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Electricity production and the power plants are the assets of the country,
which make the backbone of the country strong by providing the citizens the
facility to live in. The efficiency of the power plant is largely dependent
upon the available resources. If the available resources were present in large
quantity, the electricity produced would also be more otherwise not.
Electricity can be produced in many ways. The input material and the way
electricity is produced could be different but the output is same. Each process
of the production of the electricity has its own advantages and disadvantages
and the efficiency of the process varies from process to process. The way of
the process could be from wind, solar, thermal, air etc. Wind energy is used
for the production of electricity; similarly, solar energy is the unlimited
source of energy, which is also used these days to cope up the increasing
demand for the electricity.
Heat energy is also used to make the electrical energy to be
used as a power. This power is used for many purposes. Heat energy is very
useful for the production of the electricity. Technology advancement plays a
vital role in the overall success. There are many ways for the power
generation.
Power plants have their own significance in the life. 90 %
of the tasks are dependent upon the
Subsequently, the power plants play has great importance for
us as they are a major source of producing energy to meet of daily based energy
need. However, every machinery has its own life, therefore, to maintain its
effectiveness; there is required maintenance that should be provided for a specific
period. Considering this aspect, the following writing is aimed to create
understanding about the importance of reliability-centered maintenance for
Power plant (S. KHALID, 2000).
What is Reliability Maintenance
The reliability centered maintenance ensures that all the
manufacturing and production systems are operating in a safe and reliable
manner. Reliability maintenance also provides assistance and support in the
functions of production. However, the core purpose of reliability maintenance
is to attain the desired output by implementing the cost-effective strategy
(Mian, 1999).
It was a misconception in the past that in compels system
every component has a right age after which it requires to be repaired or
renovated to ensure the effective functioning of the complex system. Schedule
maintain program was also based on this thinking. However the meditation of
this maintaining program when the Boeing 747 incident took place in the 1960s
following the same preventive maintenance program (Idhammar, 2005).
However, the formal definition of the Reliability centered
maintenance has beam presented by the Society of Automotive Engineers. The SAE
has developed a slandered criteria for the implementation of the SAE JA-1011.
However, to define the comprehensive approach of RCM process, seven basic
question being asked. Following are these seven questions developed by the SAE
(Dekker, 2005):
In the present operating context, what are the function of an asset and its performance standard?
What is the way in which the assets can full fill or fail to
perform its function appropriately?
What are the possible causes of function failure?
What is the consequence of the failure of each function?
How does each failure matter?
How the prediction or prevention of failure of each function
can be made?
If no suitable proactive task is found that what should be
done?
Hence these seven question together make a systemic process
through which the maintenance requirement of a physical asset can be determined
in its operating context. The process of accessing a physical asset's
maintenance requirement in its operational context is named as Reliability
Centered Maintenance.
At the first step of RCM process, the function of each asset
is defined in its operating context along with the desired performance
standard. At the second step, the possible failure is identified which might
hinder the function of the respective asset. The third sept is to identify the
causes of each functional failure such as the event responsible for the failure
of the function. The event that contributes toward the functional failure of an
assist is called failure mode. At the fourth step of the process, all the
effects of the failure are listed and the consequences of the failure are
described at the system level. These consequences are further classified in to
for categories which are the following (Smith, 1993):
Consequences of hidden failure
Consequences of safety and environment
Consequences of operations
Non-operational consequences
All the failures do not cost equally, therefore the
identification of consequences of each failure enables the organization to set
its priorities accordingly. After the completion of the fourth step, the RCM
has huge information about the operations of the system along with the causes
and consequences of each functional failure. The final step of this process
involves the selection of the maintenance task for detecting or preventing the
failure. However, at the step, only effective and applicable tasks are
selected. In this way, the RCM process can be utilized for creating a
cost-effective strategy of maintenance while addressing the leading causes of
equipment failure (Ribrant & Bertling, 2007).
2. BACKGROUND of Reliability Centered Maintenance for Power
Plant
The main motive and objective of this paper are to discuss a
reliability-centered maintenance program (RCM) for Rabigh Operation Maintenance
Company (ROMCO) risk critical elements, which were achieved through the SAP
System results. Safety system was the base in the selection of those risk
critical elements, which means those risk critical elements make the power plant
system to accomplish all the safety functions and if these components fail
safety system challenges may initiate.
The purpose of this paper is to make a deep understanding of
the maintenance of the power plants that are reliable. The maintenance of the power
plants is never an easy task to do. The teams of engineers always work hard to
provide the benefits to the other people. The plant has the capacity to produce
the electricity in Mega Watts. These requirements are being met by the
specialized engineers.
First of all, any source, say water is made to fall onto the
turbine blades and then the mechanical energy is produced due to which the
blades of the turbine start to rotate and finally the mechanical energy is
being converted into the electrical energy.
Plant maintenance could be from any part. It may be the
maintenance of the single part of the plant or the whole plant maintenance. The
plant maintenance of the complete plant requires the serv8ices of many
professionals. The complete overhauling is done.
RCM is a technique, which is done to protect the equipment
from being failed. It is a technique for doing the maintenance of the overall
plant. A complete maintenance is done with the help of the RCM technique which
is used to make the equipment to work efficiently without any loss. The aim of
this writing is to give the deep understanding of the fact about how to save
the equipment from failure. Hence, it is a failure analysis technique. Faults
within the system are analyzed completely. Methods are sorted out for the
application of the maintenance techniques. Sometimes non-destructive testing
techniques are also applied to the plant to detect the destruction caused by
the different reasons. These testing techniques are very helpful for the
detection of faults. Those faults, which cannot be seen from the naked eye,
made be visible with the help of the non-destructive testing technique.
Safety is of paramount importance in the daily life. All the
rules of the safety must be followed to protect the personnel working there and
the assets. Safety can decrease the rate of failure analysis. If the rules and
regulations of the safety of the plant are being followed properly, the need of
the RCM can also be reduced. The need for the maintenance comes where there is
any faulty part present or the efficiency of the plant is reduced. If the
machine is get chocked, or there is some inaccuracy in the working of the
machinery, the RCM maintenance is applied to fix up the things.
Reliability-centered maintenance can be done on the equipment as present below.
Steam turbine
Gas turbine
Water steam cycle
Water treatment plants
Boiler system
Cooling water system
The recovery system of the boilers
Evaporators of the plant
Gas operated plant
Preventive techniques of Reliability Centered Maintenance
for Power Plant
Preventive measures are taken to avoid the failure
techniques. Initially, failure is detected along with its type to check the
damage of the material. The maintenance of the RCM is usually completed in 6
months. That is why during this time, the plant is closed, and only the
maintenance is done to fix up the things.
There are many types of preventive maintenance techniques that
are used for the usefulness of the many things. All of the techniques have the
different functions to perform. Some types are using the infrared radiation to
detect the fault or the destructing. The defected parts of the plant are being
separated to treat for further use. Some other types of the maintenance, which
use the radioactive materials to detect the fault, are also there. Many of the
fault tracing tests are also done and the material is passed through the beam
of rays, which a point out the area where there is a little fault or the
structure is, little broken. A little fault in the machinery can do the biggest
destruction. That is why the engineering is applied to detect the faulty
materials to detect the materials under consideration.
Coal-based power plants are also used for this purpose.
Auxiliaries are also required to make the plant more suitable for the
generation of the electricity. The more the plant is efficient, the more
electricity will be generated. RCM is the latest technique for the maintenance
of the plant, which is producing the electricity. The optimum maintenance of
the plant is being done by this technology. This is the latest technology that
is introduced in the new time.
Safety and improvement in plant availability may be achieved
by the RCM of these components. RCM of these components may also reduce the cost
of maintenance of the components. At present time, the reliability-centered
maintenance is in the process of ROMCO. Accordingly, this paper may help the
department of maintenance to provide guidance and help for the establishment of
RCM program for the risk critical elements that is expressed for the effective
reliability qualities of each of the domains. The main and the only objective
of RCM is to provide an effective set of criteria for the investigating the
components which are considered to be the risk critical components. The
objective and purpose are based upon risk.
This would be helpful in understanding which components are
risk critical and which components are not. In the scope of RCM program only
risk critical components are included. The RCM which is proposed in this paper
is only applicable on a portion of the total plant maintenance program. The
parts and types of equipment should also continue to receive maintenance which
is not described in this paper. The utility of the RCM program will not prevent
other activities of maintenance. The proper maintenance of other equipment is
also considered essential.
Initially, the maintenance was done to make sure that there
is any new opportunity available for the consideration. All the maintenance was
done to devise the new ways of the checking of the defects in the operation.
But now, the strategy is changed a bit. Now people are more focused towards the
economical maintenance and the failure analysis mode. The new technology and
the processes are now considering these ways to protect the equipment from
being failed. RCM is the new technology, which is not very much common in all
the fields. It is considering its job effectively in the detection as well as
the maintenance of the field.
The domestic needs of electricity are provided by generation of electricity. In the recent times, 65% of the electricity is provided by the steam turbines and fossil fuels. Nearly 30 desalination plants are provided by the Saudi government. The consumption rate of energy is 20% of the total energy consumption. Renewable energy sources are required to fulfill needs and SAP is the plant of electricity production. The production of electricity depends on the environmental concerns. The transmission and distribution of electricity for the customers are concerns of SAP (Demirbas, Hashem, & Bakhsh, 2017).
Basing upon the above given description the RCM program thus includes two major components. First is to investigate risk critical components and the other domain is getting the information about essential maintenance activities. The application of the top level RCM program is illustrated in the figure 1-1. First step and the overall process are risk focused while for the individual components the program is reliability focused. As discussed earlier the first step is to identify if the component is risk critical or not. If a component is not risk critical it will not be included in the components of the RCM program. If the component is proved to be risk critical then it will be included into the RCM program (Mian, 1999).
For the identification of the risk critical component the process begins with the description of the functions which should and must be performed for the safe operation of the power plant. Furthermore, the identification of systems that gives proper safety function including the components that enable each system to perform safety function and mitigation of accidents are included in the next step. After that the support systems for the necessary system which provides proper safety functions and the elements which enable theses support system are identified and information about these components is collected (Mian, 1999).
Reliability centered maintenance can also determine normally
operating systems and the components that could initiate and start the accident
which may cause safety challenges.
After the process of determining the risk critical
components RCM program gets the information about which activities of
maintenance are needed to make sure the proper working of those risk critical
components which were identified. The techniques evaluate the mode of failures
of these risk critical components in the first step and collects the
information about maintenance activities required to protect against the
failures and after that these components are to be included in the RCM program.
The following pic shows the proposed methodology of using RCM for Power plant.
3. GOALS of Reliability Centered Maintenance for Power Plant
The goals of the RCM project is to make the power plant
error free to make it more productive. The purpose of these goals is to make
sure that the RCM maintenance is up to the mark. How effective is this
maintenance as this is the new technique, so the comparison must be made to
draw the conclusion between the conventional technology and the latest
technology to make the evaluation of the process? the goals are also defined to
check if there is the loss or the profit due to this type of maintenance. How
much investment is being returned and how many ways can be there to make this
technique a worthwhile. How much is this technique effective in the reduction
of the failure of the equipment that is being caused?
The goals of the maintenance of the power plant are mainly
related to the fact that efficiency of the plant is related to the source. The
source is mainly related to the economics and the cost and the availability of
it. It is also related to the maintenance of the whole plant to make it more
feasible. This maintenance is also related to the feasibility check of the
plant due to which it is said that the plant is ready for the production of the
electricity to make it worthwhile. The power plants are designed for the
feasibility analysis. If the production of the electricity is more in the
demand, then it can be said that the utilization of the electricity is also in
the good range.
To keep equipment’s efficiency high, reduce failure rate,
reduce the cost, labor, and tools.
