Fallsem2016-17 2291 RM001 Mee253 TH PDF

MEE 253
Reliability, Maintenance and Safety

Dr JAYAKRISHNA K
Associate Professor
School of Mechanical Engineering
VIT University
jayakrishna.k@vit.ac.in
9894968596
UNIT I
Reliability definition Reliability function Graphical representation a
priori, a posteriori probabilities of survival. Component mortality Mortality

curve Useful life Reliability mathematics - Failure Rate, Mean Time
Between Failures (MTBF) Mean Time To Failure (MTTF), Bathtub
distribution, Down time, Repair time, Availability, Reliability Allocation,
Mechanical Reliability.
Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

SMEC, VIT UNIVERSITY
Definition of Reliability Management

Reliability management is an engineering discipline for applying scientific
know how to a component, assembly, plant or process so it will perform

its intended function, without failure for the required time duration when
installed and operated correctly in a specified environment.

Basic elements of Reliability

The definition has four important elements:
Probability
Adequate Performance
Duration of adequate performance (time)
Operating conditions

Definition of Probability
Probability may simply be dened as likelihood of occurrence of a given event.
Mathematically, it can simply be expressed as follows

=

o A value between 0 and 1
o Precise meaning
Ex. Probability of 0.95 means that 95 of 100 items will still be working at stated
time under stated conditions

Adequate Performance
Performance
Adequate performance what is expected of a product
Ex. A 5 ampere fuse is said to perform adequately if the fuse blows off when
the current passing through it exceeds 5 amperes

Duration of adequate performance

Duration
The period for which the performance of the product is satisfactory
When a product is put in use, its performance level goes down with time due to
deterioration, wear and tear etc.,. Hence it becomes necessary to specify a

duration (time limit) during which the performance of the product will be
adequate (satisfactory).

The operating conditions (environment) in which a product is expected to
function adequately to the stated product life.
Ex. An air conditioning unit designed to perform in hot and dry climate will
not perform satisfactorily in wet climatic conditions.
The shock absorber of a motor cycle may perform satisfactorily on even roads,
but its life span ill be very short when used on uneven rough roads.

Definition of Reliability
Generally defined as the ability of a product to perform as expected over

time
Formally defined as
The probability that a product, piece of equipment, or system performing
its intended function for a stated period of time under specified operating
conditions

Need of Reliability Management

Why is it needed?
Reliable operation of critical equipment
Planning of maintenance activities

Improved quality of an item

Is Failure Good ??
ISRO failure history
December 25, 2010: GSLV-F06 launch unsuccessful due to snag in stage-1
April 15, 2010: GSLV-D3 developmental flight carrying GSAT4 onboard. Failure. Plunges
into sea.
July 10, 2006: Second operational flight of GSLV (GSLV-F02) with INSAT-4C onboard.
Satellite could not be placed in orbit. Rocket falls into sea.
September 20, 1993: First developmental launch of PSLV with IRS-1E on board. Satellite
could not be placed in orbit.
July 13, 1988: Second developmental launch of ASLV with SROSS-2 onboard. Satellite could
not be placed in orbit.

March 24, 1987: First developmental launch of ASLV with SROSS-1 satellite on board.
Satellite could not be placed in orbit.

August 10, 1979: First experimental launch of SLV-3 with Rohini Technology Payload
onboard. Satellite could not be placed in the orbit.

The task of reliability

The three main task of reliability are,
1.
To study the existing system in detail each sub-component in a system

is analysed carefully and its reliability is determined. Then the properties
and interdependence of each sub-component is clearly understood.

2.
To determine the best way of increasing the reliability by having

parallel redundant units, standby redundant units, y adopting preventive
maintenance etc.
3.
To maximise system reliability for a given conditions/parameters

Repairable items
Repairable items
A repairable item is one which can be put back in service economically.
In a repairable system, failure can occur any number of times.
Ex. Engines used on aircrafts, cameras, all type of automobiles, machine tools
etc.

Non-repairable items
Non-Repairable items
A non-repairable item is one which fails completely or items which not be in
reach when a repair occurs or items on which it is not economical to go in for
repairing.
In a non-repairable system failure can occur only once.
Ex. A Lighting bulb, A transistor, Space craft etc.

Probability & Time

The probability of a product surviving until time (t) is given by the following
function:
= (Exponential distribution)
o A value between 0 and 1
o Precise meaning
Ex. Probability of 0.95 means that 95 of 100 items will still be working at stated
time under stated conditions

Reliability @ t
If we have a large number of items that we can test over time, then the Reliability
of the items at time t is given by
number of items put on test at time t

number of survivors at time t = 0
At time t = 0, the number of survivors is equal to number of items put on test.

