) as well as flexibility and technological change to improve environmental sustainability. 2 In addition, NASA believes the RCM approach will aid the Centers in complying with the requirements of Executive Order 13423, Strengthening Federal Environmental, Energy, and Transportation and Energy Independence and Security Act of 2007 by: implementing the policy of the United States that Federal agencies conduct their environmental, transportation, and energy-related activities under the law in support of their respective missions in an environmentally, economically and fiscally sound, integrated, continuously improving, efficient, and sustainable manner. The NASA RCM Logic Tree, which provides a consistent approach to all equipment maintenance, has been modified to address sustainability (see Figure 3-2). NASA team members and contractors are encouraged to adopt the use of the NASA RCM Logic Tree and, where appropriate, perform an FMEA in the development of commissioning Pre-functional and Functional Tests. All Construction of Facilities (CoF) funded projects should include an RCMbased commissioning process to include training on the FMEA. In addition to the increased awareness of the energy implications in facilities management since 2000, an increased emphasis has been placed on facility security in the wake of the September 11, 2001 attacks. The NASA RCM Logic Tree and accompanying criticality tables have been modified to include security. Other significant changes to this guide are as follows: Information on commissioning has been expanded PT&I technology information has been updated RCM integration with computerized maintenance management systems (CMMS) and/or Computer Aided Facility Management (CAFM) has been included
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NASA RELIABILITY-CENTERED MAINTENANCE GUIDE FOR FACILITIES AND COLLATERAL EQUIPMENT Wireless data collectors have been integrated with CMMS Key Performance Indicators (KPIs) and the Presidents Management Agenda Scorecard have been included RCM as a Quality Assurance (QA) tool Statistical Process Control (SPC) and Pareto Analysis The role of RCM in the Deferred Maintenance (DM) Model Generic FMEAs are provided for all major facilities equipment and systems in Appendix J
RCM principles and techniques have been used by NASA Headquarters, Centers, and Field Activities to improve their stewardship of the more than 44 million square feet of facilities and the associated billions of dollars of collateral equipment contained within by implementing and/or refining the following: Energy Management Control Systems Predictive Testing and Inspection (PT&I) (See Chapter 6.0 Predictive Testing and Inspection Technologies, page 6-1, and Chapter 7.0 Predictive Testing and Inspection Criteria, page 7-1.) Key Performance Indicators (KPIs) (See Chapter 12.0 Key Performance Indicators.) Performance Based M&O Contracts (PBC) (See Chapter 10.0 RCM Contract Clauses.) Failure Modes and Effects Analysis (FMEA) (See Section 4.2 Failure Modes and Effects Analysis, page 4-13.) Age Exploration (AE) (See Section 5.5.7 Age Exploration, page 5-30.) Commissioning, Recommissioning, and Retrocommissioning (See Chapter 10.0 Building Commissioning.) LEED Certification