Glossary

The following is a list of terms used in this book, along with their meaning or definition as applied herein.
Accelerated test A test in which the applied stress is higher than design values so as to reduce the time to failure. The basic failure mechanism and failure modes must not be altered in this process of acceleration. Age-exploration A method used to decide maintenance intervals when failure rates are unavailable. We choose an initial interval based on experience, engineering judgment or vendor recommendations. Thereafter we refine the intervals based on the condition of the equipment when inspected. Each new inspection record adds to this knowledge, and using these we make further adjustments to the maintenance intervals. Asset register A database containing an inventory of all the physical assets along with a hierarchy of sub-assemblies and component elements which may be replaced or repaired. Each asset is listed with details of its make, model, size, capacity, serial number, and vendor details. It is also identified by a tag number. Availability 1) The ability of an item to perform its function under given conditions. 2) The proportion of a given time interval that an item or system is able to fulfill its function. Availability = {time in operation - ( planned + unplanned) downtime} / time in operation Breakdown Failure resulting in an immediate loss of product or impairment of technical integrity. Circadian rhythm A natural biological cycle lasting approximately 24 hours, which governs sleep and waking patterns.

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Compliance A measurement of the percentage of completion at the end of a defined period of the routine maintenance jobs due in that period. Condition Based Maintenance The preventive maintenance initiated as a result of knowledge of the condition of an item from routine or continuous monitoring. Condition Monitoring The continuous or periodic measurement and interpretation of data to indicate the condition of an item to determine the need for maintenance. Confidence rating When used in RBI, it is a measure of the confidence we have in the estimate of remaining life. It is affected by a number of factors, such as a history of prior inspections, their quality, and expected process variability. It is a fraction, ranging from 0.1 to 0.8. Conformance Proof that a product or service has met the specified requirements. Corrective Maintenance 1) The maintenance carried out after a failure has occurred and intended to restore an item to a state in which it can perform its required function 2) Any non-routine work other than breakdown work required to bring equipment back to a fit for purpose standard and arising from: *defects found during the execution of routine work *defects found as a result of inspection, condition monitoring, obsevation or any other activity. Coverage factor The ratio of the number of defects found to the number that are present. It is a measure of the effectiveness of the technique or process, and used in the context of RBI and IPF. Criticality A measure of the risk, i.e., a combination of probability and consequence of a failure, when used in RCM, RBI, and IPF analysis. When used in the context of system effectiveness, it is a measure of the sensitivity of system effectiveness to a small change in the reliability or maintainability of a sub-system or equipment item. Defect An adverse deviation from the specified condition of an item.

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Degradation circuit A section of the process plant with similar materials of construction and similar operating process conditions which are therefore exposed to the same degradation mechanisms and rates. Diagnosis The art or act of deciding from symptoms the nature of a fault. Disruptive stress The physical or mental stress a person feels that threatens, frightens, angers, or worries a person, resulting in poor or ineffective performance. Down Time The period of time during which an item is not in a condition to perform its intended function. Efficiency The percentage of total system production potential actually achieved compared to the potential full output of the system. End-to-end testing A test in which the sensor, control unit, and executive element of a control loop are all called into action. Ergonomics The science that matches human capabilities, limitations, and needs with that of the work environment. Evident failure A failure that on its own can be recognized by an operator in the normal course of duty Facilitative stress The physical or mental stress that stimulates a person to work at optimum performance levels. Fail safe A design property of an item that prevents its failures being critical to the system. Failure The termination of the ability of an item to perform any or all of its functions. Failure cause The initiator of the process by which deterioration begins, resulting ultimately in failure. Failure effect The consequence of a failure mode on the function or status of an item.

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Failure mode The effect by which we recognize a failure. Failure Modes and Effects Analysis A structured qualitative method involving the identification of the functions, functional failures, and failure modes of a system, and the local and wider effects of such failures. Fatigue The reduction in resistance to failure as a result of repeated or cyclical application of stresses on an item. Fault An unexpected deviation from requirements which would require considered action regarding the degree of acceptability. Function The role or purpose for which an item exists. This is usually stated as a set of requirements with specified performance standards. Hidden failure A failure that, on its own, cannot be recognized by an operator in the normal course of duty. A second event or failure is required to identify a hidden failure. Incipiency Progressive performance deterioration which can be measured using instruments. Inspection Those activities carried out to determine whether an asset is maintaining its required level of functionality and integrity, and the rate of change (if any) in these levels. Inspection interval factor A de-rating factor applied to the remnant life estimate to determine the next inspection interval. It depends on both the confidence and the criticality rating. Instrumented protective systems These instruments protect equipment from high-consequence failures by tripping them when pre-set limits are exceeded. Item A system, sub-system, equipment or its component part that can be individually considered, tested or examined. Life Cycle Costs The total cost of ownership of an item of equipment, taking into account the costs of acquisition, personnel training, operation, maintenance, modification, and disposal. It is used to decide between alternative options on offer.

