Reliability-Centered- Design

Implementation Guide

Sacramento Regional County Sanitation District

PRELIMINARY
FOR REVIEW ONLY

June 2012
 Reliability-Centered- Design
Implementation Guide

Contents
1.0 Objective ................................................................................................................................................ 1
2.0 Approach ............................................................................................................................................... 1
3.0 Expected Outcomes ............................................................................................................................... 2
3.1 Asset Reliability..................................................................................................................................................3
3.2 Process Availability ............................................................................................................................................3
3.3 Asset Maintainability ..........................................................................................................................................3
3.4 Preventive Maintenance Requirements ...............................................................................................................4
3.5 Predictive Maintenance Requirements: ..............................................................................................................4
3.6 Spare Parts Requirements ...................................................................................................................................4

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Sacramento Regional County Sanitation District
EchoWater Project
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 Reliability-Centered- Design
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1.0 Objective
The Reliability Centered Design (RCD) methodology, which takes its roots from Reliability
Centered Maintenance (RCM) principles, was motivated by the need to address overall system
functional performance and reliability, starting early in the design process. By identifying and
using more reliable components, simpler replacements, and easier inspections, RCD results in
more reliable and maintainable designs, thus minimizing maintenance requirements, and
optimizing system life-cycle costs.

The primary objectives of the RCD methodology are:

1. The integration of operations and maintenance requirements into the design process,
including incorporation of preventive and predictive maintenance strategies;
2. The implementation of a systematic approach to maximize process availability by
increasing asset reliability, operability and maintainability; and
3. The establishment of criticality-based decision making on asset redundancy and
spares inventory.
This document establishes the basic framework for implementing RCD in designs of the
projects comprising the EchoWater Project. The design consultants will be expected to use this
document as a guide in developing a design process that is based in RCD principles. Project-
specific RCD details will be developed by each design consultant based on the scope and
relevance of the design elements within each

2.0 Approach
A system is made up of series of integrated assets designed to perform a common function.
While all assets within a process are necessary, they do not all, necessarily, carry the same
functional criticality. Critical assets require a concomitant level of reliability and redundancy
designed into them to sustain their operational performance under most conceivable scenarios,
while other, less critical, assets may not receive the same level of redundancy. Similarly, the
maintenance strategies and spares inventories may be markedly different for assets with
differing levels of criticality and failure scenarios. The RCD approach focuses on maintaining
functional reliability through examination of critical assets, or features, which can disable an
entire function.

For example, an aeration system has many assets that make up the process, including aeration
blowers to provide the biological mass with oxygen, dissolved oxygen probes for controlling
the oxygen levels and a process control system for the entire function to perform as intended. If
a single blower fails, there is usually ample redundancy for continued satisfactory operation
and the restoration of the blower capacity. If a single dissolved oxygen probe fails, there is
ample time to troubleshoot and correct the problem before significant process impacts are
evident. However, the failure of an otherwise small feature in the process control system could
conceivably disable the entire aeration system. In this example, a reliable design would have
sufficient redundant blower capacity to respond immediately, and a thoughtfully designed and

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EchoWater Project
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 Reliability-Centered- Design
Implementation Guide
maintained process control system to sustain system operations under all conceivable failure
scenarios. The dissolved oxygen probe would be designed with overlapping sample areas and
adequate spares in inventory to sustain the operation.

Key features of the Program-wide RCD implementation approach are depicted by the template
shown below. As noted, each phase of the Program includes specific activities for application
of RCD- driven design. The approach also leads to development of maintenance strategies and
standard operating practices (SOPs) based on Reliability Centered Maintenance (RCM)
principles, and collection of relevant information for input into the Computerized Maintenance
Management System (CMMS).