Therefore, the reliability at t = 0 is
R(0) = 1 = 100%
After this, the reliability, R(t), will decline as some components fail (to perform in
a satisfactory manner).
Redundancy
Redundancy
Redundancy is the existence of more than one means for carrying out a given
function
Also, each means of accomplishing the function need not be necessarily

identical.
Ex. Reaching a destination by any mode of transportation or by any route.

Active redundancy
Active redundancy
Active redundancy is one in which all redundant items are operated
simultaneously, instead of switching on only when a need arises.
Ex. Fighting against terrorism.

Standby redundancy
Standby redundancy
Standby redundancy is one in which the alternative means of performing the
function is not operated until needed.
The alternate means is switched on only when the primary means of performing
the function fails.
Ex. Fire fighting.

Failure rate [/Z]

The failure rate (usually represented by the Greek letter ) is a very useful quantity.
Failure is the termination of the ability of an item to perform a required function
Mathematically, it is defined as the probability of a component failing in one (small)
unit of time.
Let NF = Number of failures in a small time interval, say, t.

NS = Number of survivors at time t.
The failure rate can then be calculated by the equation:
Some products are scrapped when they fail e.g. hairdryer

Others are repaired e.g. washing machine.
Failure rate [/Z]

ExampleIf there are 200 surviving components after 400 seconds, and 8 components fail
over the next 10 seconds, calculate the failure rate after 400 seconds .

Failure rate [/Z]

ExampleIf there are 200 surviving components after 400 seconds, and 8 components fail
over the next 10 seconds, calculate the failure rate after 400 seconds .
Failure rate after 400 seconds can then be calculated by the equation:
400 =
8
20010
= 0.004 = 0.4%
This simply means that 0.4% of the surviving components fail in each second

Failure Density fd
Failure Density fd
Failure density, =

Mean Failure Rate [h]

Mean failure rate, h
Mean failure rate, =
(1+2+3++)
Mean failure rate is the overall failure rate for the entire test cycle
Where
Z = Failure rate
T= Tth hour

Steps to calculate reliability of an item

To establish reliability of an item:
Conduct a series of tests until a number of them fail.
Calculate failure rate [].
Calculate reliability for a given time using [ ]

Slip test - Reliability ?

A Trial data shows that 105 items failed during a test with a total operating time of
1 million hours. Find the reliability of the product after 1000 hours i.e. (t) =1000.

Slip test - Reliability ?

Solution
The failure rate
105
1.05 10 4
1000000
Reliability of the product after 1000 hours i.e. (t) =1000

4 1000)
1000 = (1.0510
1000 = 0.9

= 0.9
Mean time to Failure (MTTF)

MTTF applies to non-repairable items or devices.
MTTF is defined as "the average time an item may be expected to function

before failure".
MTTF is the mean time to first failure
MTTF can be estimated from a suitable sample of items which have been tested to
the point of failure

MTTF is simply the average of all the times to failure.
Ex:- If four items have lasted 4,000 hours, 5000 hours, 6000 hours and 5,000 hours,
Then MTTF is 20,000/4 or 5,000 hours.

Mean time to Failure (MTTF) for small sample size

The formula used to calculate MTTF when the sample size is small
1
=
=1
Where, N = Number of specimens

ti= Time to failure for the ith specimen

Mean time to Failure (MTTF) for large sample size

The formula used to calculate MTTF when the sample size is large
1
=

=1
Where,
N = Number of specimens
nk= Number of failures during kth hour
t = Time interval

Mean time between Failures (MTBF)

The MTBF applies to repairable items.
MTBF is defined as the mean time between two successive component failures.
(Need not be identical components)
Total device hours
=
Number of failures
MTBF is a function of time. When a system is operated MTBF will fluctuate and
then stabilise.
For example, consider an item which has failed, say, 4 times over a period of 20,000
hours.
Ex:- If four items have lasted 4,000 hours, 5000 hours, 6000 hours and 5,000 hours,
Then MTBF is 20,000/4 or 5,000 hours. (Same as MTTF)
Mean time to Failure (MTTF) and Mean time

between Failures (MTBF)
For the particular case of an exponential distribution,
=
Where, is the failure rate.

This equation can also be written the other way round:
=
1
=

Maintainability
Maintainability means design for ease of maintenance.
It is concerned with those actions taken during development of a facility so that when
the facility is installed and operated, it can be maintained with ease.
Maintainability is the ability of an item, under stated conditions of use, to be retained
in, or restored to, a state in which it can perform its required functions, when
maintenance is performed under stated conditions and using prescribed procedures

and resources.

Mean time to repair (MTTR)

MTTR is the statistical mean time for active repairs.

Mean time to ?