4. RESEARCH QUESTIONS of Reliability Centered Maintenance
for Power Plant
How is RCM an effective mode maintenance for a Complex
system like Power Plant?
Does RCM have the capacity to enhance or maintain the
effectiveness of the Power Plant's functionality?
How could RCM be used to enhance the return on investment?
Does RCM be effective in reducing failure system of complex
systems?
5. THE STATEMENT OF PURPOSE of Reliability Centered
Maintenance for Power Plant
The major power plants have a lifespan, therefore, after a
certain time, their working efficiency started to decrease. Considering this
issues, there need to provide some proper maintenance to continue the
functionality of the plant in an effective manner. Subsequently, the in the
following wring, it is aimed to use recently developed advanced engineering
techniques for the maintenance of the power plant. Considering this aspect, it
is aimed to use the advanced Reliability Centered Maintenance to enhance the
maintain the efficiency of the equipment, reduce the failure risk, cost and
manpower for the power plant project. This approach is aimed to maximize the
return on investment and reduce the plausible uncertain expense due to the
failure of the plant operation.
The significance of the study of Reliability Centered
Maintenance for Power Plant
It is considered a very important topic for the improvement
in the field of the maintenance of the plant. It can be said that without the
study of the learning techniques of these models and processes for the power
plant is necessary to bring the change in the field so that the error can be
minimized and the production of the power plant can be enhanced.
If the research is not done on this subject, then
conventional methods will be used which are only targeted for the fault
detection without considering the cost of the overall plant. Hence, it provides
a good topic to research for the further usage of the process. to cope up the
need of the increasing population of the human world, the power plant should be
capable enough to produce enough power so that there is no deficiency.
The scope of the study of Reliability Centered Maintenance
for Power Plant
New ideas are being generated from the RCM technique and the
old methods that are not feasible enough should be replaced with the new ideas
that are more productive. This will give the opportunity to provide the new
ideas and ways that can lead towards the generation of more power that will
cope up the demand of the today world. for the consideration of the future
demand, the more ways can be learned that can lead to the success of the plant.
New ideas and the innovative ways can be developed which can lead towards the
success. Hence it can be said that the more powerful source it would be, the more
production of the electricity would be there to meet its requirements.
The coal-based technique of the RCM plant is also giving the
results in the more productive manner and hence it can be said that the
technique is giving the results in the more powerful ways. In the future, the requirement of the power
consumption and hence the power generation will be higher than the present
demand and this can lead towards the better future. A more generic way can be
developed with the help of which we can grow and lead the technology towards
the new era.
Limitation of the study of Reliability Centered Maintenance
for Power Plant
This study is limited to the scope of the future scope and
is not discussing the future cost of the project. This study is much helpful for
the future consideration of the power generation regarding the future quantity
of the power. But it has some limitation that is not considering the cost of
the future maintenance of the power plant which will be used in the future. A
lot of research is done on this topic but the research and the study are
limited to the fact that the future economics of the plant is absent. The
reason behind Is that the future may lead towards the successful growth and the
career of the plant. This is because in the future, there will be less
anticipation regarding the future technology and hence the cost estimation
cannot be done for the future. Overall, speaking, the RCM technique is
economically good and it is leading the future towards the better achievement.
Summary of chapter 1
The chapter no 1 is more related to the future demands of
the power and the proper planning of the estimation of the technology. It is
also said that the future consideration is also demanding in this field. This
chapter is more about the related technology and is giving the future
consideration about the future needs. Also, it can be said that the summary is
also related to the fact about the related technology and the terminology of
the past. The comparison is done of the conventional resources and the future
aspects are also considered to make the report a productive one. Since it is
the new technology and its application is few in many of the fields. Hence, the
more idea can be taken from the fact that the idea can be generated from the inspection,
analysis, observation and then the analysis of the part under consideration.
That part is then subjected to the maintenance for the better correction of the
part so that it may produce the same electricity as it is producing before the
fault is there in the machinery.
Research questions are made in the details and the proper
goals of the report are also defined in such a manner to provide the goal and
the path a much productive and efficient. Fewer details are focused on the
future cost that is more dependent upon the technology advancement and the
population of the people in the sector. RCM is a good initiative in the field
of maintenance and it should be adapted to prolong its use so that more people
can take the benefit from it and the technology can be used for the further
use. Conventional ideas were ideas that are more expensive and the time took
was more of these techniques. New ideas are more feasible and new and giving
the results in the more productive ways. There are more advantages of the new
technologies as compared to the previous technology but the overall process is
more advantageous from the engineering considerations.
6. Literature Review of Reliability Centered Maintenance for Power Plant
Various maintenance strategies are combined in the frame
work of RCM in an integrated manner for increasing the functional probability
of a component or system to work effectively it is operating context as per its
designed life cycle. These strategies includes the protective maintenance
techniques, time directed preventive maintenance, run tofailureand the
condition based maintenance. The core purpose of the RCM process is to provide
the reliability at the lowest possible cost. However, the RCM process required
clear maintenance goals supported by the economic justification and
technologies (Abou-Chakra, 2014).
RCM Philosophy of Reliability Centered Maintenance for Power Plant
The philosophy of RCM is based on the method of system
enhancement that enable the management to identify and devise the maintenance
and operational strategies in a cost effective manner. In this way the risk of
a system’sfailurecan be managed in a cost effective manner. The RCM is very
effective for the situationswhere the financial resources are very limited.
Moreover fundamentally the RCM is quite different as compare to the other
maintenance strategies. The RCM can preserve the function of the system up to
the desired level. In simple terms it is a systematic process of defining a
planned maintenance program while keeping the cost effective and preserved the
critical functions of the plant. Moreover another considerable aspect of RCM
philosophy is that it classified the level offailureon the bases of the
criticalconsequences(Dodman, 1997). The fundamental objective of this
philosophy is the cost effectiveness while channelizing the resources for the
high priority tasks. RCM identified required designed and justified maintenance
strategies along with the operational modification according to the priority
levels. The task of maintenance are selected for preventing the functional
failures through maintenance and addressing the causes of such failures.
Moreover the RCM operates on the bases of productive maintenance along with the
traditions process. The reliability centered maintenance for the electrical
power plant is a complex system that is installed at local electrical power
plant. The functions are complex and maintenance concept is required to improve
the complex system. The concept of RCM can be applied to the reliability
factors and the systematic approach includes evaluation, cost of development,
design, effective programs of maintenance and supplement programs. For the
energy power plant the problems and analysis are linked with the technical
operations and reliability of the functioning.
RCM Principles and Key Features of
Reliability Centered Maintenance for Power Plant
Following are the key features and principles of the RCM
The first key feature of the RCM is to preserve the function
of the system. This sept can be seen in differentaspect as it force a change by
replacing the typical view of minting equipment with the functional preservation(Besnard
& Bertling., 2010).
The second principle of RCM process is the identification of
thefailuremode that caused thefailureof the function. At this step the most
critical decision is that whether a complete maintenance plan is required or
the modification in operation or design would be enough.
The third principle of the RCM process is to prioritize the
main functional failure. This is very integral step of the entireprocess as the
philosophyof cost effectiveness is achieved at this step. To support the
critical functions of the equipment resources and efforts are dedicated to it
whereas, their unavailability leads towards the major degradation of the plant
or sometime the complete shutdown (Besnard & Bertling., 2010).
Theforth principle of the RCM process is the selection of
effective and applicable maintenance task for the item of high priority. The
purpose of item prioritizing is to make cost effective and efficient use of the
resources
RCM Components of Reliability
Centered Maintenance for Power Plant
The following figure shows the component of the program in
RCM. From this picture it can be seen that there are various parts in an RCM
program for maintenance including; reactive, preventive, proactive active and
condition based maintenance(Yssaad & Chaker., 2014).
Collection of data and selection of
system of Reliability Centered Maintenance for Power Plant
In the RCM process collection of data and system selection
has great importance. For this aspect, there is required to critically analyze
various types of data to develop a system. It is important because there are
great possibilities that the weak system or the failure of the systems major
component might leave bad effects on the productivity of the system greatly
enhance the cost of the maintenance. Following are some of the significant
factors that have direct impact on the system selection(Abou-Chakra, 2014).
Time between the failure which is also present as (MTBF)
Cost of the maintenance
Required time to repair
Availability
Criticality Analysis of
Reliability Centered Maintenance for Power Plant
The working on the nuclear power plant is analyzed by using
the tool called as “Criticality Analysis”. It is used to evaluate the failure
and it helps to evaluate hoe the equipment’s fails. It helps in evaluating the
impacts of the failure on the organizational performance. For the working
systematically on the nuclear power plant and to judge the performance checking
is done. For evaluation all the assets of plant is checked in order to
systematically and the basic purpose is to run the working or functioning
smoothly. All the items or equipment’s are prioritized and material is
classified at different levels. PM\PdM initiatives taken for the improvement of
the development and for the reliability. FMEA\FMECA is required in the nuclear
power plant for identifying the basic information. All the equipment’s criticality
calculated on the base of algorithm (1) one made on the base of information
collected. In the figure 4, calculation steps for the reliability of the
equipment’s criticality mentioned and on the basis of those risk factors
analyzed(Dodman, 1997).
RCM develop a setup of work according to the provided
criteria as the critical risk has been identified are 125 critical risks. The
system related to the programs are economical effective. Working and the plant
need maintenance on continuous basis. The maintenance program is based on the
following steps like (S. KHALID, 2000);
It is based on the identification of the risk critical
components.
It is based on determining the maintenance necessary
activities for ensuring the reliable operations.
The electrical plant is on step of working and major focused
point is to find the “reliability” in continuous working.
RCM Goals and Benefits of Reliability Centered Maintenance for Power Plant
RCM risk identification and safety implementation team serve
on the base of various galas and it help in determining the optimum level of
maintenanceschedule or program. For the better efficiency or performance
effective strategy is used for the maintenance of the plant and its equipment’s.
For RCM program implementation or achieving the goals operational efficiency is
increased and the cost of the project is controlled. RCM major goals is safety
of the plant in all the situations and benefits for saving the cost. RCM team
has to perform in all the crucial system functions and it has to maintenance
all the actions. The team of the RCM is most important and beneficial for
endeavoring the nuclear power plant system reliability. The functioning of the
RCM team or department is maintain on the lowest possible cost. It is very
beneficial for the ongoing safety and environmental issues. For the reliability
of the project first list of risk has been developed on the base of critical
components. The list of the risk components has been developed for the
maintenance (RCM) program for ROMCO(Besnard & Bertling., 2010).
Safety of the electrical power plant is the major and basic
concern. For this purpose risk components identified from the ROMCO level
results. The electrical power plant needs maintenance and safety is ensured
within the minimum cost. For the safety and maintenance a criteria is provided
to the department and guidance to perform the duties. Maintenance department
set a reliability to counter the risks on the plant and divide them according
to their characteristics (S. KHALID, 2000).
The major considerations in functioning of the plant perform
the safe operation. For smooth working and to save any kind of problem the risk
factor is identified and perform the safety functions including the mitigation
of accidents. For the next step is to provide the support system for
identifying the functions. It also includes the components of failure and
accident or transient for safety challenges. Different kinds of methodologies
used by the RCM department of identify the risks or failure components are as
(Abou-Chakra, 2014);
Fist analysis of the plausible failure moods,
Risk critical components identification,
Defining the level for maintenance activities
Possible solution to mitigate the failures
Incorporated all the risk and reasons into the RCM program
System and its Boundary of
Reliability Centered Maintenance for Power Plant
For the better understanding of the RCM functions and the
RCM methodology for resolving the key issues or problems it is need to
understand the related terms. For better functioning it is important to know
the system definitions related to RCM and nuclear power plan functioning.
