Reliability Centered Maintenance Analysis Research Articles

Determining a Reliability Centered Maintenance (RCM) analysis model for large diameter prestressed concrete water pipelines

Which maintenance task to perform on an asset is generally known but the schedule of when to perform the task may not be well defined. If the task is performed early, while it may benefit the asset, it may also be expending resources that could be better used elsewhere. If the task is not performed soon enough, the asset may fail, or the asset may require more extensive maintenance be performed. Reliability Centered Maintenance (RCM) is an analysis process used to determine the most effective maintenance strategies. RCM analysis can help an agency establish the most cost effective maintenance strategies for an asset and help establish the best schedule for implementing those strategies. The ultimate goal of an RCM is to determine the required function of an asset with the required reliability at the lowest operation and maintenance costs by identifying revealing indicators of potential failures to establish a condition based strategy; essentially, predicting failures and identifying procedures to minimize the risk of the failure. This paper reviews potential models for predicting the progression of distress of prestressed concrete pipe segments for use in an RCM analysis and proposes a regression model operators can use to forecast when to perform maintenance activities. The paper further considers the condition of the drinking water infrastructure in the United States, developing the case for evaluating predictive models to forecast when a pipeline may reach a specified limit state. The results of this study suggest that RCM analyses for large diameter water pipelines can improve reliability, reduce maintenance costs, and extend the useful life of a pipeline regardless of age or material. Further, using a regression style model with gathered data can be used to forecast when specific maintenance thresholds may be reached, prompting predictive maintenance actions.

Automatic identification of maintenance significant items in reliability centered maintenance analysis by using functional modeling and reasoning

Complex industrial systems adopt reliability centered maintenance (RCM) for maintenance optimization to improve safety and reduce maintenance cost. Preserving function is the core maintenance principle, yet the function concept has not been systematically studied in the context of RCM. This article presents a framework of model-based RCM analysis, which is driven by functional modeling and reasoning. The study focuses on identifying the so-called maintenance significant items through assessment of failure consequences. Multilevel flow modeling (MFM) is proved competitive to identify sufficient system functions that expect maintenance to preserve. It is also able to define failure modes and represent their interactions with system functions, which are essential to RCM. A failure analysis tool for RCM is developed by taking advantage of the causal reasoning capability of MFM, which can be used to automatically analyze consequences of all failures predefined for a target system and generate equipment classifications useful to maintenance optimization. The study provides the possibility of RCM automation, which has been highly demanded by various complex industries. Moreover, as a fundamental functional knowledge framework, MFM can easily accommodate changes in design and operation, which affords the opportunity of implementing a living RCM program.

Determination of Maintenance Task on Tanker Vessel’s Marine Boiler Using Reliability Centered Maintenance (RCM) II Method

There are several types of tanker accidents: collision, fire, grounding etc. In fire accident, the major causes of ship accidents are explosions on marine boilers and damage to ship components. In addition to operational factors, maintenance factors are also the major cause of the accident. In this case, consideration is needed to improve the safety factor of the marine to the operational side. It is also needed to develop the maintenance with the Reliability Centered Maintenance (RCM) approach. This study explores the method of maintenance for marine boiler maintenance systems on tankers using the RCM II method. This study also determines the characteristics of asset failure to assist in assessing the level of risk to asset operations. Based on the results of the RCM analysis, it could be seen that there are 128 maintenance tasks consisting of 3 types of activities: Condition Monitoring (CM), planned maintenance (PM) and One-Time Change (OTC). For failure modes that have high risk, preventive maintenance is performed at intervals every 1 to 7 days. For the longest preventive maintenance, intervals carried out on the safety valve are every 2 years.

Analisa Perbaikan Manajemen Perawatan Dengan Metode Reliability Centered Maintenance Bagian Cnc Wirecut di PT X

PT X is one of the manufacturing companies in Indonesia, which specializes in manufacturing molds and dies which offers products to the internal group and the domestic market. This study discusses the policy analysis of machine repair maintenance management using the RCM (Reliability Centered Maintenance) method approach at the PT X manufacturing company. Some of the problems that occur are sudden engine failure, which will cause over production. One machine that is considered critical is the CNC Wirecut K90 machine. With the application of using RCM it is expected to improve machine reliability through several systematic RCM implementations: system selection and information collection, defining system boundaries, system descriptions and function block diagrams, describing system functions and functional failures, compiling Failure Mode and Effect Analysis (FMEA), composing Logic Tree Analysis (LTA), selection of actions. The new policy set by the Realibility Centered Maintenance (RCM) method consists of 14 failure modes that are resolved by time-directed (CD) and 6 failure modes that are overcome by run to failure (RTF). In the FMEA analysis, there are 4 components that most often fail to function, namely the electrode pin, wire guide, filter and contact fit. The determination of this component is based on the RPN value and data in the field. In the RCM analysis, the electrode pin, wie guide and contact fit components are included in the run to failure (RTF) treatment policy category. Meanwhile, the filter component is in the category of condition direction (CD) maintenance policy with an average failure rate of 29,951 days.

