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Reliability
Reliability
The growth in unit sizes of equipment in most industries with the result that the consequence of failure has become either much more expensive, as in the case of low availability or potentially catastrophic makes the following more important:
System Reliability
These predictions can only result from careful consideration of reliability and maintainability factors at the design stage.
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Industrial Engineering
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Reliability
In reliability analysis of engineering systems it is often assumed that the hazard or time- dependent failure rate of items follows the shape of a bathtub with three main phases. The burn-in phase (known also as infant mortality, break-in , debugging):
System Reliability
During this phase the hazard rate decrease and the failure occur due to causes such as:
Incorrect use procedures Poor quality control Poor test specifications Over-stressed parts Incomplete final test Wrong handling or packaging
Inadequate materials
Marginal parts
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The useful life phase: During this phase the hazard rate is constant and the failures occur randomly or unpredictably. Some of the causes of the failure include: A. Insufficient design margins
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E. Unavoidable failures
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The wear-out phase (begins when the item passes its useful life phase):
During this phase the hazard rate increases. Some of the causes of the failure include:
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A.
B.
C.
D.
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Reliability
The whole-life of failure probability for the generality of components is obtained by drawing the three possible (t)
However, the following will vary by orders magnitude from one sort of item to another:
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I.
II.
III.
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Estimates of the parameters of the whole-life failure probability profile of the constituent components are an essential requirement for the prediction of system reliability.
System Reliability
Additional information, such as repair-time distribution, then leads to estimates of availability, maintainability, and the level (and cost) of corrective and preventive maintenance.
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Reliability
Regard the large and complex system (plant) as a hierarchy of units and items (equipment) ranked according to their function and replaceability.
2.
At each functional level, the way in which the units and items (equipment) in this level is connected is determine (The equipment in general could be connected in series, in parallel or in some combination of either)
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System Reliability
The appropriate measure of reliability is calculated for each unit and item (in this analysis The appropriate measure of reliability is the failure survival R(t). The analysis starts from the component level upwards and at the end of the analysis the survival probability of the system Rsystem(t) is calculated. All the component mean failure rates are calculated. They are either being known or susceptible to estimation.
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3.
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4.
5.
6.
At each level the survival probability calculation takes the functional configuration into account.
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The result Rsystem( (t) of the system can be used in the selection of design or redesign alternatives, in the calculation of plant availability, or in the prediction of maintenance work load.
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7.
System Reliability
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System Reliability
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A few important prerequisites are given for application of the Boolean theory:
The system must be non-repairable, that is, the first
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system failure ends the systems lifetime. Thus, for repairable systems it is only possible to calculate the reliability up to the first system failure. failed state of condition.
The system elements must be either in a functional or The system elements are independent, that is, the
failure behaviour of a component is not influenced by the failure behaviour of another component.
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Reliability
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Series-Connected Components For a system of n series-connected components (independent and non identical), survival probability of the system is:
System Reliability
Since survival probabilities must always be less than 100%, it follows that Rss(t) for the system must be less than that of any individual component.
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If the times-to-failure of the components behave according to the exponential p.d.f, then the overall p.d.f of times-to-failure is also exponential:
System Reliability
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Rss(t) = exp (- i t)
System Reliability
MTTFss = exp (- i t) dt = 1/ i
The hazard rate of the series system is :
ss(t) = i
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Parallel-Connected Components A system with components connected in parallel, fails if all the components in this system fail. (at least one of the units must work normally for system success)
System Reliability
If the failure behaviour of any component in the system is quite uninfluenced by that of the others (failure probabilities are statistically independent), the failure probability Fps(t) that all components will fail before time t has elapsed is given by the product of the separate failure probabilities, F1(t), F2(t), .Fi(t).
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Industrial Engineering
Reliability
For a system with n parallel-connected components, the failure probability of the system:
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Industrial Engineering
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System Reliability
If the times-to-failure of the components behave according to the exponential p.d.f, then the overall p.d.f of times-to-failure is not a simple exponential. For example, if the system compose of two component, then the system times-to-failure p.d.f :
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For exponentially distribution times to failure of unit i, the parallel system reliability is:
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And the mean time to failure for the identical unit parallel system is:
MTTF = (t) t dt
Series and Parallel System Reliability
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Industrial Engineering
To improve reliability of the system by making some of the equipment redundant to the other.
2. System Reliability
Extensive preventive maintenance can be pursued with no loss in plant availability since the separate parallel units can be isolated.
In the event of failure corrective maintenance can be arranged under less pressure from production or from competing maintenance tasks.
3.
In the case of very high reliability units, there are only very marginal increments in reliability to be gained by installing redundant capacity unless the safety factors become evident.
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RC
RC = 1 (1-RC)(1-RC)
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Example
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Example
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System Reliability
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Example
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Industrial Engineering
Example
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A system composes of three components. These components have constant failure rates of 0.0004, 0.0005, 0.0003 failures per hour. The system will stop working, if any one of its components fails. Calculate the following: 1. The reliability of the system at 2500 hour running time? 2. The system hazard rate? 3. Mean time to failure of the system?
System Reliability
Industrial Engineering
Example
Reliability
Another system composes of four items and each one of these items has constant failure rate of 0.0008 failures per hour. These items when they work the system will work. However, when any one of the system's items fails, the whole system will come to a complete halt. Calculate the following: 1. The reliability of the system at 2000 hour running time? 2. The system hazard rate? 3. Mean time to failure of the system?
System Reliability
Industrial Engineering
Example
Reliability
A machine has two independent cutting parts. Any one of these cutting parts is sufficient to operate the machine. The hazard rates for the two parts of this machine are constant and they are 0.001 and 0.0015 failures per hour. Calculate: 1.The survival probability of the machine at 300 hour of running time? 2.The mean time to failure for this machine?
System Reliability