Systems of Reliability Centered
Maintenance for Power Plant
In the nuclear power plant functioning it is better to
understand the basic system of working or process. All the systems for working
in organization, company, firm or on plant is based on three components. These
three components of system includes the followings like,
Input
Process or system
Output
The system on the power plant is a kind of model that
represents the specific rules or regulation. System start or began form the
step of “input” and the middle point is the “Process or system”. On the last of
the system or model is the output or the result of the working and it may be the
performance or efficiency of the plant (Besnard & Bertling., 2010).
Complex System of Reliability
Centered Maintenance for Power Plant
On the industrial level working it follows the complex
system on the plants. Plants or industrial systems are always considered the
most complex system according to nature. Complex systems means that it have
various kinds of challenges or dangers or life threats. Complex system is
adopted for the safety of the nuclear power plant. In nuclear power plants it
need more care (Abou-Chakra, 2014).
Modeling a Complex System of
Reliability Centered Maintenance for Power Plant
Complex systems are possible to be made up of many major
systems by character which are included of more simple working components down
to relative elements for example capacitors, pulleys, buttons, gears and
resistors etc. The system block diagram shows the basic design and terms which
are used for modeling a complex system. A complex system is meant a power plant
in the diagram (Abou-Chakra, 2014).
The highest level shows the plant which has the highest
scope, after that a lot of systems which have smaller scopes can be seen in the
diagram. A plant or complex is obtained by the addition of all these systems.
Each system consists some components and accordingly each of the components has
its own functions in comparison with the system. The components are said to be
the basic structure or the building blocks of a complex system because these
components provide the important functions to the system.
There are three basic elements which keep the system
operating. Which are known as material, information and the energy. The basic
motive of the system is to change these three elements. On the basis of these
three elements we can classify main functional elements (Besnard &
Bertling., 2010).
Data
Signal
Material
Energy
A system can produce, distribute and transmit the signals
which are used in sensors. It also can convert the data to other forms which
are required by the users. A system can also provide support for a system which
means it can change the shapes and designs of the materials. Energy is provided
to the system. All these components are physical shape of these elements.
Furthermore, all these functional elements can further be divided into six
categories which are electro-mechanical, thermo-mechanical, electronic,
mechanical, electro-optical and software. The most small and lowest level in a
system includes as the parts. These parts are required to hold the other
components in system and may not provide proper functions to the system. For
example transistors, resistors, gears, ropes, pulleys, coils and mirrors are
the parts used in the different categories which are discussed above (Besnard
& Bertling., 2010).
Maintenance in RCM of
Reliability Centered Maintenance for Power Plant
Maintenance is a process of keeping something in its
original condition by taking good care of it using steps like to avoid
something to break and bringing something back to working if it was broken or
not working properly. By doing a regular preventive maintenance you are
confirmed that your equipment and machines remains to operate under safe and
sound conditions both for the operator or worker and the machine itself.
Possible issues or problems can be fixed in time before they cause some harm.
With regular maintenance comes with maximum efficiency of the machine and it
also increases the life span of the machine or equipment. Small regular
maintenance do consumes some time but it saves us the actual time waste of the
breakdown of the machine if it get broke, so it take less time than emergency
repairing or replacements of new parts, by maintaining them regularly we can
use the original parts for long time.
According to the research conducted by Moubray (2015) now
the reliability centered maintenance also known as RCM is an approach of industrial
betterment, which is mainly focused on the identifying and establishing the
maintenance, operational and capital improvement strategies and problems
occurring that will manage or lessen the risks of equipment failure very
efficiently. With the applications of the RCM principles, maintenance is
calculated and applied in a logical manner that gives the best benefit to a
system’s owner. The objective of RCM is to achieve reliability and best
performance for all the operating modes of all parts of the plant or its
components and equipments at a reasonable cost. Although there are number of
applications of reliability centered maintenance RCM but the 7 basic
applications which are mostly used in all procedures are:
Analysis preparation
Analyzing the equipment
Pointing out functions
Indentify functional breakdown
calculating the effects of breakdowns
finding the reasons of failure
choose maintenance steps
The main advantage of RCM approach is that the fundamental
favorable position of a RCM approach is that future Preventive Maintenance
based errands or RBI arranging in view
of RBM will be liable to objective and precise audit, which enables assets to
be allotted to the most elevated hazard territories first. This method avoids a
lot of extra money on manpower and financial assets, resulting in more accurate
usage of the overall audit and maintenance budgets, and development of plant
safety and reliability levels.
Background of Reliability Centered Maintenance for Power
Plant
According
to the research conducted by Abou-Chakra (2014) focused on the RCM (Reliability
Centered Maintenance) derived in the industry of airline in the late 1950’s the
money used for the maintenance tasks in the industry had become very big to
place a new audit to check the purposes of these tasks. So, around 1960, a team
was created which consist auditors of both the audit team and the airline
employees to find the powers of a preventive maintenance. The making of this
team finally guides to a new number of steps and rules for airlines and
aircraft manufacturers to use, so in this was RCM was formed and now it is
using many different fields such as RCM for power plant.
Plant security and improvement is achieved by the RCM of the
plant’s components. RCM of the parts of the plant also decreases the cost of
maintenance of the plant. At present time the reliability centered maintenance
is under the process for ROMCO (Rabigh Operation Maintenance Company). This
will help the department of maintenance to provide guidance and help for the
development of RCM program for the risk critical elements. The main and the
only objective of RCM is to provide an powerful set of procedure for auditing
the parts which are considered to be the risk critical components, as the
objective and purpose is based upon risk
According to the research conducted by Braaksma, Klingenberg, & Veldman (2013) the primary principles of RCM are:
It seeks to save system or machine function. Dismissal of
function through various equipments, improves functional reliability but it
increases the life span cost in terms of new equipment or its parts and the
operation cost. So it is a function oriented task.
RCM is mainly determined on the system. It concerns in
taking care of the whole system than single parts of the function or process.
Reliability centered maintenance works with failure causes
in a real order. The connection between the time of operations and the breakdowns
is important. RCM is not only concerned with simple breakdown rate but it also
finds to know the chances of deficiency at certain ages.
RCM is used for safety and cost saving, there is no
compromise on safety at any cost therefore cost capability becomes the
criteria.
RCM deals with 3 types of the maintenance tasks:
a) Time directed.
b) Condition directed.
c) Failure finding
RCM program maintenance actions of Reliability Centered Maintenance for Power Plant
The RCM aims are to point the most economical and workable maintenance steps to lessen the factor of risk and chance of breakdown in equipments and systems. This let the systems and components usage to maintain in the best cost effective way. The main actions are:
Perform no maintenance, in this type of maintenance it
assumps that collapse can occur in any part, and that a is not damaging to the
operation. When it experiences high failure rates,huge quantity of extra time,
and inventories in big amount becomes familiar.
Regular timed audits is an essential part of the preventive
maintenance, lubrication, cleanings and replacement of parts and process. PM is
also known as time saving process.
Predictive maintenance and monitoring are parts of the CBM.
It measures the trend of the performance of the plants by using different
techniques. The maintenance is replaced with the randomly timed maintenance
tasks. Before the big breakdowns, the continuing analysis of plant’s condition
lets us for planning and fixed maintenance tasks or simply repair it before the
failures.
The equipment or the parts of the plants are desgined again
if all the above tasks fails to finish the risk than can convert into any major
breakdown at any time costing the industry big time. Sometimes risk carrying
part is just removed or replaced by a new one.
RCM Components of Reliability Centered Maintenance for Power
Plant
These are the basic steps or guidelines which are formed during the first investigation and are arranged as reactive about the small items, non critical components or parts of the machines or the process steps which are unlikely to fail. Preventive is the next step in which preventive maintenance takes place and all the mandatory precautions are taken by regular maintenance of the all the parts. Predictive Testing and Inspection of all the possible failures and than the proactive approach is used in which actions are taken before any harm can cause, so all the risk critical components or process are maintained before the hazard happened.
Objective of RCM of Reliability Centered Maintenance for
Power Plant
According
to the research conducted by Fischer, Besnard, & Bertling (2011) the main
and the basic objective of applying the RCM in an industrial plant is to
increase the life of available plants, equipments, components and processes and
reduce its maintenance cost. It is a corporate level maintenance strategy, these
strategies are used for the plant to maintain it using cost effective
maintenance techniques
Critical analysis of Reliability Centered Maintenance for
Power Plant
According
to the research conducted by Dodman (1997) the RCM is based on critical
analysis and failure analysis most importantly. Those failures that are already
happened are than used as a reference to never let the same thing happened
again, because that can have serious consequences. During the failure analysis,
these questions will must be asked
How each equipments fail?
What is the cause of each failure?
What are the functions and operation standards in each
system?
What are the consequences of each failure?
How can we prevent them?
What to do if you cannot avoid a failure?
These are some of the important questions that will be asked
after every failure and we should know these all before the failure so that the
failure will never happen again.
Definition and Background of Maintenance
According to the research conducted by Yang, Tavner,
Crabtree, & Y. Feng (2014) Maintenance is drive from the word of
maintained. Maintenance is a process by which we can keep our things in good
form and its quality, proper maintenance always keep the things in best shape and
its quality and there is no chance of damage or disorder of the object or
thing. During the 18th century, when the revolution in the industries begins,
many roads, canals and railway tracks were built for the better development of
the industries. This development required the much time and cost to maintain
the overall process which then come in different forms
According to the research conducted by Smith (1993) the
Europe industries are rebuilding after the World War 2. The competition in
market is going to develop and this factor increase the labor cost, the
machinery of the production are also developing and increase the productivity
rate. The concept of maintenance is developed and the manufactures were
focusing on the changing the concept of the maintenance and upgrade it. Most of
the industries try to develop the sense of the maintenance and realize its importance.
In the industrial field, maintenance means to keep the functional body or plant
upgrade which give better performance, handling all technical issues, manage
the and administrate all the issues during the life cycle of the plant or
functional body
Maintenance Strategies of
Reliability Centered for Power Plant
According to the research conducted by S. KHALID (2000) the
maintenance strategy is process or method to achieve maintenance objectives and
goals. The colossal mechanical advances in the course of recent decades have
prompted a more prominent spotlight on building up the customary ideas of
upkeep all together not exclusively to increment efficiency yet additionally to
upgrade the dependability of generation frameworks through finding contrasting
options to the conventional ideas.
Maintenance in the industry is very important. This will
keep the best efficiency of the plant and its functions and also deliver the
best product with great quality. Maintenance cannot be done without proper
planning and strategies and guideline. The strategies of the maintenance play
very important role in achieving organizations objectives and goals by
providing the best quality product, reducing the time of delivery and maintain
a good price of the product that will attract new customers and also fulfill
their demands and needs. Maintenance strategies are very important to achieve
the maintenance
Reliability Centered Maintenance (RCM)
According to the research conducted by Fraser, Hvolby, &
Watanabe (2011) reliability centered maintenance (RCM) is a process which helps
in the determination of the maintenance requirements of the assets and its
functions so that the assets keep working good and provide excellent quality
products. RCM helps in improve the reliability of the properties and
functioning industries plants. This factor increases the importance of the
maintenance and also increase the maintenance cost as a results we get better
shape of the physical assets
According to the research conducted by Fraser, Hvolby, &
Watanabe (2011) RCM is a technique which was developed in 1960 for the first
time in the aircraft industry for the replacement of the preventive
maintenance. It relies upon the hypothesis of counteracting potential
disappointment which could have genuine results and began in reaction to the
overwhelming increment in support costs following the presentation of wide-body
planes, which made the avionics industry uneconomical. When peoples start
knowing about the RCM technique they find out that this technique really saves
much money of maintenance and ensure the availability of the asset in the good
condition which is ready for the production with its full capacity and great
quality.
