IEC TR 62010-2016 Analyser systems - Maintenance management《分析器系统.维护管理》.pdf

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1、 IEC TR 62010 Edition 2.0 2016-12 TECHNICAL REPORT Analyser systems Maintenance management IEC TR 62010:2016-12(en) colour inside THIS PUBLICATION IS COPYRIGHT PROTECTED Copyright 2016 IEC, Geneva, Switzerland All rights reserved. Unless otherwise specified, no part of this publication may be reprod

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10、ion or need further assistance, please contact the Customer Service Centre: csciec.ch. IEC TR 62010 Edition 2.0 2016-12 TECHNICAL REPORT Analyser systems Maintenance management INTERNATIONAL ELECTROTECHNICAL COMMISSION ICS 71.060.99 ISBN 978-2-8322-3684-0 Registered trademark of the International El

11、ectrotechnical Commission Warning! Make sure that you obtained this publication from an authorized distributor. colour inside 2 IEC TR 62010:2016 IEC 2016 CONTENTS FOREWORD . 5 INTRODUCTION . 7 1 Scope 9 1.1 Purpose 9 1.2 Questions to be addressed . 9 2 Normative references 10 3 Terms and definition

12、s 10 4 Classifying analysers using a risk based approach 15 4.1 General . 15 4.2 Safety protection . 17 4.3 Environmental protection 17 4.4 Asset protection 19 4.5 Profit maximisation . 19 4.6 Performance target . 20 4.7 Maintenance priority . 21 4.8 Support priority . 21 5 Maintenance strategies 21

13、 5.1 General . 21 5.2 Reliability centred maintenance (RCM) . 21 5.2.1 General . 21 5.2.2 Reactive maintenance . 22 5.2.3 Preventative or planned maintenance (PM) 22 5.2.4 Condition based strategy . 23 5.2.5 Proactive maintenance 23 5.2.6 Optimising maintenance strategy . 23 5.3 Management systems/o

14、rganisation . 24 5.4 Training/competency . 26 5.4.1 General . 26 5.4.2 Training needs . 26 5.4.3 Selecting trainees 26 5.4.4 Types of training 26 5.4.5 Vendor training 27 5.4.6 Classroom training . 27 5.4.7 Technical societies 27 5.4.8 User training 27 5.4.9 Retraining 28 5.5 Optimal resourcing 28 5

15、.5.1 General . 28 5.5.2 Equivalent analyser per technician (EQAT) calculation method 29 5.5.3 Ideal number of technicians . 29 5.5.4 In-house or contracted out maintenance 30 5.5.5 Off-site technical support requirement . 31 5.6 Best practice benchmarking 31 5.7 Annual analyser key performance indic

16、ator (KPI) review . 31 6 Analyser performance monitoring 32 6.1 General . 32 IEC TR 62010:2016 IEC 2016 3 6.2 Recording failures reason/history codes . 33 6.2.1 General . 33 6.2.2 Typical failure pattern 33 6.3 SPC/proof checking 35 6.3.1 Analyser control charting . 35 6.3.2 Control chart uncertaint

17、y limits 37 6.4 Analyser performance indicators . 38 6.4.1 Key performance indicators (KPI) 38 6.4.2 Additional analyser performance indicators 39 6.4.3 Points to consider in measurement of analyser availability . 40 6.4.4 Points to consider in measurement of operator utilisation 42 6.4.5 Points to

18、consider in measurement of analyser benefit value . 43 6.4.6 Deriving availability, utilisation and benefit measurement 43 6.4.7 Optimising analyser performance targets . 44 6.4.8 Analyser maintenance cost against benefit 48 6.5 Analyser performance reporting 48 Annex A (informative) Equivalent anal

19、yser per technician (EQAT) . 50 A.1 Part 1 Calculated technician number worksheet . 50 A.2 Part 2 Equivalent analyser inventory worksheet calculation methodology . 50 A.3 Part 3 Equivalent analyser inventory worksheet . 52 Annex B (informative) Example interpretation of control chart readings 57 Ann

20、ex C (informative) Determination of control chart limits by measuring standard deviations of differences . 59 Annex D (informative) Adopting a maintenance strategy 61 Annex E (informative) Examples of analyser cost against benefit and analyser performance monitoring reports 62 Annex F (informative)

21、Typical reports for analyser performance monitoring 67 Bibliography 69 Figure 1 Flow path detailing interrelationships of subject matter in IEC TR 62010 . 7 Figure 2 Generalized risk graph . 16 Figure 3 Failure mode pattern 24 Figure 4 Organisation of analyser functions . 25 Figure 5 Relative mainte

22、nance costs 30 Figure 6 Life cycle diagram 34 Figure 7 Reliability centred maintenance failure patterns . 35 Figure 8 Control charting diagram 36 Figure 9 Examples of analyser results 37 Figure 10 Example of control charting with linear interpretation 41 Figure 11 Deriving availability, utilisation

23、and benefit measurement . 43 Figure B.1 Example of accurately distributed control chart reading 57 Figure B.2 Example of biased control chart reading . 57 Figure B.3 Example of drifting control chart reading . 58 Figure B.4 Example of control chart reading, value outside warning limit . 58 Figure C.