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Maintainability 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. It is usually characterized by the time required to locate, diagnose, and rectify a fault. Maintenance The combination of all technical and associated administrative actions intended to retain an item in or restore it to a state in which it can perform its required function. Maintenance Strategy Framework of actions to prevent or mitigate the consequences of failure in order to meet business objectives. The strategy may be defined at a number of levels (i.e., corporate, system, equipment, or failure modes). Mean availability With non-repairable items, the point availability has the same value as the survival probability or reliability. As this varies over time, the average value of the point availability is the mean availability. Method study An industrial engineering term, meaning a systematic and structured analysis of work flow. The purpose is to eliminate waste and reduce delays. Modification An alteration made to a physical item or software, usually resulting in an improvement in performance and usually carried out as the result of a design change. Net Positive Suction Head The difference between the suction pressure of a pump and the vapor pressure of the fluid, measured at the impeller inlet. Non Routine Maintenance Any maintenance work which is not undertaken on a periodic time basis. Operational Integrity The continuing ability of a facility to produce as designed and forecast. Outage The state of an item being unable to perform its required function.

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Overhaul A comprehensive examination and restoration of an item, or a major part of it, to an acceptable condition. Partial closure tests When total closure of executive elements is technically or economically undesirable; the movement of the executive element is physically restrained. Such tests prove that these elements would have closed in a real emergency. Performance Indicator A variable, derived from one or more measurable parameters, which, when compared with a target level or trend, provides an indication of the degree of control being exercised over a process (e.g., work efficiency, equipment availability). Planned Maintenance The maintenance organized and carried out with forethought, control, and the use of records, to a predetermined plan. Population stereotype The behavior expected of people or equipment (e.g., valves are expected to close when the wheel is turned clockwise). Under severe stress or trauma, people do not behave as trained or according to procedure; they revert to a population stereotype. Preventive Maintenance The maintenance carried out at predetermined intervals or corresponding to prescribed criteria and intended to reduce the probability of failure or the performance degradation of an item. Redundancy The spare capacity which exists in a given system which enables it to tolerate failure of individual equipment items without total loss of function over an extended period of time. Reliability The probability that an item or system will fulfill its function when required under given conditions. Reliability Centered Maintenance A structured and auditable method for establishing the appropriate maintenance strategies for an asset in its operating context. Reliability Characteristics Quantities used to express reliability in numerical terms.

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Remnant life An estimate of the remaining life of an item. It is used in the context of RBI to determine the next inspection interval. Repair To restore an item to an acceptable condition by the adjustment, renewal, replacement, or mending of misaligned, worn, damaged, or corroded parts. Resources Inputs necessary to carry out an activity (e.g., people, money, tools, materials, equipment). Risk The combined effect of the probability of occurrence of an undesirable event and the magnitude of the event. Routine Maintenance Maintenance work of a repetitive nature which is undertaken on a periodic time (or equivalent)basis. Safety Freedom from conditions that can cause death, injury, occupational illness, or damage to asset value or the environment. Shutdown A term designating a complete stoppage of production in a plant, system, or sub-system to enable planned or unplanned maintenance work to be carried out. Planned shutdowns are usually periods of significant inspection and maintenance activity, carried out periodically. Shutdown Maintenance Maintenance which can only be carried out when the item is out of service. Standby Time The time for which an item or system is available if required, but not used. System Effectiveness The probability that a system will meet its operational demand within a given time under specified operating conditions. It is a characteristic of the design, and may be evaluated by comparing the actual volumetric flow to that theoretically possible when there are no restrictions at the input or output ends of the system. Technical Integrity Absence, during specified operation of a facility, of foreseeable risk of failure endangering safety of personnel, environment, or asset value.

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Test interval The elapsed time between the initiation of identical tests on an item to evaluate its state or condition. Inverse of test frequency. Time and motion study An industrial engineering term, used to break down complex movements of people and machine elements. It helps eliminate unnecessary movements and utilize the workers abilities fully. Turnaround A term used in North America meaning planned shutdown. See Shutdown above. Work Order Work which has been approved for scheduling and execution. Materials, tools, and equipment can then be ordered and labor availability determined.