Risk-based maintenance policy selection using AHP and goal programming

Maintenance policy selection is a multiple criteria decision making. The criteria often considered are cost and reliability of maintenance. There has been a growing interest in using risk of accidents as a criterion for maintenance selection. This paper presents an approach of maintenance selection based on risk of equipment failure and cost of maintenance. Analytic hierarchy process (AHP) and goal programming (GP) are used for maintenance policy selection. A case study in a benzene extraction unit of a chemical plant was done. The AHP results show that considering risk as a criterion, condition based maintenance (CBM) is a preferred policy over time-based maintenance (TBM) as CBM has better risk reduction capability than TBM. Similarly, considering cost as a criterion, corrective maintenance (CM) is preferred. However, considering both risk and cost as multiple criteria, the AHP–GP results show that CBM is a preferred approach for high-risk equipment and CM for low risk equipment.     

基于物联网技术的设备状态维修安全管理研究

随着物联网(IOT)技术的不断发展,状态维修(CBM)理论逐步运用于设备安全管理中。通过构建基于物联网技术的设备状态维修安全管理体系,建立CBM预测决策模型,并通过设备轴承状态维修的例证来说明模型的可用性。结果表明:设备实现物联网后,基于物联网技术的设备状态维修安全管理是科学可行的,便于设备的维修管理,提高设备的安全工作寿命。     

Risk-based maintenance (RBM): a quantitative approach for maintenance/inspection scheduling and planning

The overall objective of the maintenance process is to increase the profitability of the operation and optimize the total life cycle cost without compromising safety or environmental issues. Risk assessment integrates reliability with safety and environmental issues and therefore can be used as a decision tool for preventive maintenance planning. Maintenance planning based on risk analysis minimizes the probability of system failure and its consequences (related to safety, economic, and environment). It helps management in making correct decisions concerning investment in maintenance or related field. This will, in turn, result in better asset and capital utilization.

This paper presents a new methodology for risk-based maintenance. The proposed methodology is comprehensive and quantitative. It comprises three main modules: risk estimation module, risk evaluation module, and maintenance planning module. Details of the three modules are given. A case study, which exemplifies the use of methodology to a heating, ventilation and air-conditioning (HVAC) system, is also discussed.     

Using data mining technology to explore causes of inaccurate reliability data and suggestions for maintenance management

Reliability data reflects equipment safety and provides a reference for setting inspection period, thereby serving as crucial information for the implementation of equipment integrity management policies. The calculation foundation of reliability data is maintenance records of adequate data quality. However, maintenance records of doubtful quality are common. Despite excluding poor quality recodes and using only the remaining maintenance recodes to calculate the reliability data, the calculated results generally lack a sufficient degree of confidence. This study applied data mining technology, including quality metrics, the association rule, and clustering, to explore the cause of low-quality maintenance data. The results revealed that the low data quality of maintenance records was due to ineffective maintenance policies, the low integrity of key system columns, nonadherence to the policy, and misunderstanding of column definitions. The proposed method successfully identified the causes of low-quality maintenance records. By incorporating the method into the function module of a CMMS, operators can equip the system with self-diagnosis, self-supervision, and continuous optimization functions.     

基于动态信息技术的设备主动维护预知平台的设计

石化企业规模大、设备种类繁多且分布广,为规范设备的管理流程、提高设备的管理水平及设备可靠性,提高企业的经济效益和安全性,建立了基于Oracle数据库与RBI和RCM技术的设备预知维护信息平台,并结合RBI及RCM技术信息输入与安全评价方法,实现设备的故障预知及维护规范。该平台与石化的生产运行管理相结合,可实现设备的信息化管理,在及时排除设备故障隐患的同时,保障设备的正常运行,为改善企业生产安全现状和提高设备管理水平,提供了新的方法。     