Many industries start using this method.RCM techniques also
give us information of the failure estimation and what are possible ways by
which any failure happen in the process or functioning plant in the industry
What are the operating procedures and functions which a
functioning plant performing?
What possible failures can happen in the functions?
What are the possible causes of the function failures?
What possible can happen if a functional failure happens?
What are the impacts of the failure?
What are the protective methods could be used to prevent the
failure?
What are the alternatives if a protective procedure is not
available?
According to the research conducted by Albarkoly & Park
(2015) RCM technique is the combination of the all the maintenance strategies
such as preventive, reactive and proactive strategies. RCM provide collective
results of all the maintenance strategies and can achieve the highest level of
reliability of the asset or the plant equipment and all the components of the
industry. The RCM techniques reduce the cost of the maintenance by giving the
information about, what are the features which needed to maintain first and
priorities the maintaining schedules.
RCM is a modern
and best technique for maintenance and it required a fully organize and
operational program for maintenance. These programs are arranged on the basis
of priorities of the equipments whose maintenance needed to be done. RCM also
help us to gather the labor and financial investment according to the
importance of the functional plant or equipment and also provide the
information about the risks and loses which are caused by the failure in the functional
operation, so these strategies can be helpful in increasing the efficiency of
the equipments by improving the reliability of the functional plans and
equipments
Process of RCM of Reliability Centered Maintenance for Power Plant
According to the research conducted by Adoghe, Awosope,
& Ekeh (2013) RCM is an essential part of the operation and maintenance
program. The implementation of the RCM involves any changes in the system of
the established policies of the industry. These changes will be tested first
and its results should be monitor carefully to avoid future problems and
issues. RCM efficiency depends on the time when it is implemented and in what
steps we involve its applications
Preparation
Analysis
Task selection
Task comparison
Task comparison review
Records
Preparation of Reliability Centered Maintenance for Power
Plant
According to the research conducted by Dekker (2005) the
preliminary stage has various advances which essentially include the
determination of the frameworks to be dissected, assembling the essential
information for the examination. Moreover the guidelines or criteria to be
utilized as a part of the choice and investigation process must be set up. As
for the demonstration we can say that key assumptions, critical evaluation
criteria, non critical evaluation criteria and development of the process for
review
System selection
Definition of the system boundaries
Acquisition of documentation of the materials
Interviews and plant personnel
System selection of Reliability Centered Maintenance for
Power Plant
According to the research conducted by Márquez, Tobias,
Pérez, & Papaelias (2012) the initial steps which involved in the process
of the RCM are collection of information and data, drawings of the operational
plant design, experienced persons and labor that have total information about
the equipment and the authorities who makes decisions for the process. Likewise
choice and survey criteria must be built up to guarantee that the endeavors of
authority plant faculty are all around focused and utilized profitably all the
while. The implementation of the criteria allows analyzing the outsets that
there is chance of the value addition in the process of the system and the
results can enhance the reliability. If this is not happening in that case then
we should try to change the system with other alternatives
Definition of the system boundaries of Reliability Centered
Maintenance for Power Plant
According to the research conducted by McMillan & Ault
(2014) when we are applying the RCM process it is important to define the
boundary of the system. Mostly plant coding system used but sometimes it is
incomplete so before review the process of the RCM makes sure that everything
is in order and included in the system boundary
System boundaries usually lined as:
Mechanical: system boundary in the mechanical line include
all the moving parts and the rotating parts of the equipments, it also include
the static parts of the equipments.
Electrical: it includes all the sources of the electrical
power, and also all the electrical parts of the equipments. It also include
electrical power source, circuit breakers and control supplies and everything
electrical associated with them.
Control and instrumentation: it includes the systems which
have control or power on the functions of the equipments and which are used to
alter the equipment process. For the demonstration we can say that, pressure
controller such as valve, for level control we use Rota meter, for electrical supplies
we use switches and circuit breakers
According to the research conducted by Idhammar (2005) a
complete analysis is made weather which components should be included in the
system boundary and which components should be excluded from the system
boundary. There is no specific methodology or technique which can be used for
this analysis; it is completely based on the judgment and experiences so that
the results of the analysis come as effective and authentic
Acquisition of documentation of the materials
According to the research conducted by Yssaad & Chaker
(2014) in this step we gather all the information of the operational manuals of
the process of the equipments. First of all it is important to collection the
maintenance history of the plant, so we get the idea why the new issue happens
and what are the weakness in that maintenance. Different block diagrams of the
systems such as piping, electrical circuits, mechanical parts and specially
drawing of the plant. RCM program focus on the maintenance including; reactive,
preventive, proactive active and condition based maintenance
Interview and Plant Personnel of Reliability Centered
Maintenance for Power Plant
According to the research conducted by Sallak, Schön, &
Aguirre (2010) the interviews are conducted when there is no proper record and
documentation of the plant equipments. These interviews are conducted with the
plant personnel operators who supervise and operate the plant on daily bases.
They are highly experienced and professional. Each department such as mechanical,
electrical, system control and instrumentation are responsible for their part
of work and answer for it. Engineers, supervisor, workers all are included in
the interview to collect every valuable information from them
According to the research conducted by Mkandawire, Ijumba,
& Saha (2015) times for the interviews are scheduled and the availability
of the every staff members should be considered. Analysis mostly based on the
interviews of the all the members such as engineers of every department
electrical, mechanical, instrumentation and control and operating engineers
These interviews are the part and important feature of the
RCM process. This activity promotes the team work and also increases the
productivity of the work and there is chance of the time saving in the process
of the RCM.
Analysis of Reliability Centered Maintenance for Power Plant
According to the research conducted by Ribrant &
Bertling (2007) when the system is selected and all the initial preparations
are done, now it’s time for the analysis. Experience in the process of the
analysis is very important because it increase the chances of the effective
decision making. These experiences can be hired or already present in the
industry which can be utilized for this special occasion. The initial data
which is collected may be have incomplete information and knowledge, it is
important to utilize local staff and the experience hired peoples who has great
experience in RCM process
The first step in the process of analysis is to gather a
highly experience team which provide suitable suggestion and solution s according
to their experience and qualifications. Stages which are involved in the
analysis process are:
Identification of System Functions
System Functional failure analysis
Equipment identification
Reliability and Performance Data collection
Identification of failure modes
Identification of failure effects
Determination of Component Criticality
Identification of system functions of Reliability Centered
Maintenance for Power Plant
According to the research conducted by Mian (1999) plants
equipments usually have one or more functions which are their responsibility to
perform. The main purpose of the maintenance is to makes sure that equipments
are performing their functions in their best performance and efficiency. In the
first of the analysis in the process of RCM is to define the function of the
selected equipments. Simple block diagrams will be helpful for this activity
and provide the basic information of the functions
Equipments usually refer their names by their functions, such as distillation unit, condenser, and extraction pump. Sometimes it is difficult to define the second function of the specific equipment but it is very important in the process of RCM.
System functional failure analysis of Reliability Centered
Maintenance for Power Plant
When functions are defined, there must be a failure with one
of the function. This failure should be documented with the whole mechanism and
how it is happen and what are the outcomes of this failure.
Equipment identification of Reliability Centered Maintenance
for Power Plant
When the analyzing is in process, it is necessary to
identify all the equipments whose failure leads to the whole functional
failure. This can only happen when you follow the path of the function. In this
activity all the mechanical and its parts should be included such as pumps,
valves, filters, vessel and heat exchangers. In the same method electrical
equipments and their parts are also included and identified.
All the equipments are indentified with their unique applications which are performing within the system. This will help in analyzing the all the important information of the equipments and their reliability data
Reliability and performance data collection of Reliability Centered Maintenance for Power Plant
The analysis of the RCM process are based on the information
provided by the manufacture data and the all the history of the plant. All the
activities of the plant, condition monitoring, inspecting and all the
maintenance activities which are in process help in building future data. The
analyst should also ensure the complete of the data information which is
collected from the future actions.
Identification of the failure modes of Reliability Centered
Maintenance for Power Plant
According to Bertling, Allan, & Eriksson (2005) Failure
modes are the fail in the operation of the component of the equipment such as
failure of the pump to stop or start, failure of the valve to close or open,
these are consider as a failure modes. This statement is mostly used in the
reliability to describe the failure modes. The experts which are working on
maintenance further collect the information about why this failure happens.
Well in case of the pump, we can say that switch gear defect happen and in case
of the valve, there was a problem with the actuator or the spindle.
Identification of the failure effects of Reliability
Centered Maintenance for Power Plant
The experts who are analyzing the failure should provide the
information about the effects of the failure on the safety of the plant,
personal safety of the staff members, and the effects on the environment and
most importantly the effect on the performance of the plant equipment. These
effects should be documented and the experts of the analysis should provide the
countermeasures to decrease the effects of the failures
Determination of component criticality of Reliability Centered Maintenance for Power Plant
According to the research conducted by Sallak, Schön, &
Aguirre (2010) if the component failure result in the great loses of the
equipment or damage the plant that will be consider as a critical. In the
nuclear power plant the component consider as a critical if the failure can
cause one of the following action:
If the failure cause sudden shut down of the plant without
the schedule time.
Failure leads to the decrease in the power or efficiency.
When there is a chance of the great safety hazards
When failure cause the great damage of the plant
When the failure leads to disturb the environmental emit
limit.
When failure cause a fire.
Non critical components of Reliability Centered Maintenance
for Power Plant
The components which can cause failure but these failures
can be tolerated. It the component is still running in the process this may
cause in a big failure and after that maintenance should become necessary.
There is whole procedure to fine out the non critical components or the run to
failure components:
What is the cost of the repairing or replacement if the
component keeping running in the system and fail?
What if the component fail cause failure in the critical component.
What if simple maintenance can prevent the degradation of
the component
What are the personal safety hazards if the component keeps
running in the process and fail?
What are the effects
of the fail of the non critical component of the critical components?
Task Selection of Reliability
Centered Maintenance for Power Plant
According to the research conducted by Little, Chilton,
Goldman, & Miller (2010) after the completion of the analysis we move to
the next step in the process of RCM is to allocate the maintenance tasks to the
equipments and its systems which are identified in the process of analysis.
Task selection is the key to the proper maintenance which can save cost of the
maintenance, by applying specific strategies which result in achieving best
maintenance with great results of safety measures, environmental protection and
economic goals. The task selection activity use some serious logics and decision
making which results in the systematic arrangements:
Prevention maintenance
Condition monitoring
Inspection and functional testing
Run to failure
Task Selection Guidance of Reliability Centered Maintenance
for Power Plant
The main purpose of the task selection is to prevent the
fail in the functions. There is a guideline which provides us the best criteria
to select our task for the RCM process:
Point out the tasks which can provide the information about
the failure mechanism.
Make the list of the existing issues related to the
reliability
Make the suggestion that can solve the issues related to the
reliability and non bearable failures in the process.
Do not try to make relation between the task selection and
the maintenance program that are already in process.
Never try to depend
on the current maintenance procedures that they will provide the best results
after maintenance, failure can be experiences in that cases.
Point out the tasks that will protect from the failure
effects not the tasks which try to prevent the failure in the equipment.
Never try to promote the task which has no power to prevent
the after effects of the failure in the equipment.