Maintenance - Corrective
Maintenance - Corrective
The actions which are performed when a failure occurs in order to bring back the
item to the specified conditions is called as maintenance corrective.

Maintenance - Preventive
Maintenance - Preventive
The actions which are performed as an attempt to retain an item in a specified

condition by providing systematic inspection, detection and prevention of anticipated
failure is called as maintenance corrective.

Preventive Maintenance Down Time (PMDT)

When preventive maintenance is carried out, the system cannot be used and the time
spent to carry out preventive maintenance is called as preventive maintenance down

time (PMDT)

Mean Time Between Maintenance (MTBM)

If during the calculation of MTBF, if the preventive maintenance down time (PMDT)
is taken in to consideration, then the value obtained is called as mean time between
maintenance (MTBM)

Supply down time

Supply down time is the time during which a delay in maintenance activities occur
due to non-availability of items.

Administrative down time

Administrative down time is the time during which delay in maintenance activities
which has not been accounted under the supply time.

Active repair time

It is the actual time spend by one or more maintenance personnel rectify a repair.

Mean Down Time (MDT)

The statistical mean of down times including supply down time and administrative
down time is termed as mean down time [MDT].

Availability
Availability means operational readiness of the system
Availability is also put as the ability of an item to perform its required function at a
stated instant of time or over a stated period of time.
Availability is under the combined aspects of its reliability, maintainability and
maintenance support.

Availability
Operational availability
Inherent availability
=
+
MTBM = mean time between maintenance
MTD = mean down time

MTBF = mean time between failures
MTTR = mean time to repair

The Concept of the Bath-tub Curve

Bath-tub curve represents the pattern of failure of both simple and complex products.
The vertical axis in the figure is the failure rate at each point in time along the
horizontal axis.
Higher values here indicate higher probabilities of failure.

The bath-tub curve is divided into three regions:
Infant mortality/burn-in region/debugging region/break-in region,
Useful life/Constant failure/Service failures and

Wear-out.



Infant mortality
This stage is also called early failure or debugging stage.
The failure rate is high but decreases gradually with time.

The failure rate at the beginning of infant mortality stage is high and then it decreases
with time after early failures are removed by burn-in or other stress screening methods.
Some of the typical early failures are:
poor welds
poor connections
contamination on surface in materials
incorrect positioning of parts, etc.


Useful Life
This is the middle stage of the bath-tub curve.
This stage is characterised by a constant failure rate.
This period is usually given the most consideration during design stage and is the
most significant period for reliability prediction and evaluation activities.
Product or component reliability with a constant failure rate can be predicted by the
exponential distribution.
The failures at this stage are may be due to application of loads in excess of the
design strength, improper maintenance etc.


Wear-out stage
This is the final stage where the failure rate increases as the products begin to wear
out because of age or lack of maintenance.

When the failure rate becomes high, repair, replacement of parts etc., should be done.
Some of the typical failures at this stage are:
Poor maintenance
Wear due to friction
Wear due to aging
Corrosion and creep
Wrong overhaul practices
Short designed-in life of the product

Reliability statistical distributions

There are many statistical distributions used for reliability analysis,
Exponential distribution
Weibull distribution
Normal distribution
Lognormal distribution and
Gamma distribution

General and Specic Hazard Rate Functions

The general hazard rate of an item is dened as
.(1)
t
1
Where,
(t) = item hazard rate (i.e., time t dependent failure rate)
f(t) = item failure density function (probability density function)
F(t) = cumulative distribution function (i.e., the item failure probability at time t)
R(t) = item reliability at time t
General and Specic Hazard Rate Functions

The denominator of equation (1) can be expressed as follows:
(t) =1
(t)dt
0
.(2)
Differentiating Equation (2) with respect to t , we get

=
.(3)
Substituting Equation (3) into Equation (1) yields
.(4)
This expression is quite useful to obtain item hazard rate when the items reliability
function is known.
Hazard Rate for Exponential Distribution

The failure density function of the exponential distribution is dened as
= , t 0, >0
.(5)
where
is the distribution parameter (in reliability studies, it is known as failure rate) and t
is time. Inserting Equation (5) into Equation (1), we get the following expression for
exponential distributions hazard rate:
.(6)
=
.(7)
General and Specic Reliability Functions

The general reliability function can be obtained by using Equation (4).
Thus, rearranging Equation (4), we get

1
t dt =
dR t
R t
.(8)
Integrating both sides of Equation (8) over the time interval [0, t], we get
()
t dt =
1
dR t
R t
.(9)
since at t = 0, R(t) = 1. Evaluating the right-hand side of Equation (9) and
rearranging the resulting expression yields

.(10)
General and Specic Reliability Functions

Thus, using Equation (10), we get
.(11)
Equation (11) is the general expression for the reliability function.