煤矿安监系统数据通信可靠性的研究

煤矿安全生产监控系统的通信网络可归纳为单分站单设备、单分站双设备、双分站单设备和双分站双设备几种组网模式,通过对其任务可靠性和基本可靠性进行比较分析,综合考虑任务完成概率和维护成本两方面的要求,提出了双分站,局部(高故障点处)双设备的组网模式,以期有效提高通信网络的系统可靠性。     

A structured approach to improved condition monitoring

Improved condition monitoring of production equipment enhances process safety and the ability to prepare maintenance, to perform maintenance efficiently, and thus reduce downtime and associated costs. Currently, there is a somewhat limited focus on condition monitoring of static equipment, such as heat exchangers and separators. This is due to organizational barriers, available technology, and budget constraints at management level. The objective of this article is to present a three-step approach that supports the decision-maker in the selection of condition monitoring methods for production equipment. The approach is exemplified by a heat exchanger and the focus is on condition monitoring in the operational phase, including assessment of life cycle costs (LCC).     

Development of a risk-based maintenance (RBM) strategy for a power-generating plant

The unexpected failures, the down time associated with such failures, the loss of production and, the higher maintenance costs are major problems in any process plant. Risk-based maintenance (RBM) approach helps in designing an alternative strategy to minimize the risk resulting from breakdowns or failures. Adapting a risk-based maintenance strategy is essential in developing cost-effective maintenance policies.The RBM methodology is comprised of four modules: identification of the scope, risk assessment, risk evaluation, and maintenance planning. Using this methodology, one is able to estimate risk caused by the unexpected failure as a function of the probability and the consequence of failure. Critical equipment can be identified based on the level of risk and a pre-selected acceptable level of risk. Maintenance of equipment is prioritized based on the risk, which helps in reducing the overall risk of the plant.The case study of a power-generating unit in the Holyrood thermal power generation plant is used to illustrate the methodology. Results indicate that the methodology is successful in identifying the critical equipment and in reducing the risk of resulting from the failure of the equipment. Risk reduction is achieved through the adoption of a maintenance plan which not only increases the reliability of the equipment but also reduces the cost of maintenance including the cost of failure.     

虚拟仪器技术在特种设备安全检测领域中的应用研究

笔者将虚拟仪器技术应用到矿用绞车、起重机、电梯等特种设备的安全检测、运行状态监测及设备故障诊断 ,通过LabVIEW图形化编程语言编制的软件系统 ,实现信号运算、分析、处理 ,从而实现各种测试。该技术的研究与开发是电子技术、计算机技术、检测技术、机械工程技术的有机结合 ,是现代设备安全检测技术的一次创新。根据河南省经贸委组织的技术鉴定结论认为 ,该项目成果填补了国内特种设备安全检测方面的空白 ,具有国内领先水平 ,对保障人员的人身安全 ,提高设备运行的可靠性有着重要的社会意义和经济价值     

Study and application of Reliability-centered Maintenance considering Radical Maintenance

Radical Maintenance (RM) takes the root causes of failures as executive objects to make maintenance decisions. A Root Cause Analysis (RCA) is carried out on the function failure of equipment to perform RM and to create a maintenance plan using the combined methods of Failure Mode, Effects and Criticality Analysis (FMECA), and Fault Tree Analysis (FTA). Evaluation criteria and matrixes of criticality are used to evaluate the criticality level of failure modes. Moreover, Minimum Cut Sets (MCS) and importance calculation are applied to analyze the fault tree quantitatively. Based on our research, the concept and the analysis process of Reliability-centered Maintenance (RCM) considering RM are proposed and then applied to an actual engineering project in the petrochemical industry. The results of the application are presented through a maintenance strategy based on the project analysis by establishing the evaluation criteria and matrixes of criticality for petrochemical rotating machines and a fault tree of compressor vibrations. The direct causes of the induction of vibration faults in rotating machinery are classified according to the fault mechanism and frequency domain features in this paper. The research shows that using RM in the traditional RCM can help assign maintenance resources rationally and improve the quality of maintenance strategies.     

