IEC TR 62010:2016
(Main)Analyser systems - Maintenance management
Analyser systems - Maintenance management
IEC TR 62010:2016(E) provides an understanding of analyser maintenance principles and approaches. It is designed as a reference source for individuals closely involved with maintenance of analytical instrumentation, and provides guidance on performance target setting, strategies to improve reliability, methods to measure effective performance, and the organisations, resources and systems that need to be in place to allow this to occur.
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IEC TR 62010 ®
Edition 2.0 2016-12
TECHNICAL
REPORT
colour
inside
Analyser systems – Maintenance management
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IEC TR 62010 ®
Edition 2.0 2016-12
TECHNICAL
REPORT
colour
inside
Analyser systems – Maintenance management
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 71.040.01 ISBN 978-2-8322-3684-0
– 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 definitions . 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
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/organisation . 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
5.5.1 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 indicator (KPI) review . 31
6 Analyser performance monitoring . 32
6.1 General . 32
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 uncertainty 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 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 analyser 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
Annex 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) 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 maintenance 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 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.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 Plant "A". 67
Table 1 – Typical application of elements in the risk graph.
...
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