Application of Reliability Centered Maintenance Concept to Petrochemical Industry

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Reliability Centered Maintenance (RCM) is a well-known method in several industries. RCM is a structure decision process to cost-effective determines and optimum maintenance requirements. This paper proposes the application of the RCM concept to a petrochemical case study. The results indicate that preventive maintenance plans and available time of maintenance staff are improved significantly. KEYWORD: Reliability Centered Maintenance (RCM); Preventive Maintenance (PM) International Conference on Industrial Technology and Management Science (ITMS 2015) © 2015. The authors Published by Atlantis Press 445 2 LITERATURE SURVEY 2.1 Reliability Centered Maintenance (Moubray, 1997) Maintenance has been evolved through three generations. The first generation covered the period up to World War II. During the time, industry was not very highly mechanized. Hence, maintenance was simple whereby the machine was fixed only when it failed. In the second generation (between 1950’s and 1970’s), machines of all types were more complex. Then downtime came into focus and the concept of preventive maintenance became worldwide. In this period, a scheduled maintenance was planned in advance. In the third generation (after 1970’s), a big change in maintenance was noticed. The maintenance was expected not only to increase machine availability but also with minimum maintenance cost. As a result, the concept of RCM, which is a process to determine the maintenance requirements of physical equipment, was developed. Seven steps of the RCM process are shown in Figure 3. Figure 3: Seven steps of the RCM process Step 1: Functions and performance standards: define the functions and performance standards of equipment. Step 2: Functional failure: define the performance expectations of equipment. Step 3: Failure modes: define the failure modes of equipment. Step 4: Failure effects: define the failure effects of equipment at each failure mode. Step 5: Failure consequences: define the failure consequences to the production process when the equipment cannot be in service at the expected level. Step 6: Preventive tasks: choose the suitable maintenance strategy for all failure modes. Step 7: Default tasks: update the new maintenance list and schedule in the computerized maintenance management system (CMMS) 2.2 Literature Review Penrose (2005) proposed maintenance strategies which are suitable for motor management by using RCM techniques on electric motor. This paper describes about effective maintenance strategies such as condition-based monitoring (CBM) and assists maintenance staff for selecting the optimum in performing the right maintenance on the right equipment at the right time for the right reasons. Yu & Zhao (2005) proposed maintenance plan based on RCM, which considered the condition of electrical equipment and its importance in the power system network. The actual condition of electrical equipment can be identified based on various criteria. They suggested identifying the criticality equipment which must be maintained first. Ozdemir & Kuldasli (2010) proposed an RCM program for Turkish national power transmission system. This paper described steps of applying the RCM methodology and decision tree diagram for selecting right maintenance strategy to achieve the target to improve the reliability of the system by minimize the failure with applying appropriate maintenance procedure. 3 RESEARCH METHODOGY The first step of RCM is data collection. Motor and switchgear which are the main equipment of class C are chosen in this study (Table 3). Normally the equipment with fully redundant has two units (one is on duty and the other is standby), whereas the equipment with not-fully redundant has only one. Table 3: Motor and Switchgear data Type Class Fully Redundant Not Fully Redundant Total Motor C 144 76 220 Switchgear C 250 81 331 Appropriate maintenance strategies have been developed specifically for fully and not-fully redundant equipment. The functional failures, failure modes and failure consequences for each equipment group are shown in Tables 4 and 5.