WE GuELes REALL PELL) TT OR ee Andrew K.S. Jardine Albert H.C. Tsang ere enonMaintenance, Replacement, and Reliability Theory and Applications SECOND EDITION Andrew K.S. Jardine Albert H.C. Tsang <,,.,,. TRUONG 24 HANG HAI VET NAAT TAI LIEU THU ViEN @) CRC PressMIX Paper from responsible sources ESC FSC* C014174 RC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL. 33487-2742 (©2013 by Taylor & Francis Group, LLC ‘CRC Press isan imprint of Taylor & Franels Group, an Informa business Noclaim to original US. Government works Printed on acid-free paper ‘Version Date: 20130308 International Standard Book Number 139781. 4665-5485-6 (Hardback) ‘This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, bu the author and publisher cannot assume responsiblity for the validity ofall ‘materials or the consequences oftheir use. 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CCC isnot for-profit organization that provides licenses and registration fr avaiety of user, Fr organizations that have been granted a photocopy license bythe CCC, a separate system of payment has been arranged, ‘Trademark Notice: Product or corporate names may be trademarks or regatered trademarks, and ae used only for dent Aeation and explanation without inten to infringe Library of Congress Cataloging-in-Publication Dat Jardine, A.K-S. (Andrew Kennedy Siling) ‘Maintenance, replacement, and reliability : theory and applications / authors, Andrew KS. Jardine, Albert LC. Tsang -- Second edition, pagesom.~- (Dekker mechanical engineering) Summary: “Completely revised and updated, his second edition ofa bestseller provides the tools ‘ede for making data-rivenpiyskal asset management decisions. The books solly based on the results of real-world research in physical asset management, including applications ofthe models presented inthe text. Software that implements many ofthe procedures and models featuted inthis ‘textbook has been developed and can be downlgade, along with PowerPoint Slides and est bank ‘with over 100 examination questions, fom the CRC website Provided by publisher. Includes bibliographical references and index ISBN 978-1-4665-5485-6 (hardback) 1 Industrial equipment--Maintenance and repair-Mathematial models 2. Reliebility (Engineering)--Mathematical models. 3. Replacement of industrial equipment-Matheratical ‘models. 4. Mathematical optimization, I. Tsang, Albert H.C. IL Tite 115192,)37 2013 655.200 dea 2013008023 Visit the Taylor & Francis Web site at hutpuewn:taylorendfrancis.com land the CRC Press Web ste at Iipulwww.crepressicomDedication To my wife Renee, daughter Charis, and son Alvin. Albert H.C. Tsang To BANAK (minus an A), their spouses and bairns (Callum, Cameron, Lachlan, Meghan, and Andrew). Andrew K.S. Jardine~~ Contents Preface for the First Edition... Preface for the Second Edition ... Acknowledgments for the First Edition. Acknowledgments for the Second Edition. Chapter 1 Introduction 1.1 From Maintenance Management to Physical Asset Management... 1.2 Challenges of PAM. 1.2.1 Emerging Trends of Operation Strategie 1.2.2 Toughening Societal Expectations. 1.2.3 ‘Technological Changes... 1.2.4 Increased Emphasis on Sustainability. 1.3 Improving PAM............ 1.3.1 Maintenance Excellence. 13.1.1 Strategi 13.1.2 Tactical 1.3.1.3 Continuous Improvements... 13.2 Quantum Leaps... 14 PAS 55—A Framework for Optimized Management of Physical Assets... 1.5 Reliability through the Operator: TPM. 1.6 — Reliability by Design: RCM... 1.7 Optimizing Maintenance and Replacement Decisions 18 The Quantitative Approach .. 