RELIABILITY CENTRED

MAINTENANCE (RCM)
A pragmatic approach to improve crane
reliability
Graeme Massie
Technical Resource Manager Cranes &
Lifting
Presentation Overview
Background Where RCM originated
Benefits Why Use RCM
RCM Process
Data Sources Lack of Actual Data
Discussion
Background
Need identified due to some major disasters such as: Bhopal,
Chernobyl & several aircraft disasters
Airline Industry were first to react
Known within the airline industry as MSG3 (Maintenance
Steering Group 3)
All aircraft maintenance regimes are generated using this
process
Industry recognises J ohn Moubray as one of the leaders in
developing the RCM process
Benefits
Management of crane safety and environmental integrity
Ensures an acceptable level of reliability/ Availability
Provides an audit trail for maintenance selection and challenge of
current regimes
Greater Maintenance cost effectiveness - time and money is directed
to maintenance tasks that make a real difference to integrity and
reliability
Selection of appropriate maintenance task
Longer useful life of expensive items
Identifies single point failures
Process
Input (RCM Check List)
Function Functional Failure System
Main
Equipment
Sub Equipment
Applicable
to Current
Crane
Type/
Model
Single Line
Component
Failure
Applies
Included in RCM Review Comments
Provide structure to
support the forces
applied during crane
operations
Unable to provide
structure to support the
forces applied during
crane operation
Structure
A Frame
Structure X X
Sheaves X X
Boom Rope Anchor (Dead
End)
X X
Connecting Pins/bolts to M/C
Bed
X X Pins
Boom
Structure X X
Sheaves X X
Boom Foot Bearings / Pins X X
Connecting Bolts/ Pins X X Bolts
Rams
Main Hoist Winch Support Fitted on chassis
Aux Hoist Winch Support Fitted on chassis
Main Hoist Anchor (Dead
End)
X X
Chassis
A frame Support X X
Boom Hoist Winch Support X X
Main Hoist Winch Support X X
Aux Hoist Winch Support X X
Boom Foot Pins Support X X
Slewing Bearing Support X X
Operators Cabin Support X X
Pedestal
Structure X X
Slewbearing support X X
Check
List
FMEA FCA MSS PMRS
Failure Modes and Effects Analysis (FMEA)
Function What operation the equipment is expected to do
Function failures - the way it can fail to fulfil its function, and includes both
total & partial loss of function. This is normally the opposite of the function
Failure modes - what credible physical events would cause each functional
failure
Local and system effects following or leading to the failure event, what
happens to equipment directly associated with the failure and what effect
does it have on other systems and equipment
Category - The effects information is used to distinguish the consequence
category for each identified failure mode, five consequence categories
It is essential that when carrying out FMEA the assumption is that no
maintenance is done.
Check
List
FMEA FCA MSS PMRS
Failure Category
Check
List
FMEA FCA MSS PMRS
Failure Category
Consequence
Category
Failure
Mode
Failure Mode
Conditions
Required
Failure Mode Consequence
A Hidden Combined with one
other failure mode
or event
Safety and/or environmental
hazard.
B Evident Direct Only Safety and/or environmental
hazard.
C Evident Direct Only Operational capability adversely
affected, but no effect on
safety or environment.
D Evident Direct Only No effect on safety,
environment or operation.
E Hidden Combined with
other failure modes
or events.
No effect on safety or
environment.
Check
List
FMEA FCA MSS PMRS
Failure Modes and Effects Analysis (FMEA)
Typical function groups considered are:
Provide structure to support the forces applied during crane operations.
Support and manoeuvre the load in a safe and efficient manner using the boom hoist
system.
Support and manoeuvre the load in a safe and efficient manner using the main and
auxiliary hoist system.
Support and manoeuvre the load in a safe and efficient manner using the slew system.
Provide a safe and efficient method for transfer of oil under pressure between the
hydraulic pumps and motors.
Provide pneumatic controls to ensure that the crane operates in a safe and efficient
manner
Provide electrical supply to all crane components required for safe and efficient operation.
Provide protection to ensure that the crane is operated within its design envelope.