Try to explain the hidden failures
Task selection hierarchy of Reliability Centered Maintenance
for Power Plant
While selecting the task there is a proper hierarchy which
should be followed. This hierarchy is made on the basis on reduction in the
cost of the maintenance while provide the full information about the
reliability and availability. Task selection should be selected on the preference
of the following:
Performance monitoring
Predictive maintenance
Non-Intrusive Maintenance
Intrusive Maintenance
Renewal
The selection of the responsible personnel based on the
following:
Actions operators may perform as part of normal rounds
Actions operators may perform that are not a part of normal
rounds
Actions requiring skilled craft work
Actions requiring minimal craft skill
Time-based intrusive maintenance
The maintenance programs which provide the cost effective
results must review the history data if possible. Considering an operator for
this job is important because his work is to deal the equipment operation so
the daily basis and have all the information about the equipment plant. To get
the maximum useful results it is important to consider all the aspects and the
departments should take responsibilities of their actions and take part equally
in the maintenance programs to achieve the maximum performance of the equipment
of the plant
Task Options of Reliability Centered Maintenance for Power
Plant
While selecting the task there are some procedures to be consider
for specific equipment:
Condition directed task of Reliability Centered Maintenance
for Power Plant
For condition directed task to be pertinent, it must be
conceivable to identify lessened disappointment protection for a particular
disappointment component. The undertaking must have the capacity to identify
the potential disappointment condition and there must be a sensible,
predictable measure of time between the main sign of potential disappointment
and the genuine disappointment. All the more particularly, in any case, while
deciding the recurrence for condition observing assignments, the recurrence
ought to be predictable with the time interim between the primary sign of
potential disappointment and the real time of inability to permit a condition
guided errand to be done.
Time based task of Reliability Centered Maintenance for Power Plant
Time based task should be selected on the basis on the time
priority that is which equipment is needed to maintain first. Time management
is the basic concept in this types this type of task. For this purpose the
history data of the maintenance and the experienced personnel should be
consulted. Now the time is measured in the failure will happen and the time for
the degradation of the specific equipment of the plant.
Failure finding task of Reliability Centered Maintenance for
Power Plant
For disappointment observing errands to be material the
segment must be liable to a disappointment component that isn't obvious to
staff amid ordinary activity of the hardware and there is no other relevant and
successful sort of errand to keep the disappointment from happening. Practical
tests are valuable disappointment discovering errands for defensive highlights
and interlocks. In any case, it must be guaranteed that the test completely
checks the component. In the event that a gadget should square activity of a
valve or pump begin, ensure this capacity is tried, not only that the input
works appropriately.
While deciding recurrence for disappointment discovering errands, thought ought to be given to the expected recurrence of interest, disappointment rate and passable of disappointment. Additionally, it must be recalled that playing out the disappointment discovering assignment may build the measure of wear or debasement in the part, and additionally may put the framework in a perilous or irregular condition.
Task Comparison of Reliability Centered Maintenance for Power Plant
Task comparison is the important step in the process of the
RCM. It is the activity in which we compare the present task selection results
with the maintenance activities which are already in process. This comparison
give us important information about the changes needed in the process of the
maintenance and if there is possibility to control the resources which are used
in the process of the maintenance. It also gives us a chance to alter our
commitments which will result in better maintenance and better working
environment.
To get the maximum results of the comparison it is important
to consider all the components which are related to the maintenance planned
procedures such as functional tests, operator activities, performance test and
preventive maintenance tasks. It is necessary to obtain the authentic
information about the performance of the plant from the interview in the case
in which previous data in not available or insufficient to monitor and make
suggestion about the maintenances tasks. This helps in analyzing the
information in the best way and provides multiple suggestions which can used to
improve the performance of the equipment of the plant.
Task comparison performance of Reliability Centered Maintenance
for Power Plant
Little, Chilton, Goldman, & Miller (2010) the task
comparison is done by the experienced and professional experts who has great
knowledge in this field and provide useful information and suggestions:
Retain: already present tasks for the component of the
equipment of the plant which suggest the RCM tasks which are same as the task
of the preventive maintenance tasks.
Modify: the difference between the preventive maintenance
task and the suggestion of the RCM task provide the better task which has more
effectiveness if applied.
Delete: replacement of the RCM tasks which are more
effective than the previous tasks.
Delete: it is apply to the tasks which has no more use and
are unimportant.
Delete: apply to the tasks which have components that will
run to fail after the RCM tasks.
Add: the purpose of the new preventive maintenance is to
provide the prevention to the components failure which has already present
tasks and do not provide better results. But the RCM tasks have the better
results and are applicable in every condition and provide the best prevention
to the failure of the components
Task Comparison Review of Reliability Centered Maintenance
for Power Plant
It is the activity in which we review the results of the
comparison and provide us important information about the maintenance changing
programs. These changes are important for the plant as we want the plant
equipment to perform well and work on its full efficiency. We make every
possible change which is best for the performance of the plant. Comparison of
the results reviewed by the experienced and qualified experts who give better
suggestion if there is a better alternative for the maintenance. In this step
we can make every possible change in the maintenance process and that results
in the betterment of the plant and its functions to perform on its full
capacity and provide good quality product for the industry
Final phase of analysis of Reliability Centered Maintenance
for Power Plant
According to the research conducted by Hernandez-Matias,
Vizán, Hidalgo, & Ríos (2006) he process of the task selection is done and
the procedures to review the task selection are completed; now the process of
the analysis of the RCM is ready for analyzing. The comparison of the suggested
task now provides the information about the planning of the program for the
maintenance. The main reason of the comparison is to provide the information
about the changes needed in the program which is already in the process. The
comparison of the tasks also provides the idea of the difference between the
RCM analysis and the preventive maintenance which is already in process
Records of Reliability Centered Maintenance for Power Plant
According to the research conducted by Bertling,
Reliability-centred maintenance for electric power distribution systems (2002)
RCM process is a useful technique which has possibility to increase the
efficiency of the plant equipment with proper maintenance with lost expenditure
of the cost. The preparation steps and the analysis based on them and the
suggestions which are implemented on the basis of the analysis and give
effective results on the operation of the maintenance program. These results
and decision and every step change should be documented in the record which
will be helpful in the future to manage and arrange new maintenance strategies
Benefits of the (RCM) Reliability
Centered Maintenance for Power Plant
According to the research conducted by Demirbas, Hashem,
& Bakhsh (2017) RCM is a great technique for the maintenance of the
industry plant. RCM has provided many useful results in the past 20 years and
doing great in the present time. It all started with the aircraft industry
which use the RCM for the maintenance purpose and get positive results in every
aspect such as cost, safety and maintenance. After that nuclear power plants
and other oil and gas industry use this method and achieve great results. If
the RCM process is properly applied it can reduce the routine maintenance about
40% - 70%. Using the RCM save much cost which is definitely a remarkable
approach for the industries and their business, it also give same results with
the large firms and industries which has complex units and whose maintenance
cost much time and investment
According to the research conducted by Dhillon, (2002) there
are many advantages and benefits of using RCM and have positive impact on the
safety, configuration, operations and administration. Following are the key
benefits of the RCM:
RCM process is a great technique which use all the
information from the cross discipline.
There is a chance we can check the decision making peoples.
It provides the better platform to work and have attractive
ways
It can reduce the routine maintenance by improving the
system and its efficiency
RCM process definitely reduces the cost of the maintenance
and also save much time with its great strategies.
RCM provide high quality maintenance plan and have better
information about the history plans
RCM provide full results in the form documents and have
power of managing the system in better way.
It reduces the
environmental hazards and optimizes the systems.
RCM provide team work spirit within the staff members and
they learn about the importance of the team work.
Team work help in completing the job in less time and save
much of the investment.
RCM is helpful in identifying the modes of the failure and
provide the information about how failure specific failures happen.
It provides chances to the staff members to come forward and
show their skill in the maintenance suggestions.
It provides the schedule for the maintenance for the future
to continuous performance of the plant.
It provides platform to work all the different departments
together and sort out problems and suggest its solutions together.
RCM helps in improving the performance of the plant
equipments and their efficiencies.
It ensures the plant reliability and its availability.
RCM provide better platform to learn about the maintenance,
its importance and features which make it important for the better business of
the industries
According to the research conducted by Besnard &
Bertling (2010) there is no proper measurement to measure the benefits of the
RCM. RCM is a vast method and its benefits are long term commitment. After the
implementation of the RCM its benefits can seen in the future when it provide
the plants to perform well and with full capacity and efficiency. The benefits
of the RCM only be seen when we have all the access to the reliability data for
the equipments which are in the analyzing process and when we are using the
preventive maintenance for the routine schedule intervals
The industries which are using plant equipments should need
to prepare the real time data and respond to it for the better judgment for the
life period of the equipment. It is important to build a good relationship with
the RCM to achieve long term benefits by keeping the partnership between the
personnel responsible for equipment maintenance and personnel responsible for
equipment design.
According to the research conducted by Gabbar, Yamashita,
Suzuki, & Shimada (2003) RCM is helpful in every possible way. If there is
no data available and poor information which is not enough for the maintenance,
but RCM itself can collect all the data and information which necessary for the
process of RCM
Failure can have effects on the personal safety, equipment
and environment.
The failure can alter the production of the equipment.
The failure can happen anytime, they are just hidden.
According to the research conducted by Igba, Alemzadeh,
Anyanwu-Ebo, Gibbons, & Friis, (2013) RCM provide us the chance to review
the previous data and information which is available and recorded after each
maintenance process. It gives us information about why the new failure happens,
and what are the weaknesses in the previous maintenance. A RCM study will
convey dependable advantages for any association that has put resources into
noteworthy new advancements. Unmistakable investment funds are created through
the diminishment in spontaneous downtime, the shirking of generation
misfortunes and a fall in chance based expenses. This sort of study will
uncover any holes in the current support technique; also give genuine feelings
of serenity that current upkeep methodologies are working
Utilizing the correct advancements and the correct
facilitators, a RCM think about has more extensive advantages for tasks and
support groups. It can help general abilities by giving preparing and
advancement, and by incorporating RCM programming apparatuses with different
procedures for consistent change. These devices can be utilized for long haul
gauging of whole armadas of advantages
7. RESEARCH DATA of Reliability
Centered Maintenance for Power Plant
IDENTIFYING CRITICAL RISK BY PSA
RESULTS
In reason for the identification of risk critical components
from ROMCO accidental sequences, selection of the frequency which is core melt
is done in the first step. That core melt frequency depicts the accident
background. A study for the identification of risk critical component is
illustrated in the figure 2-1. In the next step identification of those
components which files is done in this background. Other components which
caused the offsite dose comparable to 10 CFR 100 would also be considered as
the risk critical components. The process of identification of those passive
components should be focused and centered on the determination of the failure
modes which can affect the safety of the system. If any component which is the
reason behind the accident and can cause safety issues it should also be
designated as risk critical component. Though this component is not the problem
itself but is creating problems for the other components of the system (Besnard
& Bertling., 2010).
Lastly any other component which is too old or creating
causes of failures for the power plant’s basic operations should also be
declared as risk critical component. For the better identification of risk
critical components from the accident sequence most likely accident sequences
are considered. Starting events related to those sequences are identified then.
Finally, all other equipment’s or tools that are causing failures and can cause
the accident for a system are identified. Those components which are
experiencing the most failures frequently for every starting or initiating
event are considered as risk critical components. Sensitivity analysis or the
important measurement are the other techniques which can be used for the
identification of the risk critical components (Abou-Chakra, 2014).
The results that were calculated for finding the risk critical
components. The starting events taking part in about 90 percent to the total
core melt frequency are selected as basics for the identification of the risk
critical components in level one results. A list was made of 27 initiating
events for the ROMCO PSA. Ten initiating events were found to be the causes of
90 percent of the total damage frequency out of those 27 initiating events.
Following this there are the names of the events which were causing the post
initiating system to be failed. The domains are selected to identify the risk
critical components. Accident sequence contributing approximately 90 percent to
core melt frequency are investigated for the better identification of risk
critical components from the analysis of the results (Besnard & Bertling.,
2010).
The risk critical components for ROMCO are represented which
were identified from the initiating accident sequence. The results may change a
little in the list after performing essential adjustments to PSA model.