18.1 Setting Objectives. 1.8.2 Model 1.83 Obtaining Solutions from Models. 184 Maintenance Control and Mathematical Model 1.9 Data Requirements for Modeling Reference: 7 Chapter 2 Component Replacement Decisions. 2.1 Introduction... 22 Optimal Replacement Times for Equipment Whose. Operating Cost Increases with Use 2.2.1 Statement of the Problem viia 24 25 2.6 Contents 2.2.2 Construction of the Model. 31 2.2.3 Numerical Example. 2.2.4 Further Comments 2.2.5. Application 22.5.1 Replacing the Air Filter in an Automobile 22.5.2 Overhauling a Boiler Plant... Stochastic Preventive Replacement: Some Introductory Comments Optimal Preventive Replacement Interval of Items Subject to Breakdown (Also Known as the Group or Block Policy)... 2.4.1 Statement of the Problem... 2.4.2 Construction of the Model. 2.4.3 Determination of H(t)... 24.3.1 Renewal Theory Approach 2.4.3.2. Discrete Approach. 2.4.4 Numerical Example. 2.4.5 Further Comments... 24.6 An Application: Optimal Replacement Interval for a Left-Hand Steering Clutch : sone AB Optimal Preventive Replacement Age of an Item Subject to Breakdown. 25.1 Statement of the Problem .. 2.5.2 Construction of the Mode 2.5.3 Numerical Example. 2.5.4 Further Comments... 2.5.5 An Application: Optimal Bearing Replacement Age... Optimal Preventive Replacement Age of an Item Subject to Breakdown, Taking Account of the Times Required to Carry Out Failure and Preventive Replacements .....0::ne 55 2.6.1 Statement of the Problem 2.62 Construction of the Model 2.6.3 Numerical Example.. Optimal Preventive Replacement Interval or Age of an Item Subject to Breakdown: Minimization of Downtime 2.7.1 Statement of the Problem 2.7.2. Construction of the Models. 2.7.2.1 Model 1: Determination of Optimal Preventive Replacement Interval... 2.7.2.2. Model 2: Determination of Optimal Preventive Replacement Age 2.7.3 Numerical Examples..... 2.7.3.1 Model 1: Replacement Interval. 2.7.3.2. Model 2: Replacement Age... 2.7.4 Further Comments ... - 59Contents ~~ 28 29 2.10 20 2.12 ix 2.7.5 Applications... - 2.75.1 Replacement of Sugar Refinery Cloths 2.1.5.2 Replacement of Sugar Feeds in a Sugar Refinery Group Replacement: Optimal Interval between Group Replacements of Items Subject to Failure—The Lamp Replacement Problen 2.8.1 Statement of the Problem 2.8.2 Construction of the Model. 2.8.3 Numerical Exampl 2.8.4 Further Comments 2.8.5 An Application: Optimal Replacement Interval for a Group of 40 Valves in a Compressor. Further Replacement Models 2.9.1 Multistage Replacement 2.9.2 Optional Policies 2.9.3 Repairable Systems Case Study on Project Prioritization, Trend Tests, Weibull Analysis, and Optimizing Component Replacement Intervals. 2.10.1 Introduction sseee 7 2.10.2 Optimal Preventive Replacement Age for Major ‘Components... 2.10.3 Optimal Preventive Replacement Age for Item Parts (Minor Components)... 2.10.4 Conclusion for Item Parts. Spare Parts Provisioning: Preventive Replacement Spares 2.11.1 Introduction... 2.11.2 Construction of the Model 2.1.2.1 The Constant Interval Model.. 2.1.2.2 The Age-Based Preventive Replacement Model 2.11.3, Numerical Example... a 2.11.3.1 Constant-Interval Policy .. 77 2.1.3.2 Age-Based Policy. 2.11.4 Further Comments .. . 2.11.5 An Application: Cylinder Head Replacement — Constant-Interval Policy.. Spare Parts Provisioning: Insurance Spares. 2.12.1 Introduction. 2.12.2 Classes of Components .. 2.12.2. Nonrepairable Components... 2.12.2.2 Normal Distribution Approach. 2.12.2.3 Poisson Distribution Approach. 2.12.2.4 Repairable Components, 2.12.3 Cost Model —— 61 61