RCD IMPLEMENTATION TEMPLATE

RCD Objective: Design, build and commission wastewater treatment process systems for reliable operation to
meet a specified level of system availability

PROGRAM PHASE

Planning and Basis of Design Design Construction and

Report Preliminary Design Detailed Design Commissioning
Identify process systems and Define system functions and Validate prior step RCD Validate/confirm RCM
primary system functions functional failures, specify conclusions and implementation requirements for relevance to
requiring RCD (RCD reliability, availability, steps in RCD Workshop #3. installed assets.
Workshop #1 with O&M maintainability and safety
staff). (RAMS) criteria. Perform RCM Analysis (use Perform baseline predictive
PdM strategies for maintenance testing (e.g.,
Develop guidelines and Develop project-specific commissioning and baseline vibration, IR, ultrasound, motor
procedures for RCD analyses. approach tied to design testing requirements). circuit analysis, corrosion, etc.).
milestones (info sources:
Incorporate appropriate RAMS data, risk acceptance Develop documents for Finalize/document O&M
requirements and guidelines in criteria, and P&IDs). implementing RCM results in policies.
the design consultant RFPs. CMMS (Maximo) and SOPs, etc.
Conduct RCD Workshop #2 Baseline (perform) all preventive
for FMEA analyses for system Train staff on RCM-based maintenance tasks in CMMS.
functions and functional maintenance recommendations.
failures. Develop preventive maintenance
job plans based on findings of
Identify critical assets and RCM analysis
single-point failures.
Coordinate all related documents
Identify asset redundancy and with assets in CMMS
strategic spare unit
requirements.

3.0 Expected Outcomes

When the P&IDs are substantially completed for each project, the RCD attributes will be
established for all functions deemed critical to a process through the application of a Failure
Modes and Effects Analysis (FMEA). An FMEA looks at all conceivable failure scenarios for
each function and identifies potential effects (or consequences) related to each failure. This
process reveals functional vulnerabilities through the identification of critical system

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EchoWater Project
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components. This leads to more logical, asset-criticality based, engineering decisions for the
attributes represented by the following figure and described in the paragraphs below.

3.1 Asset Reliability

While there are many factors that can contribute to or detract from asset reliability, asset
selection determines to a large extent how long an asset will remain in service and the
maintenance requirements to sustain the operational availability. Assets considered critical
through RCD will be evaluated to determine the likelihood of operational availability and the
maintenance requirements to sustain a reliable operation.

3.2 Process Availability

When assets are out of service for any reason, the process capacity is potentially impacted and
the operation can be at risk. Each critical asset will be evaluated to assure capacity can be
achieved to meet operational requirements. This attribute can be achieved through system
redundancy, spares inventory, or consideration of seasonal flow trends for a system-wide
maintenance approach.

3.3 Asset Maintainability

The system design will emphasize the ability of an asset to be repaired, restored and maintained
to a specified condition using prescribed procedures and resources. In addition, design
attributes will include easy accessibility for major and minor repairs. The design will document
the list of attributes and their purpose.

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Sacramento Regional County Sanitation District
EchoWater Project
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3.4 Preventive Maintenance Requirements
The design and asset selection will consider the cost of maintenance by evaluating the
preventive maintenance requirements. Low value maintenance should be recommended for
exclusion if it does not provide a meaningful benefit. All preventive maintenance requirements
including activities and frequencies will be developed by the design consultants and submitted
in a format consistent with the District’s existing CMMS.

3.5 Predictive Maintenance Activities

Based on the RCD analysis, predictive maintenance requirements will be recommended. The
frequencies and methodology should be based upon all failure modes evaluated. All predictive
maintenance requirements, including specific activities and frequencies, should be submitted in
a format consistent with the District’s existing CMMS program.

3.6 Spare Parts Requirements and Availability

Specific recommendations, including store stocking levels, for all spare parts for assets
considered operationally critical will be made. In some cases, complete spare units maybe
appropriate when the function of the asset cannot allow long outages. All spare parts stocking
levels will be based upon usage and parts availability.

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Sacramento Regional County Sanitation District
EchoWater Project
Z:\00. Program Management\A2.06 - Procurement Support\11 - PEPS\Review Comments\6 Attachment F - Reliability Centered Design Implementation Guide.docxJune 25, 2013