Consequently, this list of risk critical components is not mature at this stage
because this is purely based on the first set of quantification results.
POTENTIAL FAILURE MODES
IDENTIFICATION
There are three paths of assessment to identify the failures
in a system. These three paths are known as;
Identifying the failure mode of sub elements of the risk
critical components using different analytical methods
Identifying the failure mode of sub elements of the risk
critical components via history.
Identification of existing maintenance related requirements
and the activities.
These three paths of assessment are generally named as
assessment path A, assessment path B, and assessment path C respectively.
An expanded version of RCM program is shown in the figure
3-2 for the identification of the most frequent and important modes of the
failure. Assessment path A and assessment path B both are choices for the
identification of the most frequent failures modes. Path A can be used for the
complex components for example feed water system or the diesel generator system
or in the scenario where failure history is not reachable (Besnard &
Bertling., 2010).
Path B can be used for least complex components and in the
situations where history data is reachable and available to us. Both of these
assessment paths should benefit in providing better estimates of failure modes
to use them according to the relevant situations. In the identification of
dominant failures of sub elements it is almost similar to identify the risk
critical components. For example no history data is available for the ROMCO
right now so RCM program would have to go with path A of assessment but in the
near future when the plant would be operating the history would also be
available and the assessment path B should be adopted. Unlike these two assessment
paths C is essential assessment path and should be done for each risk critical
component regardless of path B and A(S. KHALID, 2000).
The activities performed in this assessment are shown on the
left side of the as shown in figure. In this assessment analysis of different
failure modes is conducted to identify the dominant risk critical component. In
this option different tools are used to identify sub elements of risk critical
components whose failures are of these types; single element failure which cause
the failure of other component and is likely to repeat in future, Latent
element is the element which is not traceable further tests are demanded and
the element that has common cause potential for the failure and the element
which needs the repairs and may take large amount of time to repair(S. KHALID,
2000).
There are some methods for the prevention of parts against
the failures which are given as: for determining the failure mode the risk
critical factor would be identified by the assessment path B. yet the history
is not available for ROMCO but the importance of assessment path B in
identifying the risk critical component is more as compared with the path A.
history availability is essential while facing the challenge of determining the
failure cause in a system. It may prove helpful while combining the components
in categories which will suggest the summon cause failure components ahead of
us. Most appropriate method is to group the same components in the same
environment and then look at history. Accordingly the development of the
analysis is the first step in this regard while tracing out the cause of
failure for a risk critical component. In the next step a list of the failure
modes is created. This could be done in accordance with the sub elements
failure using is history data is unavailable and in the case the history data
is not available. This list should be structured by dominant sub component
failure. The frequency of the occurrence of these elements is thus calculated
and then the categories are ranked according to the most happening events. Most
occurring events show the most suitable elements for the failure causes of a
system (S. KHALID, 2000).
EFFECTIVE MAINTENANCE ACTIVITIES
IDENTIFICATION
In the following figure thePSA based process is presented
for the identification of critical components of risk. It is based on the
assessing the existing activities of maintenance and the proper recommendations
for the risk critical components are represented by a box. That box is showing
assessment path C. This assessment path is done after going through the prior
paths of assessment A and the assessment path B. As discussed earlier the
assessment path C is compulsory. This path of assessment will proceed to
collect and view all the maintenance activities which happened already and the
proper recommendations for the components from all the sources (S. KHALID,
2000).
A plan would be suggested for the maintenance for the
components according to the existing maintenance activities and the activities
which are not done before. Both sets of maintenance activities would be
suggested with proper reasoning definitions. A base will be produced for every
maintaining action in which answer of basic questions like why each
recommendation is in not existing category would be given. In detail steps will
be presented as initiating points for the assessment of the maintenance needs
for component. In this way we can say that the major components which are
likely to cause the failure to system would be those which are identified in
the assessment A, B and C (S. KHALID, 2000).
Engineering judgment provides the base in the process of
getting information about maintenance and to get the protection against the
major failure modes of a component. On the other side there are also some of
the options which are based upon the determining sub element’s failure, its
affects and the frequency or repeating chances. The configuration that may help
in the process of getting information about effective maintenance is
represented in the following picture. This picture provides help in the
completion of the task impacting maintenance determination(S. KHALID, 2000).
All possible failure modes of risk critical component are written as a list in
the left side of the picture. Next columns are representing the results of
these sub elements with the help of resources for repair, effect on risk
critical component, effect on technical specifications, common cause failure
etc.
Figure 5: RCM Rrisk critical component
8. METHODOLOGY of Reliability
Centered Maintenance for Power Plant
Methodology of Reliability
Centered Maintenance for Power Plant
Methodology is very important for the RCM department
especially working in an electrical power plant. RCM has developed nearly seven
kinds of methodologies. Methodology is used how to maintain the given task or
complete the work given and it includes the following steps like (Besnard &
Bertling., 2010).
Following methodology is applied in RCM program for the
complex system maintenance;
The first step is the collection of data and selection of
the system
At the second step, the boundaries of system is defined
At the third step the system and the functional block are
described
At the fourth stage, failure of system’s function are
addressed
At the fifth stage the analyses are made on the failure and
its effects
At the sixth stage logic tree diagram is developed
The seventh stage of the RCM program is based on the
selection of the task
For resolving the problems, issues or technical maintenance
methodology is the path or way to solves these. Task selection and Logical
decision tree analysis are very important to maintain the equipment’s on plant.
System functioning and system description are used for the safety of the
electrical power plant. In the CRM maintenance department, system boundary is
very important to control the risks. Information collection is very important
to reduce the risk factors and continuous maintenance of equipment’s increase
the functions and performance (Abou-Chakra, 2014).
Methodology for the Project of
Reliability Centered Maintenance for Power Plant
In this section techniques to develop a RCM program for the
risk critical components would be discussed. This technique is beneficial in
developing a RCM program for risk critical components which were discovered by
the approach of PSA model. That methodology is discussed in details in the
above given sections (Abou-Chakra, 2014). Determining the defensive and
protective maintenance activities are involved in establishing a reliability
centered maintenance program for the risk critical component. Those maintenance
activities may include condition monitoring or other maintenance relevant
activities. For example restructuring which is according to the requirements of
the components. There are two steps which throw ample light on RCM program for
a risk critical component. Those steps are illustrated by figure. In this
figure, the step by step evaluation process is presented for the critical Risk
Components. Determining the major component failure modes that should be
resolved is the first step. Getting information about the maintenance
activities for these major component failures is involved in the second step
(Besnard & Bertling., 2010).
9. SUMMARY of Reliability Centered Maintenance for Power Plant
In this research, the focus is given on to create
understanding about the importance of Reliability centered Maintenance in
maximizing the return over investment on the complex projects such as Power
plant, andfocus given on the evaluation of the effectiveness of the advanced
engineeringmaintenanceapproach known as RCM. Subsequently, this research has
organized to create understanding that RCM has the capacity to enhance the
efficiency of the complex system such as power plant and at the same time, it
is effective in reducing the cost of the maintenance, cost of labor and human
power.
Subsequently, to support the argument various relevant
studies and their finding has be used as an evidence. These studies provides
great understanding about the working principles, techniques, and advantages of
using RCM. Moreover, some researches were done to support the article and case
studies were used to analyses the impact and usefulness of the RCM to reduce
the failure risk, to enhance the equipment’s efficiently and to reduce the
overall maintenance cost.
From the analyses it is concluded that RCM has been found a
very effective and advanced engineering method of complex system’s maintenance
but at the same time, it required very deep observation of the system to
understand the lope holes and to implement the RCM procedures to get the
required objectives. Considering this aspect, it is found that qualitative
analyses are required to understand the potential failure modes of the critical
components. Following this, there is need to decide the best plausible solution
for the problem. Overall, it is concluded that RCM program has great potential
to enhance the return over the investment of complex system by the mean of
reducing the failure risk, cost of maintenance and by strengthening the
efficiency of the system.
10. Research Questions of Reliability Centered Maintenance for Power Plant
Discuss the RCM analysis process and explain how it can be performed?
Discuss some of the goals of implementation as well as the
benefits that could be there in RCM analysis process?
How could RCM be helpful for the complex system like the
power plant and what safety practices and cost limitations could be focused on
this aspect?
What are some cost-effective maintenance strategies for RCM?
How can RCM be focused to establish an efficient maintenance
for the power plant?
Discuss and analyze some functional failures of RCM?
What present and future plans can be focused in order to get
positive results through the RCM approach?
What are some other preventive diagnosis and predictive
maintenance techniques for the power plant?
How can RCM approach minimize the operating functions
related to the power plant?
Discuss reliability matrix that can be used to minimize the
cost related to each component of RCM?
11. Results of Reliability
Centered Maintenance for Power Plant
Table 1: The number of articles based on research
questions or themes
|
Theme |
Number
of Articles |
List
of Authors |
|
Discuss
the RCM analysis process and explain how it can be performed? |
3 |
Moubray
(2015) Abou-Chakra
(2014) Fischer,
Besnard, & Bertling (2011) |
|
Discuss
some of the goals of implementation as well as the benefits that could be
there in RCM analysis process? |
2 |
Dodman
(1997) Yang,
Tavner, Crabtree, & Y. Feng (2014) |
|
How
could RCM be helpful for the complex system like the power plant and what
safety practices and cost limitations could be focused on this aspect? |
2 |
Bertling,
Reliability-centred maintenance for electric power distribution systems
(2002) Demirbas,
Hashem, & Bakhsh (2017) |
|
What
are some cost-effective maintenance strategies for RCM? |
5 |
Igba,
Alemzadeh, Anyanwu-Ebo, Gibbons, & Friis, (2013) Braaksma,
Klingenberg, & Veldman (2013) Ghorani,
Fotuhi-Firuzabad, Dehghanian, & Li (2015) Bertling,
Allan, & Eriksson (2005) Márquez,
Tobias, Pérez, & Papaelias (2012) |
|
How
can RCM be focused to establish an efficient maintenance for the power plant? |
3 |
Mian
(1999) Little,
Chilton, Goldman, & Miller (2010) Hernandez-Matias,
Vizán, Hidalgo, & Ríos (2006) |
|
Discuss
and analyze some functional failures of RCM? |
4 |
Yssaad
& Chaker (2014) Sallak,
Schön, & Aguirre (2010) Mkandawire,
Ijumba, & Saha (2015) Ribrant
& Bertling (2007) |
|
What
present and future plans can be focused in order to get positive results
through the RCM approach? |
2 |
McMillan
& Ault (2014) Idhammar
(2005) |
|
What
are some other preventive diagnosis and predictive maintenance techniques for
the power plant? |
2 |
Adoghe,
Awosope, & Ekeh (2013) Dekker
(2005) |
|
How
can RCM approach minimize the operating functions related to the power plant? |
4 |
Smith
(1993) S.
