Were we somehow smarter in 1984? Gulf Oil Spill Continued

With the number of comments and responses to the two recent articles I posted on this event I could not help going back to books on Reliability Basics. One of my favorite books for reference is "Reliability Toolkit: Commercial Practices Edition" released by the Reliability Analysis Center out of Rome, NY. While the book was released in 1988 the section I reference has been available to the public since 1984.

It seems that nearly every day I read an article that refers to the failure of the BOP (Blowout Preventer) Valve, with all that has been written about the BOP Valve one would have to believe that this was a critical item in regard to this process. Keeping this in mind I pulled out my favorite old textbook and took a look at what the research funded our tax dollars recommended in regard to Critical Item Reliability. While I admit to being a bit of a geek, I found it quite interesting that we had a plan of recommendations in place to deal with critical items that dates back twenty-six years.

According to the Reliability Toolkit, a critical item is a component whose failure can significantly affect safety, operating success or repair costs. (I would guess that in today’s world we could add environmental impact to that statement) It goes on to say that "Critical items include high valued components, new technologies, limited life items, single source or custom components and single failure points where failure cause a total loss of operating capabilities.

Wow! I don't claim to have a vast knowledge of oil platform components but I would say that the above paragraph clearly describes the component we have been reading about the last four weeks.

Going back to the book, the next section lists criteria for "What Causes Critical Items"

1. Use of necessary advanced technology or processes
2. Marginal component capability in adverse conditions
3. Low part or product reliability
4. Failures that cause other components to fail
5. High cost custom designed parts
6. Limited or single source vendors for critical applications
7. Severe Safety and Environmental Impact

I don't know about you but I'm beginning to see some red flags here so I elect to read on to learn about "Critical Item Control Checklist". In this section we learn about major concerns and recommended actions. I would have to say that if I had a critical item in my design, I would want to take a close look at this check list.

The first major concern asks the question; "Has a failure mode analysis been considered for critical items?" The recommend action is to "Develop failure mode identification procedures so that control of the item can be invoked". That sounds a lot like Reliability Centered Maintenance to me!

Concern - Have compensating features been considered for the design?

Action - Consider features like safety margins, overstress testing or fault tolerance

Concern - Have reliability improvements been considered?

Action - Evaluate special stress tests, checkouts, vendor quality procedures, alternate components and operating duty cycles.

Concern - Does the operating environment strain or exceed design limits?

Action - Include fault tolerant designs, safety margins and external changes

Concern - Does failure of the item jeopardize safety or does a single point of failure disrupt mission performance?

Action - A list of critical items and personnel responsible for controlling and reviewing procedures must be established!

Let's just say that it has been an interesting afternoon of reading and affirmation; what I learned about reliability at RIT several years ago still applies nearly everything I do today. When it comes to reliability the tools and techniques made available by some very bright people are right at our finger tips. The experience and knowledge of the people who install, operate and maintain this equipment so often ignored hold the answers making sure events like these never happen to begin with.

I find it hard to believe that we were smart enough instruct people how to identify and address critical items in 1984 and in the year 2010 we quite simply were not smart enough to read and act.