船舶设备事故中的人为因素分析与控制研究

根据设备维修系统设备维修的人为失误环节和船员失误分析模式以及轮机管理人员具有明感知设备的运行状态、隐感知设备的故障趋势等特点,实施有效管控措施。结合航运市场特性,基于设备可靠度,提出风险性和经济性的维修方式策略,可大幅提高航运公司的安全航运水平和经济效益。利用维修系统的信息流,建立了船舶设备维修管理信息系统,整合设备运行状态、船员的综合素质状态及组织管理信息,以便于阻断导致事故发生的事件链,提高航运公司的船舶运输安全。     

特种机电设备远程监控若干关键技术研究

以可能对城市公共安全造成威胁的机电类特种设备为主要研究对象,探讨对特种设备的在线监测和控制问题,以期提高设备的监测和控制水平,减少和预防事故的发生。根据远程监控系统的基本要求并考虑到实际情况,构造了一种以Internet为骨架、多种异构网络并存的特种机电设备远程监控系统网络拓扑结构模型,并对其中若干关键技术进行研究。重点讨论数据采集、网络技术、故障诊断技术、数据处理技术和数据安全技术,给出了具体的实现措施。部分技术在实践中得到应用,使用效果良好,实现了对特种设备的安全运行监控和故障的预测预报。笔者研究的课题对建立区域性大型机电设备的远程监控、故障诊断和安全管理系统,同样具有重要的现实意义。     

Reliability and availability modeling of Subsea Xmas tree system using Dynamic Bayesian network with different maintenance methods

Subsea Xmas tree is a vital equipment for offshore oil and gas development. Aiming at the fault mode of subsea Christmas tree system under production conditions, the fault tree of subsea tree system was established, which was transformed into Dynamic Bayesian network, and the reliability and availability of subsea tree system with different repair states are quantitatively analyzed. In this paper, the DBNs are partially verified by the method based on three axes. The results show that the reliability of subsea vertical tree system is slightly higher than that of subsea horizontal tree system. After repair and maintenance, the performance of subsea tree system has been significantly improved, and the improvement of the system performance by preventive maintenance is more obvious. Compared with the perfect repair, the performance of the system with imperfect repair is not significantly reduced. Compared with perfect repair & preventive maintenance, the performance of the system with imperfect repair & preventive maintenance is slightly reduced. In addition, the influence of failure rates and degradation probability on reliability and availability is analyzed. By comparing the influence of failure rates on the system performance of non-maintenance and maintenance, it is found that the change of failure rates has the greatest influence on the reliability and the least influence on the availability of perfect repair & preventive maintenance. By comparing the performance of each component in the subsea tree system, it is found that the failure rates has the most obvious influence on the chock module, and gate valve and tree cap have the most significant influence on the reliability of the system. In order to improve the reliability of subsea tree system, it is necessary to improve the reliability of chock module, gate valve and tree cap.     

污水处理厂设备维护管理优化研究

以JL污水处理厂设备管理优化过程为例,充分吸取LCC,TPM中的先进思想,以设备运行可靠性及设备维护经济性为追求目标,建立了设备管理优化体系。流程体系上,通过建立作业指导文件,建立标准化维修程序,对于操作过程及时进行记录,建立可视化、可追溯的管理方法;指标体系上,根据设备重要性及运行状况,确定设备风险指数,分级管理;建立控制指标,并动态调整;管控体系上,建立设备“户口”,对设备的维护、保养、使用等信息进行全面登记;考核设备维护的全面性、及时性、可靠性、合规性;重视设备维护的预计与预警;技术体系上,通过设备监测仪器的使用,对设备运行状况定量化。通过不断推进设备预防性维护工作,设备完好率不断提升,仪表完好率从2016年的97.34%,96.55%水平,分别提升至99.08%,98.72%;维护费用也保持在较低水平,检修费与资产比例在实施的前两年分别降至1.49%,0.85%,实现了污水处理厂节能降耗及运行可靠性的强化。     