KHALID (2000) Fraser,
Hvolby, & Watanabe (2011) Albarkoly
& Park (2015) |
|
Discuss
reliability matrix that can be used to minimize the cost related to each
component of RCM? |
3 |
Dhillon
(2002) Besnard
& Bertling (2010) Gabbar,
Yamashita, Suzuki, & Shimada (2003) |
Table 2: Article summaries of Reliability
Centered Maintenance for Power Plant
|
Title |
Author(s) |
Year |
Summaries
|
|
Introduction
to Reliability-centered Maintenance |
Moubray
|
(2015) |
RCM
is an approach of industrial betterment Establishing
the maintenance, operational and capital improvement strategies Applications
of the RCM principles, maintenance is calculated and applied in a logical
manner. |
|
Application
of Reliability Centered Maintenance (RCM) in Electrical Power Plant |
Abou-Chakra
|
(2014) |
Fist
analysis of the plausible failure moods, Risk
critical components identification Defining
the level for maintenance activities Possible
solution to mitigate the failures Incorporated
all the risk and reasons into the RCM program. |
|
A
limited-scope reliability-centred maintenance analysis of wind turbines |
Fischer,
Besnard, & Bertling |
(2011) |
RCM
in an industrial plant Reduce
its maintenance cost Corporate
level maintenance strategy Cost
effective maintenance techniques |
|
Reliability
centered maintenance minimizes costs and maximizes plant availability |
Dodman
|
(1997) |
Philosophy
of RCM is based on the method of system enhancement Management
to identify and devise the maintenance and operational strategies Managed
in a cost effective manner |
|
Wind
turbine condition monitoring: technical and commercial challenges |
Yang,
Tavner, Crabtree, & Y. Feng |
(2014) |
Risk
critical components RCM program Collects
the information about maintenance activities Proposed
methodology of using RCM for Power plant |
|
Reliability-centred
maintenance for electric power distribution systems |
Bertling
|
(2002) |
Objective
of applying the RCM in an industrial plant Processes
and reduce its maintenance cost Plants,
equipments, components Strategies
to maintain plant Focus
on the cost effective maintenance techniques |
|
The
cost analysis of electric power generation in Saudi Arabia |
Demirbas,
Hashem, & Bakhsh |
(2017) |
RCM
has provided many useful results in the past 20 years Aircraft
industry RCM
for the maintenance purpose Nuclear
power plants |
|
A
systems approach towards reliability-centred maintenance (RCM) of wind
turbines |
Igba,
Alemzadeh, Anyanwu-Ebo, Gibbons, & Friis, |
(2013) |
Previous
data and information which New
failure happens Correct
advancements and the correct facilitators Preparing
and advancement Incorporating
RCM programming apparatuses |
|
Failure
mode and effect analysis in asset maintenance: a multiple case study in the
process industry |
Braaksma,
Klingenberg, & Veldman |
(2013) |
Failure
mode and effect analysis (FMEA) Preventive
maintenance planning Supported
by empirical evidence |
|
Identifying
critical components for reliability centred maintenance management of
deregulated power systems |
Ghorani,
Fotuhi-Firuzabad, Dehghanian, & Li |
(2015) |
Focus
to reduce the investment costs Dilemma
in power systems Focused
maintenance management |
|
A
reliability-centered asset maintenance method for assessing the impact of
maintenance in power distribution systems |
Bertling,
Allan, & Eriksson |
(2005) |
Different
maintenance strategies Maintenance
strategies of the cost and system reliability Functional
relationship that is there between maintenance and failure rate |
|
Condition
monitoring of wind turbines: Techniques and methods |
Márquez,
Tobias, Pérez, & Papaelias |
(2012) |
Total
information about the equipment and the authorities Utilized
profitably Chance
of the value addition in the process Enhance
the reliability |
|
Pakistan's
Chashma Nuclear Power Plant A preliminary study of some safety issues and
estimates of the consequences of a severe accident |
Mian
|
(1999) |
Identification
of the risk critical component Safe
operation of the power plant Initiate
and focus on the accident Proper
safety function |
|
Exploring
iterative and parallel human computation processes |
Little,
Chilton, Goldman, & Miller |
(2010) |
Prevention
maintenance Condition
monitoring Inspection
and functional testing Run
to failure Explain
the hidden failures |
|
Evaluation
of techniques for manufacturing process analysis |
Hernandez-Matias,
Vizán, Hidalgo, & Ríos |
(2006) |
Framework
for the interesting and better use of modelling technique Monitor
carefully to avoid future problems |
|
Reliability
centered maintenance optimization for power distribution systems |
Yssaad
& Chaker |
(2014) |
RCM
program used for maintenance including; reactive, preventive, proactive
active and condition based maintenance. |
|
Transferable
belief model for reliability analysis of systems with data uncertainties and
failure dependencies |
Sallak,
Schön, & Aguirre |
(2010) |
Level
of complexity to problems Understanding
on imprecise reliability data Focus
on complex failure dependencies |
|
Transformer
risk modelling by stochastic augmentation of reliability-centred maintenance |
Mkandawire,
Ijumba, & Saha |
(2015) |
Applying
the RCM process Important
to define the boundary of the system Rotating
parts of the equipments Sources
of the electrical power |
|
Survey
of failures in wind power systems with focus on Swedish wind power plants
during 1997-2005 |
Ribrant
& Bertling |
(2007) |
Identification
of System Functions System
Functional analysis Identification
of failure modes focus
on reliability techniques |
|
Towards
reliability centred maintenance of wind turbines |
McMillan
& Ault |
(2014) |
Feature
of the RCM process Promotes
the team work Increases
the productivity RCM
support effective decision making |
|
Can
you really Justify Reliability Centered Maintenance |
Idhammar
|
(2005) |
RCM
is mainly determined on the system RCM
is used for safety and cost saving Maintenance
in the industry Maintenance
strategies such as reactive, preventive, proactive strategies. |
|
Asset
maintenance planning in electric power distribution network using statistical
analysis of outage data |
Adoghe,
Awosope, & Ekeh |
(2013) |
Operation
and maintenance program Established
policies of the industry Approach
for centered asset management Quantitative
statistical analysis |
|
Applications
of maintenance optimization models: a review and analysis |
Dekker
|
(2005) |
System
selection Definition
of the system boundaries Acquisition
of documentation of the materials Interviews
and plant personnel |
|
Reliability-centered
maintenance |
Smith
|
(1993) |
Focus
on the consequences of hidden failure Focus
on the consequences of safety and environment Focus
on the consequences of operations Focus
on the non-operational consequences |
|
Reliability
centered maintenance (RCM) program |
S.
KHALID |
(2000) |
RCM
has following effectiveness It
is based on the identification of the risk critical components. It
is based on determining the maintenance necessary activities for ensuring the
reliable operations. The
electrical plant is on step of working and major focused point is to find the
“reliability” in continuous working. |
|
A
review of the three most popular maintenance systems |
Fraser,
Hvolby, & Watanabe |
(2011) |
RCM
helps in improve the reliability of the properties and functioning industries
plants Replacement
of the preventive maintenance Give
us information of the failure estimation and what are possible ways |
|
Implementing
a Strategy of Reliability Centered Maintenance (RCM) in the Libyan Cement
Industry |
Albarkoly
& Park |
(2015) |
Maintenance
plan and have better information Financial
investment according to the importance Focus
on failure in the functional operation |
|
Engineering
maintenance: a modern approach |
Dhillon |
(
2002) |
RCM
process is a great technique Better
platform to work and have attractive ways Improving
the system and its efficiency Quality
Power
of managing the system |
|
Reliability-Centred
Asset Maintenance—A step towards enhanced reliability, availability, and
profitability of wind power plants |
Besnard
& Bertling |
(2010) |
RCM
process is to prioritize the main functional failure Critical
functions of the equipment resources By
replacing the typical view of minting equipment with the functional
preservation |
|
Computer-aided
RCM-based plant maintenance management system |
Gabbar,
Yamashita, Suzuki, & Shimada |
(2003) |
RCM
is helpful in every possible way Poor
information which is not enough for the maintenance Personal
safety and equipment and environment |
12. Discussion of Reliability
Centered Maintenance for Power Plant
Methodology Used of Reliability
Centered Maintenance for Power Plant
For the analysis of the current research, there are the
focuses on the qualitative and secondary analyze. However, for the effective
secondary analysis, the current research considered the articles especially
from the Google scholar so that there could be the better evaluation of the RCM
project. The current researchers made the questions and analyze the
effectiveness of the RCM techniques on the power plant through getting
understanding from the previous researchers. Current research focuses on the
articles related to the RCM approach, the research is conducted based on
establishing the maintenance, operational as well as the capital improvement
strategies
With the analysis of the past research, the RCM principles
for maintenance of power plants, followed by authors evaluation based on their
primary research are considered, the maintenance for the research is calculated
in a logical manner so that the reliability could be attained from the prior
researchers. Thus, the secondary research questions are considered so that
better evaluation and the results could be attained. Current research focused
on different studies so that there could be the best possible analysis of each
question and so that author or research point of view regarding the analysis of
the RCM for maintenance of power plants could be known.
There is the focus on the secondary research so that best
results could be achieved and sp the current research could also achieve the
best performance. The secondary analysis based on the questions and can be
considered as best because there is the need to analyze purposes of prior
studies that are related to the questions. The secondary research helps to
focus on the original work and help to identify as well as consider to answers
of the entire research questions. The current research investigates alternative
perspective so that could be better considerations of the past research and so
that best and quality qualitative research or secondary analysis can be a
focus.
Current research finds out the articles and helps the
questions to get the answers based on the secondary and qualitative data
methods. The research is based on the secondary analysis because it is
beneficial and economical. The secondary analysis considers all the research
questions and with the findings of the previous research; answers are reliable
and has its significance because there is the in-depth analysis. Through the
investigations of the relevant studies, the current research also analyzes or
focuses on the researches authenticity so that answers could be taken out
through the investigation on researchers that are based on the evaluation and
objectives related to the research questions.
Analysis of the Research of
Reliability Centered Maintenance for Power Plant
The research questions get the better results because
analysis of the effective articles is done, the research questions are related
to the RCM analysis process and there is the focus on the goals of
implementation regarding the RCM analysis process. However, the articles find
effective answers to these questions. The research questions based on the
complex system like the power plant and what safety practices and cost
limitations, the researchers are considered from different articles.
The articles that are concerned also based on the
cost-effective maintenance strategies for RCM as well as the discussion that is
done on some functional failures of RCM. The researchers focused on the better
technique for the present and future plans can be focused in order to get
positive results through the RCM approach. Cost effective maintenance and regarding
RCM are also discussed. All the researchers that are considered provided the
efficient results to current research because all the material based on power
plant maintenance is evaluated in an effective way so that there could be
better analysis of the current problems or research questions.
13. Recommendations of Reliability Centered Maintenance for Power Plant
The concept of the maintenance of the operating plants such
as power plants become much importance and there been develop new technologies
and techniques which makes the maintenance easy and effective which results in
great performance of the plant and its equipments. Reliability centered maintenance
(RCM) is a great technique and much useful in industrial sectors and work as a
great tool in the improvement of the plant efficiency. It also help in
identifying weaknesses in the plant operations and failure which can be happen
and also suggest the solutions for the problems and failures with best results.
The application of the RCM provide the best results in the
efficiency of the plant, save much cost in the maintenance, improve the product
quality, improve the production rate, recommend future maintenance plans and
schedules, identify the failures and future failures, suggest the solution of
the failures that would be used to overcome the cause of the failures. RCM
technique has great recommendations which are much helpful in the implementation
of the RCM process and also have future development in the industrial sectors
and also help in the development of the industry.
Increase in Efficiency of the Plant
of Reliability Centered Maintenance for Power Plant
RCM is a great approach which is used to maintain the equipments of the plan in its shape and quality. Every industry is developing the methods which can result in the increase of the efficiency of the plant. They are investing in the procedures. Well RCM is best approaches which will increase the efficiency of the plant by maintaining the process and components of the equipments and provide the valuable results which provide the information about the proper maintenance and lead in the best performance of the plant and work on its full efficiency.
RCM keeps the equipment failure in the check list and keep monitoring if there is a failure or chances of future failures. RCM is a good approach to which regulates the proper maintenance of the plant and its important parts and monitor its activities and regulate the system.
Save Cost of the Maintenance of
Reliability Centered Maintenance for Power Plant
Maintenance of the pant and its equipment required proper
knowledge and information about it and the peoples who are trained to do the
maintenance. RCM provide the maintenance plans and provide the information when
the maintenance is required. Maintenance required much of the investment such
as if the part of the equipment is broken need to replace or repair, labor cost
and material cost. These are the work routine maintenance and cost much money
on the daily basis.
