CHAPTER CONTENTS PAGES
2.13.3 Use for facilities and other industries 19
2.14 Relationship of RCM to other disciplines 19
2.15 Case study 1: Drum Water level system 20
2.16 Case study 2: High Pressure feedwater pump 21
CHAPTER 3 METHODOLOGY 23
3.1 RCM background study 24
3.2 Project process planning 25
3.3 Project process flowchart 26
3.4 Literature review findings 27
3.5 Statistical process control in maintenance engineering 28
3.6 Performing industrial survey 28
3.7 Data analysis 29
3.8 Decision diagram Building 29
3.9 Data acquisition 30
3.10 Report preparing procedure. 31
CHAPTER 4 RESULTS 32
4.1 Data acquisition and results 32
4.2 Reliability determination 33
4.3 Operation parameter 35
CHAPTER 5 RESULTS ANALYSIS 36
5.1 Reliability data 37
5.2 SPC results 38
5.2.1 Gauge glass 38
5.2.2 HPFW pump 39
5.3 Graph 40
5.3.1 Gauge glass operation 40
5.3.2 HPFW pump Operation discharge pressure 41
5.3.3 Gauge glass MTBF 43
5.3.4 HPFW pump MTBF for high temperature failure 44
CHAPTER 6 DISCUSSION 45
6.1 Results discussion 45
6.2 Maintenance history 47
6.3 Decision diagram 49
6.4 Fault tree diagram 52
CHAPTER 7 CONCLUSION 54
7.1 Conclusion 54
7.2 Future recommendation 55
REFERENCES 59
BIBILIOGRAPHY 61
APPENDIXES 63
LIST OF TABLES
NO TITLE
PAGES
2.1 FMEA worksheet for HP feedwater pump case study
16 3.1
Maintenance activities practiced At TJSB 30
4.1 Operation parameter data
35 5.1
Reliability data 37
5.2a Gauge glass SPC results 38
5.2b HPFW pump SPC results 39
6.1 Drum gauge glass maintenance history
47 6.2
HPFW pump maintenance history 48
LIST OF FIGURES
NO TITLE
PAGES
1.1 Component of an RCM program
2 2.1
Reliability exponential distribution 11
2.2 Allowing for deterioration
14 2.3
Drum water level system overview 21
2.4 HP feedwater pump system overview
22 4.1
Time between failures 33
5.1 HP drum gauge glass operation level
40 5.2
HPFW pump operation discharge pressure 41
5.3 MTBF for gauge glass
43 5.4
HPFW pump MTBF 44
6.1 Principle of condition monitoring: trending
46 6.2
Decisions diagram 51
6.3 HPFW pump fault tree diagram
52 6.4
HP drum gauge glass fault tree diagram 53
7.1 Factor affects MTBF
56 7.2
QuART PRO software screenshot problem definition 57
7.3 QuART PRO software screenshotrun test
57 7.4
QuART PRO software screenshotrelationship 58
LIST OF SYMBOLS
NO SYMBOL
REPRESENTS PAGES
1 Ao
Operational availability 8
2 Ai
Inherent availability 8
3
base of the natural logarithm 2.718281828 12 4
failure rate
12 5
MTBF
12 6
t Time
12
NOMENCLATURE
RCM Reliability centered maintenance
TJSB Teknik Janakuasa Sdn Bhd
LPP Lumut Power Plant
FMEA Failure Mode and Effect Analysis
FCA Failure Characteristic Analysis
RCA Root Cause Analysis
HPFW High Pressure Feedwater Pump
PM Preventive Maintenance
HP High Pressure
MTBF Mean time between failures
APPENDIXES
APPENDIX TITLE
PAGES APPENDIX A
FMEA worksheet prepared for both case studies 63
APPENDIX B Example of decision diagram to be constructed further
65 APPENDIX C
Gantt Chart for project planning 66
CHAPTER 1
INTRODUCTION
1.1 Maintenance and RCM