Provide sufficient power and method to drive the hydraulic pumps
Check
List
FMEA FCA MSS PMRS
Failure Characteristic Analysis (FCA)
Maintenance Strategy Selection Category
On Condition Maintenance (OCM) - Monitor some incipient condition and undertake
maintenance based on the results of monitoring, e.g., vibration monitoring or rotating
equipment.
Scheduled Overhaul (SO) - Undertake an overhaul based on an appropriate measure
of item age.
Scheduled Replacement (SR) - Replace the item based on an appropriate measure of
age.
Failure Finding Task (FFT) - Test the item to ensure that it will function when
required, e.g., test ringing the fire bells weekly.
On Failure Maintenance (OFM) - Allow the item to fail then repair it.
RE-Design (RED) - Change the equipment, system or procedures to eliminate the
failure or change its consequences.
Check
List
FMEA FCA MSS PMRS
Failure Characteristic Analysis (FCA)
Decision Logic Example
Check
List
FMEA FCA MSS PMRS
Failure Characteristic Analysis (FCA)
Incipient Condition
Wear
Corrosion
Out of Adjustment
Fatigue
Cracking
Loosening
Seizure
Degradation
Depletion
Check
List
FMEA FCA MSS PMRS
Failure Characteristic Analysis (FCA)
Strategy
LTTF (Suitable for Safety and
Non-safety Critical
Safe (Safety Critical Equipment) and
Useful Life (Non Safety Critical)
MTBF (Not suitable for Safety Critical failure modes)
Cumulative Operating Time
MTBF = Cumulative Number of Failures
Check
List
FMEA FCA MSS PMRS
Maintenance Strategy Selection (MSS)
Task Description What maintenance task are we going to carry out
Single Point Failure Does a single failure result in an uncontrolled decent of a
load/ boom
Risk (Enermech or Clients Risk Matrix) What is the risk when failure occurs
In Current PMRs Is it included in the current maintenance regime
Procedure/ Work Aid Required Is a details procedure required
Interval What interval has been selected based on the FCA
Interval Selected If driven by another failure mode this may be different
Selection Criteria Whether LTTF, MTBF, Safe Lift & Useful Life
System Hoist, Boom, Slew, Structure, Hydraulics, Pneumatics ...
Discipline Crane Op, Crane Tech, Rope Access, NDT, Vibration Tech ...
Duration (Mins)
Check
List
FMEA FCA MSS PMRS
Data Sources
Information Gathering
Review of OEM manuals
Review of previous inspection reports
Review of historical crane maintenance data held by client
Review of maintenance backlog
Review of MOCS (Management of Change)
Previous experience of same of similar types of cranes
Knowledge from personnel who have worked with or maintained
same or similar equipment
Check
List
FMEA FCA MSS PMRS
Input (FMEA)
Failure Mode Effect Analysis
Ser Function Functional
Failure
Failure Mode Local and System Effects SPF Likelihood Severity Risk Cat
1.01 Provide structure
to support the
forces applied
during crane
operations.
Unable to
provide structure
to support the
forces applied
during crane
operation.
A-frame
structural fail due
to metal fatigue.
A-frame fractures. Collapse of
A-frame and boom structure.
Any attached load will fall.
Probable injury to personnel,
possible fatality. Secondary
damage possible to platform
equipment, structure and/or
supply vessel. Loss of crane
operational capability.
Y 1 4 4 B
2.01 Support and
manoeuvre the
load in a safe and
efficient manner
using the boom
hoist system.
Unable to
support and
manoeuvre the
load in a safe
and efficient
manner using the
boom hoist
system.
Boom hoist
winch primary
brake failure.
The boom hoist winch has a
multi-plate disc brake system
which is used as holding brake
only, slowing down is controlled
by the hydraulic system. A pawl
lock energized when prime
mover is stopped.
Y 2 2 4 B
3.01 Support and
manoeuvre the
load in a safe and
efficient manner
using the main
and auxiliary hoist
system.
Unable to
support and
manoeuvre the
load in a safe
and efficient
manner using the
main and
auxiliary hoist
system.