双护盾TBM不良地质段卡机脱困技术研究*

为确保双护盾TBM在不良地质中遭遇卡机事故时能快速安全脱困,依托某引水隧洞工程,研究双护盾TBM在断层破碎带段及软岩大变形段遭遇的卡机事故原因以及采用超前大管棚支护、环形扩挖法的技术难点。结果表明:双护盾TBM在断层破碎带段采用超前大管棚支护及软岩大变形段采用环形扩挖法,均能解决卡机事故问题,使其成功脱困。研究结果可为类似TBM卡机脱困提供工程借鉴。     

基于互联网+的轨道交通动力设备安全管理系统的研究

根据我国轨道交通设备安全管理的需求,提出基于互联网+的轨道交通动力设备安全管理系统平台的框架,运用J2EE开发工具,采用嵌入式高速数据采集技术、故障诊断技术,构建形成集成化、网络化和信息化的轨道交通动力设备安全管理系统。完善智能的设备安全管理系统,能有效提高轨道交通动力设备的安全监管力度,保障设备安全。     

Development and application of equipment maintenance and safety integrity management system

Equipment management in process industry in China essentially belongs to the traditional breakdown maintenance pattern, and the basic inspection/maintenance decision-making is weak. Equipment inspection/maintenance tasks are mainly based on the empirical or qualitative method, and it lacks identification and classification of critical equipment, so that maintenance resources can’t be reasonably allocated. Reliability, availability and safety of equipment are difficult to control and guarantee due to the existing maintenance deficiencies, maintenance surplus, potential danger and possible accidents. In order to ensure stable production and reduce operation cost, equipment maintenance and safety integrity management system (MSI) is established in this paper, which integrates ERP, MES, RBI, RCM, SIL and PMIS together. MSI can provide dynamic risk rank data, predictive maintenance data and RAM decision-making data, through which the personnel at all levels can grasp the risk state of equipment timely and accurately and optimize maintenance schedules to support the decision-making. The result of an engineering case shows that the system can improve reliability, availability, and safety, lower failure frequency, decrease failure consequences and make full use of maintenance resources, thus achieving the reasonable and positive result.     

基于Bayesian网络的常减压装置设备故障概率分析

为分析影响常减压蒸馏装置平稳运行的设备失效模式及故障部件,基于1 151条设备故障数据,采用Bayesian网络分析方法,分别对离心泵、压缩机、电动机构建基于Bayesian网络的设备故障概率分析模型,分析故障部件、失效模式、故障后果之间的定量概率关系。研究结果表明：离心泵、压缩机、电动机停运的关键致因部件分别为轴承箱密封故障、活塞环故障、轴承故障,同时得到导致设备停运的故障部件敏感度排序。研究结果有助于提高设备故障风险防范及检维修工作效率,同时可为备件优化方案提供思路。     

企业供电系统安全可靠运行的探讨与实践

介绍了金川公司内部供电系统的概况,对供电系统的故障、事故类型及原因进行了简要分析,对降低故障率、减少一般事故、杜绝重大事故和人身伤亡事故的对策进行了探讨和实践。从企业的人──机──环境的角度提出：①依靠科技进步,提高系统装备安全可靠性;②加强管理,使员工具有较强的安全意识和行为。这两点是供电系统安全可靠运行的两个同等重要条件。     

基于802.11n无线传感器网络的巷道人员定位技术研究

针对现阶段矿井人员定位系统定位精度低、成本高、可靠性差等问题,提出了一种基于802.11n无线传感器网络技术的真三维人员定位系统,该系统根据功能特征划分为现场设备管理层、系统运行监控层和地面监控管理层。工作时,定位分站将移动节点通过无线网络传输过来的位置坐标信息通过RS-485总线传输到光纤冗余网中,紧接着将位置坐标信息通过CAN现场总线传输到地面数据服务器内进行解压、分析处理和可视化显示。实验结果表明:当加权因子k取1.1时,该系统在井下巷道测试环境中的平均误差仅为1.15 m,且长期运行无故障,具有较高的定位精度和可靠性,降低了成本。