Comparative Study for Inspection Planning of Aircraft Structural Components

In the aircraft operation, the metallic airframes are usually exposed to the extreme loading conditions during the flights due to which the risk of failure should be assessed and held to an allowed level to prevent the associated loss. If the components are inspectable, the components should be inspected routinely so that the fatigue damage can be detected before failure, which usually requires non-destructive inspection (NDI) techniques to evaluate the damage growth during the maintenance action. There have been several methods to determine the inspection plan in the aircraft industry for this purpose. In this study, four methods: Aircraft Structural Integrity Program (ASIP), Reliability Centered Maintenance Analysis (RCMA), Modified RCMA and Stochastic Life APproach (SLAP), are selected to evaluate the performance in comparative manner for a couple of crack growth problems with the aim to help the maintenance planning engineers select their own inspection plan properly based on the performance of each method. The methods are briefly reviewed, implemented, and examined in comparison for the fatigue test data of the fastener hole specimen under an aircraft load spectrum.

TPM Maintenance Management Model Focused on Reliability that Enables the Increase of the Availability of Heavy Equipment in the Construction Sector

The purpose of this paper is to present a maintenance study focused on total productive maintenance (TPM) and reliability-centered maintenance (RCM). Its approach is based on the first pillars of TPM, preventive and autonomous maintenance, as well as the FMEA analysis of RCM for maintenance analysis, which was conducted in this study. The implementation of TPM was successful in that various preventive maintenance (PM) policies assigned to the assets were implemented and it was demonstrated that TPM application in the construction industry could reduce the excessive accumulation of maintenance with the same effective optimization, and with support from RCM analysis and its heavy equipment systems analysis. Excessive corrective maintenance accounts for high investment and delay rates in work times of the assigned project. Traditional methods of availability guarantee, such as reactive or routine maintenance, are insufficient to satisfy a heavy equipment maintenance plan; therefore, what is called for is the systematic application of RCM and TMP because they allow the selection and application of effective PM tasks. An approach that develops and thoroughly analyzes the strategies of continuous corrective and PM is used with an atmosphere of uncertainty and with operational data limited by criticism. Results show a 90% improvement in availability.

Modified Reliability Centered Maintenance Analysis Considering Probability of Detection

In the maintenance of aircraft structural parts, a routine inspection is conducted to prevent fatigue crack growth beyond the critical size during the service life. Traditionally, the inspection interval is determined by a reliability centered maintenance analysis (RCMA), which accounts for the stochastic nature of crack growth. In a practical nondestructive inspection (NDI), however, the probability of detection curve should be considered as well to reflect the detectability during the inspection. In this paper, a new RCMA is proposed that incorporates this. Despite the modern simulation approaches available in recent years, the highlight of the method is that all the equations are developed in an analytical way, which may be more useful in the real field of maintenance. Two examples are given to illustrate the applications: one is to determine the repeat inspection interval under the four POD curves in the NDI; and the other is to determine the maximum operation time until the next inspection, when an aircraft had an earlier inspection packaged with others. As a result, more appropriate inspection plans are obtained than the existing RCMA in terms of reliability and availability.

Determination of Maintenance Task on Rotary Equipment Using Reliability Centered Maintenance II Method

The process of natural gas into LNG (Liquefied Natural Gas) requires many steps and various types of chemical products. The process also produces waste. The Liquid Incinerator treats waste from LNG process. This unit often experiences damages which causes the plant do not work properly and even a down/trip problems due to the continuous operation and the absence of maintenance program, especially for rotary equipments. This causes environmental pollution because the waste is unprocessed and could have an impact on the increased cost to treat the waste elsewhere. One of approaches to analyze the causes of the damage, the impact and effective treatment for equipment is using Reliability Centered Maintenance (RCM). The RCM method is expected to be able to identify the primary and secondary functions of the system, possible failure function, Failure Mode and Effect Analysis (FMEA), and the maintenance actions on the plant. The FMEA result will be used to determine the proposed maintenance task. Based on the proposed maintenance task, the maintenance interval for each equipment is obtained. After RCM analysis is done on 4 equipments, liquid waste feeding pump (34-G-2), quencher pump (34-G-3), scrubber pump (34-G-4) and air compressor (34-K-4). For 34-G-2 failure mode, requires 78% preventive maintenance and 22% corrective maintenance, 34-G-3 requires 87% preventive maintenance and 13% corrective maintenance, 34-G-4 requires 87% preventive maintenance and 13% corrective maintenance and 34-K-4 requires 70% preventive maintenance and 30% corrective maintenance. Workpackage for each interval is created from every failure mode for each interval for maintenance / inspection.