RCM overcome all the routine maintenance and provide the
schedule for maintenance which results in saving the money of the routine
maintenance and labor cost on the daily basis. RCM will provide the maintenance
program which has all the features of the routine maintenance and provide the
overall maintenance in a single time which results in the saving money and
labor cost. It also provide a chance of the plant improvement which result in
increase in plant efficiency which increase the production rate and increase
the quality of the product which make its worth in the market and among the
customers and clients.
Improve Product Quality of
Reliability Centered Maintenance for Power Plant
Maintenance of the plant is necessary to keep its operations
and functions running with the best performance. The quality of the products
depends on the raw materials, handling of the materials and the process which
is applied on the materials. When the process on the raw materials is in
operation it is important to know that the plant has all the control measures
which results in the best quality product. If any fault happens it will alter
the product quality and there is chance of that the customers will not be happy
with your services.
RCM provide the all the information about the operations of
the plant and provide the data if there is any change happening in the
operation of the process. RCM will maintain the operation of the process
running with suitable measures and control and provide the maintenance program
which is important for the uniform operation of the process.
Improve Product Quantity of
Reliability Centered Maintenance for Power Plant
Proper maintenance regulates the operation in the uniform
condition and it provides chances to the plant and its equipments to work on
its full capacity. When the plant and its equipments are working with full
capacity and best performance it will result in increase of the production and
its quantity. This will definitely results in the increase of your product in
the market which can generate more profit. However, if the operations are not
working fine and alter the production rate that will become a problem with your
customers and they won’t get the desire quantity in time.
Now RCM is
the best technique which ensures that every function of the operation process
is working fine with proper maintenance of the plant and its equipments. RCM
also provide the data if there is change in the production rate and suggest the
solutions for the maintenance and save time and finally the plant is able to
work with its best performance and efficiency and provide the great quantity.
Identify the Failures and Future Failures of Reliability Centered Maintenance for Power Plant
Failures in the operation process of the plants or in its
equipments results in the great loss of the industry. Now there is need to
develop a system that fine us what is the failure and what are the causes of
the specific failures. When we consider different methods which can help us in
de4termineing the system failures or failures in the components of the plant we
come up with the RCM process. RCM is a best strategy which has ability to
determine the modes of the failures and failures causes. RCM also provide us solutions
of the problems and failures which occur in the plant operations.
RCM process
can also be used to determine the future failures within the plant and in its
components. It provides us an idea when a component is run to fail. So we come
up with the solutions which can prevent us from the future failures. RCM is a
great terminology and has great uses in finding the failure modes and solutions
which can improve the performance of the plant and its components.
Recommendation Solutions of the
Failures of Reliability Centered Maintenance for Power Plant
Failures in the system of the operation process of the plant
and in its equipments lead to the failure of the industry. We need such methods
which provide us best solutions of the failures of the process operations that
will increase the system performance and efficiency and also provide the
information about the failure cause and provide us permanent solutions of the
failures. RCM help us in every possible way. It provides us procedures for the
maintenance which results in the regular inspection of the plant and its
components and eliminates all the causes which can cause failures in the plant
and its equipments working. The solutions of the failures which are suggested
by the RCM process are unique and have great implementation in the process
system and also prevent us from the future failures.
Future Development and Innovation in
RCM of Reliability Centered Maintenance for Power Plant
The maintenance work must guarantee that all creation and assembling
frameworks are working securely and dependably and give the essential help to
the generation work. Besides, support needs to accomplish its central goal
utilizing a financially savvy maintenance procedure. What constitutes a
financially savvy methodology developed after some time? Before, it was trusted
each part of an intricate framework has a correct age at which finish update is
expected to guarantee wellbeing and ideal working conditions. This was the
reason for booked maintenance programs. RCM is a process which provides us all
the information about the maintenance and when the maintenance is needed.
Reliability centered maintenance (RCM) will provide us
future strategies which will be helpful in the maintenance of the machines or
plants and their components. RCM is the best method which can be used to ensure
the reliability of the plant and its components. The RCM process is very useful
in the oil and gas industries, manufacturing industries and other big firms
which have plant equipments and operation systems. RCM is the precise procedure
to streamlining unwavering quality and related upkeep strategies as for
operational necessities. Financial advancement of machine unwavering quality in
respect to hierarchical objectives is the essential goal of the RCM procedure.
Just expressed, RCM
guarantees that if a dollar is spent on enhancing unwavering quality, the full
dollar will return, in addition to some adequate profit for the speculation.
The increase in the utilization of the designing devices and strategies inside
the maintenance industries are in the assembling business in both the
operational and outline and advancement stage. These devices furthermore,
strategies can bolster the work towards accomplishing high hardware execution
gear execution, which is a need for understanding the digitalization of the
assembling industry.
RCM process is only useful when the suggestions and solution
of the RCM are implemented in the industry. There is proper need to review the
procedures and development in the process if any development occurs.
14. Conclusion of Reliability
Centered Maintenance for Power Plant
It is concluded that the reliability centered maintenance
RCM is best techniques which can be used to regulate the maintenance procedures
of the plant and its equipments within the industry. The emphasis is offered on
to make understanding about the significance of Reliability Centered
Maintenance in augmenting the arrival over speculation on the unpredictable
ventures, for example, Power plant, and concentrate given on the assessment of
the adequacy of the propelled designing support approach known as RCM. Thusly,
this examination has sorted out to make understanding that RCM has the ability
to improve the productivity of the intricate framework, for example, power
plant and in the meantime, it is viable in lessening the cost of the support,
cost of the labor and maintenance.
This thesis introduced the Reliability Centered Maintenance
program in a wide based point of view. It is not the slightest bit expected as
a total examination of the program or its execution. The issues of recognizing
maintenance frameworks for consideration in the program, advancement of
particular reviewing methodology, improvement of proper information
accumulation and interface data frameworks should be tended to in pertinent
specialized productions. Also, drive structure adjustments must be recognized
and actualized. The RCM approach gives the best results for the maintenance
programs and its strategies that improve the plant performance and its
efficiency.
The Reliability Centered Maintenance program gives the
administrations with an intelligent, productive technique for recognizing
insufficiencies before they happen. Since the program is utilized as a part of
creating maintenance frameworks, the progress to after generation application
would be moderately easy. The program can be specifically connected and used to
screen support and gear execution proficiently. RCM process has great
applications in the power plants and provides the best procedures and methods
for the maintenance and schedule the criteria of the maintenance that is
proficient and time saving and also cost saving.
This paper provides us four types of the conclusions that
are useful and have future applications and developments.
Importance of the reliability centered maintenance
Impact on the environment
Reliability and availability
Business application
The significant power plants has a life expectancy, hence,
after a specific time, their working effectiveness began to diminish.
Considering this issues, there need to give some legitimate support to proceed
with the usefulness of the plant in a viable behavior. Consequently, the in the
accompanying wring, it is intended to utilize late created propelled designing
systems for the upkeep of the power plant. Thinking about this angle, it is
intended to utilize the propelled Reliability Centered Maintenance to improve
the keep up the proficiency of the gear, decrease the disappointment hazard,
cost and labor for the power plant venture. This approach is expected to boost
the arrival over venture and lessen the conceivable dubious cost because of the
disappointment of the plant task.
Reliability Centered Maintenance process is carried out with
the serious of actions which results in the complete task of the maintenance.
The steps involved in the process of RCM are preparation, analysis, task
selection, task comparison, task comparison review and records. These steps
form a compete and detail form of the RCM process and also define the
procedures which are ready for the implementation on the operation functions of
the plant and its equipments. As for the example we can say that key
assumptions, critical evaluation criteria, non critical evaluation criteria and
development of the process for review.
In the RCM procedure gathering of information and framework
determination has awesome significance. For this viewpoint, there is required
to fundamentally investigate different kinds of information to build up a
framework. It is essential in light of the fact that there are extraordinary
potential outcomes that the feeble framework or the disappointment of the
frameworks significant part may leave awful consequences for the profitability
of the framework enormously improve the cost of the upkeep. Following are a
portion of the huge components that have coordinate effect on the framework
choice: Time present between the failures, Maintenance cost, Time needed for
the repair, and availability.
RCM build up a setup of work as per the gave criteria as the
basic hazard has been distinguished are 125 basic dangers. The framework
identified with the projects are temperate viable. Working and the plant
require upkeep on ceaseless premise. The steps which involve3d in the process
of the RCM are: the identification of the critical components and their risks,
the importance of the maintenance to ensure the reliability of the plant and
its operations, making sure that the reliability is the continuous process.
RCM chance ID and wellbeing usage group serve on the base of
different functions and it help in deciding the ideal level of upkeep calendar
or program. For the better proficiency or execution successful procedure is
utilized for the support of the plant and its equipment's. For RCM program
usage or accomplishing the objectives operational proficiency is expanded and
the cost of the venture is controlled. RCM real objectives are security of the
plant in every one of the circumstances and advantages for sparing the cost.
RCM group needs to perform in all the significant framework
capacities and it needs to support every one of the activities. The group of
the RCM is most imperative and valuable for attempting the atomic power plant
framework unwavering quality. The working of the RCM group or division is keep
up on the most minimal conceivable cost. It is extremely gainful for the
progressing security and ecological issues. For the dependability of the task
first rundown of hazard has been produced on the base of basic segments.
In this thesis, systems to build up a RCM program for the
hazard basic segments would be examined. This strategy is valuable in building
up a RCM program for hazard basic segments which were found by the approach of
PSA show. Deciding the guarded and defensive upkeep exercises are engaged with
setting up an unwavering quality focused support program for the hazard basic
part. Those support exercises may incorporate condition observing or other
upkeep applicable exercises. For instance rebuilding which is as per the necessities
of the segments. There are two stages which toss plentiful light on RCM program
for a hazard basic segment. Those means are shown by figure. In this figure,
the well ordered assessment process is displayed for the basic Risk Components.
RCM beat all the normal upkeep and give the calendar to
support which brings about sparing the cash of the standard support and work
cost on the regular schedule. RCM will give the upkeep program which has every
one of the highlights of the normal support and give the general upkeep in a
solitary time which brings about the sparing cash and work cost. It
additionally give a possibility of the plant change which result in increment
in plant productivity which increment the generation rate and increment the
nature of the item which make its value in the market and among the clients and
customers.
RCM give the all the data about the activities of the plant
and give the information if there is any change occurring in the task of the
procedure. RCM will keep up the activity of the procedure running with
appropriate measures and control and give the support program which is vital
for the uniform task of the procedure. Presently RCM is the best method which
guarantees that each capacity of the task procedure is working fine with
appropriate support of the plant and its types of gear. RCM additionally give
the information if there is change in the generation rate and propose the
answers for the support and spare time lastly the plant can work with its best
execution and productivity and give the immense amount.
RCM will give us future methodologies which will be useful
in the upkeep of the machines or plants and their parts. RCM is the best
strategy which can be utilized to guarantee the dependability of the plant and
its segments. The RCM procedure is extremely helpful in the oil and gas
businesses, fabricating enterprises and other huge firms which have plant types
of gear and activity frameworks. RCM is the exact strategy to streamlining
enduring quality and related upkeep techniques with respect to operational
necessities. Money related headway of machine relentless quality in regard to
various leveled targets is the fundamental objective of the RCM method.
It the end, we can say that the use of the reliability centered maintenance procedures work in the improvement of the plant and its functions. It regulates the functions in a systematic manner and provides the data of the maintenance and arrange important feature for the plant functions and its operations. Implementation of the RCM always works in the favor of the industry of the power plant. This thesis have all the information which is need to apply the RCM process in the industry and have ability to make improvement in the RCM process and its development in the future.
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