Main hoist winch
primary brakes
fail.
The main hoist winch has a
multi-plate disc brake system
which is used as holding brake
only, slowing down is controlled
by the hydraulic system. An
external caliper disc brake
energized when winch motion
has stopped.
Y 2 2 4 B
Check
List
FMEA FCA MSS PMRS
Input (FCA)
Failure Characteristic Analysis
Incipient Condition LTTF Safe Life Useful Life MTBF Comments
Cracks 8760 The failure interval is based on information from four years operation and
maintenance of same or similar cranes. The approximate cranes
operational running hours is 2700 per year. A review should be
undertaken if there is a substantially change to the cranes operational
duties or running hours.
Wear 8760 The failure interval is based on information from four years operation and
maintenance of same or similar cranes. The approximate cranes
operational running hours is 2700 per year. A review should be
undertaken if there is a substantially change to the cranes operational
duties or running hours.
Wear 8760 The failure interval is based on information from four years operation and
maintenance of same or similar cranes. The approximate cranes
operational running hours is 2700 per year. A review should be
undertaken if there is a substantially change to the cranes operational
duties or running hours.
Check
List
FMEA FCA MSS PMRS
Input (MSS)
Maintenance Strategy Selection
MSS Task Description In
current
PMR's
Procedures/
Work Aid
Interval Interval
selected
Selection
Criteria
System Discipline Duration
(Mins)
Comments
B-OCM Carry out a visual
inspection of the A-frame
structure for signs of
deformation, corrosion &
distortion.
Yes No 6M 6M Based on a
LTTF interval
of 12 months
the
recommended
task interval is
6 months (1/2
LTTF interval).
Structure Crane Op
Maintainer
30
B-OCM Carry out a stall test of
boom hoist circuit in the
raise position by
manually stroking boom
hoist pump, and record
pressure (350 Bar).
Note: Boom to be in rest.
Do not test for more than
3 seconds.
Yes Yes 6M 6M
Based on a
LTTF interval
of 12 months
the
recommended
task interval is
6 months (1/2
LTTF interval).
Boom Hoist Crane Op
Maintainer
30
B-OCM Carry out a stall test of
the hydraulic main hoist
circuit in the raise
function using the joystick
and record pressure (350
Bar). Note: Test input
brakes separate from
disc brake. Do not test for
more than 3 seconds.
Yes Yes 6M 6M Based on a
LTTF interval
of 12 months
the
recommended
task interval is
6 months (1/2
LTTF interval).
Main Hoist Crane Op
Maintainer
30
Check
List
FMEA FCA MSS PMRS
Output (PMRS)
Check
List
FMEA FCA MSS PMRS
Overview
It is not uncommon to review between 400 and 500 failure
modes within an offshore crane
Far higher that some other offshore equipments such as
pressure vessels and pumps
Actual data is always difficult to attain
Due to the age of some equipment OEM support is no longer
available or supported
Case Study #1
Client purchased 3 new rope luffing pedestal cranes
between 2000 - 2002
OEM stated rope change out every 24 months
Based on our knowledge of crane utilisation and experience
in consultation with the client it was moved to a 12 monthly
change out frequency
Continued to NDT ropes for 3 years
Approx 75% of ropes unsuitable for extended use
Retained at 12 month frequency
Case Study #2
Client has used same techniques and frequency of
maintenance for years no reviews carried out
No consideration to failure modes that had a direct impact
on safety/ integrity
Maintenance intrusive based
By using RCM we:
Reduced maintenance hours by 40%
Reduced maintenance costs
Increased reliability
Case Study #3
Client was keen to reduce maintenance hours and costs
Cranes not given priority and maintenance had evolved over
the years with no real strategy
Reliability was in question
RCM review unveiled:
Some maintenance tasks were carried out too frequent
no consideration to cyclic based failures
No consideration to time based failures such as
corrosion
Some safety critical tasks like spline inspection had not
been included in scheduled maintenance
Discussion
Availability of data
Practicality of sharing crane reliability data
through out industry and cross border
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