It can be used to obtain reliability function of an item when the items hazard rate is
dened by any probability distribution.

Reliability Function for Exponential Distribution

Substituting Equation (7) into Equation (11), we get the following expression for
exponential distributions reliability function:

t
e 0 dt
.(12)
R t = e
.(13)
R t =

Sample Problems
Problem 1
Time (t)
A test was conducted on 1000 components used on a
CNC machine. The total duration of the tests is 10 hours.
0
210
1
The number of components failing during each hourly

interval is noted and the results are tabulated.
No. of failures
(f)
143
2
117
3
Find the
96
4
Cumulative failure [F]
Number of survivors [S]
Failure density [fd]
Failure rate [Z]
Mean failure rate [h]
Reliability [R]
77
65
90
135
50
17
10
Solution to Problem 1
Time No. of failures Cumulative
No of
Failure
(t)
(f)
failures (F) survivors (S) density (fd)
0
0
1000
210
0.210
1
210
790
143
0.143
2
353
647
117
0.117
3
470
530
96
0.096
4
566
434
77
0.077
5
643
357
65
0.065
6
708
292
90
0.090
7
798
202
135
0.135
8
933
67
50
0.050
9
983
17
17
0.017
10
1000
0
Total
1.000
Average
Population
Failure
rate (Z)
Reliability [R]
1
895.000
0.235
0.790
718.500
0.199
0.647
588.500
0.199
0.530
482.000
0.199
0.434
395.500
0.195
0.357
324.500
0.200
0.292
247.000
0.364
0.202
134.500
1.004
0.067
42.000
1.190
0.017
8.500
2.000
0
Mean [h]
0.5785
Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR, SMEC, VIT UNIVERSITY
Sample Problems
Problem 2
Determine the MTTF for a mission time of 1000 hours life if the test data on 10
such components gave times to fail as tabulated below. Also, find the reliability of
the components.
Component Number
10
Time to failure in
hours
807
820
810
875
900
837
850
790
866
815

Solution to Problem 2
Problem 2
=1
1
=
[807 + 820 + 810 + 875 + 900 + 837 + 850 + 790 + 866 + 815]
10
= 837
=
= 1/837 =0.0012 failure/hour
t = 1000 hrs
=
= 0.3012
Sample Problems
Problem 3
The life testing data of 1000 specimens of a particular device are given in the table.
Determine MTTF of the device for an operating period of 10 hours.

Time interval in hours
Number of failures during the interval
T 1000
1000<T 1050
175
1050<T 1100
400
1100<T 1150
300
1150<T 1200
125

Sample Problems
Problem 4
If the failure rate of a component is 0.003/hour, determine its reliability and MTTF
for 1000 hours life.

Sample Problems
Problem 5
Consider a component having a failure rate of 0.610-5 failure/hours. What will be
the reliability of the component for an operating period of 100 hours?

Sample Problems
Problem 6
What is the reliability of a component for an operating period of 200 hours, having a
failure rate of 0.410-5 failure/hour. If 5000 such items are tested, how many items
fail in 200 hours?


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MEE 253

Reliability, Maintenance and Safety

priori, a posteriori probabilities of survival. Component mortality Mortality

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Definition of Reliability Management

know how to a component, assembly, plant or process so it will perform

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Basic elements of Reliability

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Duration of adequate performance

deterioration, wear and tear etc.,. Hence it becomes necessary to specify a

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Generally defined as the ability of a product to perform as expected over

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Need of Reliability Management

Planning of maintenance activities

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

not be placed in orbit.

Satellite could not be placed in orbit.

onboard. Satellite could not be placed in the orbit.

The task of reliability

To study the existing system in detail each sub-component in a system

and interdependence of each sub-component is clearly understood.

To determine the best way of increasing the reliability by having

To maximise system reliability for a given conditions/parameters

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Probability & Time

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

number of items put on test at time t

At time t = 0, the number of survivors is equal to number of items put on test.

Also, each means of accomplishing the function need not be necessarily

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Ex. Fighting against terrorism.

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Failure rate [/Z]

Let NF = Number of failures in a small time interval, say, t.

Some products are scrapped when they fail e.g. hairdryer

Failure rate [/Z]

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Failure rate [/Z]

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Mean Failure Rate [h]

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Steps to calculate reliability of an item

Conduct a series of tests until a number of them fail.

Calculate failure rate [].

Calculate reliability for a given time using [ ]

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Slip test - Reliability ?

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Slip test - Reliability ?

Reliability of the product after 1000 hours i.e. (t) =1000

Dr K JAYAKRISHNA, ASSOCIATE PROFESSOR,

Mean time to Failure (MTTF)

MTTF is defined as "the average time an item may be expected to function

the point of failure