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CHAPTER
1 THE PRODUCTION AND DISTRIBUTION PROCESS
PROCESS EFFICIENCY
Criteria for assessing efficiency
Improving efficiency
Cost measurement and pitfalls
WORK
AND ITS VALUE
Mechanization and productivity
Value added and its measurement
MANUFACTURING AND SERVICE INDUSTRIES
Conversion processes
Factors influencing the efficiency of industries
Factors affecting demand
THE
SYSTEMS APPROACH
IMPACT OF EFFICIENCY ON RESOURCES
Efficiency of utilization
Efficiency and non-renewable resources
MAINTENANCE -- THE QUESTIONS TO ADDRESS
CHAPTER SUMMARY
CHAPTER
2 PROCESS FUNCTIONS
THE
FUNCTIONAL APPROACH
FUNCTIONAL BLOCK DIAGRAMS (FBD)
FAILURE MODE AND EFFECT ANALYSIS (FMEA)
EFFECTIVE PLANNING
PREVENTION OF FAILURES OR MITIGATION OF CONSEQUENCES?
CHAPTER SUMMARY
CHAPTER 3
RELIABILITY ENGINEERING FOR THE MAINTENANCE PRACTITIONER
FAILURE HISTOGRAMS
PROBABILITY DENSITY FUNCTION
MORTALITY
HAZARD RATES AND FAILURE PATTERNS
THE
TROUBLE WITH AVERAGES
THE
SPECIAL CASE OF THE CONSTANT HAZARD RATE
AVAILABILITY
MEAN
AVAILABILITY
THE WEIBULL DISTRIBUTION
DETERMINISTIC AND PROBABILISTIC DISTRIBUTIONS
AGE-EXPLORATION
CHAPTER SUMMARY
CHAPTER
4 FAILURE, ITS NATURE AND CHARACTERISTICS
FAILURE
Failure - a systems approach
Critical and degraded failures
Evident failures
Hidden failures
Incipient failures
THE
OPERATING CONTEXT
THE
FEEDBACK CONTROL MODEL
LIFE
WITHOUT FAILURE
CAPABILITY AND EXPECTATION
INCIPIENCY
LIMITS TO THE Application OF CONDITION MONITORING
AGE
RELATED FAILURE DISTRIBUTION
SYSTEM LEVEL FAILURES
HUMAN FAILURES
CHAPTER SUMMARY
CHAPTER 5
LIFE CYCLE ASPECTS OF RISKS IN PROCESS PLANTS
DESIGN QUALITY
Marketing inputs
Operability
Maintainability
Reliability
RISKS DURING CONSTRUCTION
THE
PRE-COMMISSION AND COMMISSIONING PHRASES
PLANNING OF MAINTENANCE WORK
THE
OPERATIONAL PHASE
Steady state operations
Competence and motivation
MODIFICATIONS TO PLANT AND CHANGE CONTROL
MAINTENANCE COSTS
Failure rates and their impact
Maintenance cost drivers
Maintenance cost drivers -- shutdowns (turnarounds)
Breakdowns and Trips
END
OF LIFE ACTIVITIES
CHAPTER SUMMARY
Chapter 6
PROCESS PLANT SHUTDOWNS
FACTORS AFFECTING OPERATING RUN LENGTHS
Loss of integrity
Loss of efficiency
Incorporation of plant changes
RISKS RELATED TO PLANNED SHUTDOWNS
PLANNING
SAFETY AND ENVIRONMENTAL HAZARDS
Traffic safety
Waste management
Hazardous materials management
Fire and evacuation drills
Toll box meetings
Emergency communication conventions
Training
Rescue planning
Medical support
Reference Booklet
WORK
SCOPE AND ASSOCIATED RISKS
Freezing of work scope
Work scope changes during the shutdown
QUALITY
Quality targets and performance indicators
Competence
Records and traceability -- positive material identification
ORGANIZATION
EXECUTION
Safety aspects
Competence
Overlaps and interference
Productivity
Closing-up procedures
Area clean-up
SPECIALIZED EQUIPMENT OVERHAULS
COST
CONTROL
COMMUNICATION
CONTRACTORS
SHUTDOWN REPORTS
POST-SHUTDOWN REVIEW
CHAPTER SUMMARY
Chapter 7
FACETS OF RISK
UNDERSTANDING RISK
DESCRIPTIVE OR QUALITATIVE RISK
Framing effects
The influence of choice
Control of situation
Delayed effects on health
Voluntary risks
Risks posed by natural phenomena
Subjectivity
Morality
Dreaded consequences
FACTORS INFLUENCING DECISION-MAKING
THE
QUANTITATIVE ASPECTS OF RISK
Failure
Exposure
CHAPTER SUMMARY
Chapter 8
THE ESCALATION OF EVENTS
LEARNING FROM DISASTERS
The Challenger space shuttle explosion
The Piper Alpha Explosion
King's Cross underground station fire
Milford-Haven refinery explosion
Bhopal
Chernobyl
HINDSIGHT IS 20-20 VISION
FORESIGHT --- CAN WE IMPROVE IT?
EVENT ESCALATION MODEL
DAMAGE LIMITATION MODEL
FAILURE OF BARRIERS
EVENT ESCALATION RELATIONSHIP
EVALUATING TEST FREQUENCIES
INCIPIENT PERIOD
CHAPTER SUMMARY
Chapter 9
MAINTENANCE
MAINTENANCE AT THE ACTIVITY LEVEL -- AN EXPLANATION OF TERMINOLOGY
Types of maintenance -- terminology and application rationale
Application maintenance tasks
How much preventative maintenance should we do?
THE
RASION D'ETRE OF MAINTENANCE
THE
CONTINUOUS IMPROVEMENT CYCLE
Planning
Scheduling
Execution
Analysis
SYSTEM EFFECTIVENESS AND MAINTENANCE
Testing of pressure relief valves
Duty-standby operation
End-to-end testing of control loops
CHAPTER SUMMARY
Chapter 10
RISK REDUCTION
FREQUENCY OR SEVERITY?
RELIABILITY BLOCK DIAGRAMS AND MATHEMATICAL MODELING
HAZARD AND OPERABILITY STUDIES
FAULT TREE ANALYSIS (FTA)
ROOT
CAUSE ANALYSIS
TOTAL PRODUCTIVE MAINTENANCE
RELIABILITY-CENTERED MAINTENANCE
Functional block diagrams
Failure mode and effect analysis
Failure characteristic analysis (FCA)
Cost-effective maintenance tasks
Task selection
Preventive maintenance routines
Structural and Zonal RCM Analysis
REDUCING PERCEIVED RISKS
David and Goliath scenarios
Influence of perceptions
Public goodwill
CHAPTER SUMMARY
Chapter 11
INFORMATION FOR DECISION MAKING
Work and the generalization of data
The collection
of quantitative data
The collection
of maintenance data
Failure reduction
Reducing the consequence of failures
Cost data
The collection of qualitative data
Errors in data
collection
Fixed format
data collection
Obtaining
information from data
Decision
support
Procedures
Business
process management
Chapter
summary
CHAPTER 12 IMPROVING SYSTEM EFFECTIVENESS
System
effectiveness
Integrity and
system effectiveness
Managing
Hazards
Identification
of hazards
Control of hazards
Minimization of severity of incidents
Reducing Risks
-- some practical steps
Appreciating life cycles risks
Tools and techniques
The process of carrying out maintenance
Managing maintenance costs
Communicating
risk reduction plans
Bridging the
chasm between theory and practice
Maintenance as
an investment
Chapter
summary
Book Summary
Glossary
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