24、1 Example determination of control chart limits by measuring standard deviations . 60 4 IEC TR 62010:2016 IEC 2016 Figure D.1 Determining appropriate maintenance strategy . 61 Figure E.1 Achievable availability against manning 66 Figure E.2 Achievable benefit against manning 66 Figure F.1 Uptime in

25、Plant “A“ 67 Table 1 Typical application of elements in the risk graph 17 Table 2 Best practice availability targets 20 Table 3 Example agenda for a KPI review meeting 32 Table C.1 Example distillation analyser data for determining control chart limits 59 Table E.1 Analyser costs versus benefits . 6

26、2 Table E.2 Analyser technician resources 64 Table E.3 Technician skill and experience data 64 Table E.4 Variation of availability with manning levels and overtime 64 Table E.5 Sitewide average analyser data . 65 Table F.1 Results of analyser performance in Plant “A“ 68 IEC TR 62010:2016 IEC 2016 5

27、INTERNATIONAL ELECTROTECHNICAL COMMISSION _ ANALYSER SYSTEMS MAINTENANCE MANAGEMENT FOREWORD 1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising all national electrotechnical committees (IEC National Committees). The object of IEC is to p

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38、s to prepare International Standards. However, a technical committee may propose the publication of a Technical Report when it has collected data of a different kind from that which is normally published as an International Standard, for example “state of the art“. IEC TR 62010, which is a Technical

39、 Report, has been prepared by subcommittee 65B: Measurement and control devices, of IEC technical committee 65: Industrial-process measurement, control and automation. This second edition cancels and replaces the first edition published in 2005, This edition constitutes a technical revision. This ed

40、ition includes the following significant technical changes with respect to the previous edition: a) addition of data, examples and clarifications. EEMUA Publication 187: 2013 Analyser systems: A guide to maintenance management, has served as a basis for the elaboration of this Technical Report, with

41、 the permission of the Engineering and Equipment Users Association. 6 IEC TR 62010:2016 IEC 2016 The text of this Technical Report is based on the following documents: Enquiry draft Report on voting 65B/990/DTR 65B/1063/RVC Full information on the voting for the approval of this Technical Report can

42、 be found in the report on voting indicated in the above table. This document has been drafted in accordance with the ISO/IEC Directives, Part 2. The committee has decided that the contents of this document will remain unchanged until the stability date indicated on the IEC website under “http:/webs

43、tore.iec.ch“ in the data related to the specific document. At this date, the document will be reconfirmed, withdrawn, replaced by a revised edition, or amended. A bilingual version of this publication may be issued at a later date. IMPORTANT The colour inside logo on the cover page of this publicati

44、on indicates that it contains colours which are considered to be useful for the correct understanding of its contents. Users should therefore print this document using a colour printer. IEC TR 62010:2016 IEC 2016 7 INTRODUCTION This document covers best practices for the maintenance of on-line analy

45、sers. Analysers are used in industry to measure variables which significantly contribute to safety, environmental, asset protection and profit maximisation. Maintenance organisation, prioritising of maintenance effort, maintenance methods, correct resourcing, performance monitoring and reporting all

46、 play an important role in successful application of on-line analysers. The ultimate effectiveness of the contribution of on-line analysers is measured by the ability to perform their functional requirements upon demand. This document gives guidance on performance target setting, strategies to impro

47、ve reliability, methods to measure effective performance, and the organisations, resources and systems that need to be in place to allow this to occur. The various subjects covered in this document are discrete items and can appear unrelated in the overall scheme of analyser maintenance procedures a

48、nd strategies. The following flow path in Figure 1 ties the clauses together in a logical sequence of approach. Figure 1 Flow path detailing interrelationships of subject matter in IEC TR 62010 This document provides a mechanism by which the criticality of an analyser can be determined by means of a

49、 risk assessment. The risk assessment is based on consideration of the consequence of the loss of the analysis to the operation of a process unit, or group of process units, personnel/plant safety and the environment. Determination of a criticality rating for the analyser allows target values for reliability to be set for each criticality classification and prioritisation for maintenance and support. Such approaches are covered in Clause 4. IEC