Maintenance System of Universal Goss Printing Machine based on failure data using RCM and RCS method

Over time a machine will get experience a decrease in reliability, causing the engine to be damaged at the time of operation, thus disrupting the production line. To maintain a machine remains reliable then a good maintenance system is required. In this research, we will use Reliability Centered Maintenance (RCM) and Reliability Centered Spare (RCS) analysis on the critical system of Goss Universal printing machine based on engine failure data. The result of RCM analysis obtained the optimal preventive maintenance schedule and the type of treatment, while based on the RCS analysis obtained spare part needs following the maintenance schedule. With the result of this analysis, is expected where the machine will keep good and will continue to operate without a sudden breakdown under the production schedule's need. Based on RCM analysis for each critical subsystem obtained interval preventive maintenance for transfer roller 127.60 hours, Ink fountain roller 24.45 hours, ink form roller 29.23 hours respectively, and the wash-up device is no scheduled maintenance. For spare parts inventory strategies the result using RCS method are: transfer roller104 units, ink fountain roller requires 32 units, ink form roller 36 units and are holding spare policy required, and a wash-up device no holding spare parts.
 Keywords— Failure data, Maintenance System, RCM, RCS

Criticality-based maintenance of a coal-fired power plant

The need for an evolution from the consolidated RCM (Reliability Centered Maintenance) models is something that quite a few experts have been pointing out for quite some time now. Various authors are frequently considering the addition of different techniques in a RCM analysis to increase its efficiency and quality. The objective of this work is to present a method that identifies the most critical components of a system, in order to contribute to the prioritization of maintenance actions. The method uses reliability and risk analysis techniques, such as Hazard and Operability Study (HAZOP), Fault Tree Analysis (FTA) and Failure Modes and Effects Criticality Analysis (FMECA). It also uses a multi-criteria decision method, the Analytic Network Process (ANP), for ranking the most critical components. The method is applied in the Flue Gas Desulfurization System of a Coal-Fired Power Plant. The results obtained with the implementation of the method indicate the most critical components for which maintenance planners shall focus attention, aiming at increasing the availability and decreasing the risk in relation to the plant operation.

IMPLEMENTATION OF MAINTENANCE SCENARIO FOR CRITICAL SUBSYSTEM IN AIRCRAFT ENGINE Case study: NTP CT7 engine

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect.
 The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82.
 Keywords— preventive maintenance, reliability-centered maintenance, risk-based maintenance, risk priority number.

Implementation of Maintenance Scenario for Critical Subsystem In Aircraft Engine: Case Study NTP CT7 Engine

An aircraft company needs to "secure" their aircraft engine for a good maintenance system to keep the optimum engine's performance during the flight. This paper proposed maintenance analysis and scenario for the CT7, the main engine for aircraft at NTP company. A failure data record from four critical components of the CT7 engine is analyzed using Reliability Centered Maintenance (RCM) and Risk Based Maintenance (RBM) methods to obtain the optimum maintenance interval task for the critical subsystem of the CT7 engine and also seeing the risk of maintenance cost of the engine's failure effect. The RCM analysis result obtained seven scheduled on condition task, six scheduled discard task, and three scheduled restoration task. The interval of the maintenance schedule of each critical component varies according to the function obtained. And based RBM analysis, the risk from system performance loss is got $ 7.014.841, 90. Meanwhile, the total cost of maintenance interval based on a calculation of optimal time interval got $1.885.612, 82.
 

PERENCANAAN PENJADWALAN DAN PERSEDIAAN SPAREPART DENGAN METODE RELIABILITY CENTERED MAINTENANCE (RCM) DI PT.X

<p>PT.X is a supplier company that manufactures plastic bottles. Currently PT.X has a<br />production capacity of 4.3 million bottles per day. The production capacity can be met if the<br />production machine running well and in a reliable state. PT.X not currently have a machine<br />maintenance activities are laid out well. This often caused many damage occurs unscheduled<br />engine which causes the cost of lost opportunity (opportunity cost) for the manufacture of<br />products and the high costs of component inventory. The method used in solving the problem in<br />this study is the use of Reliability Centered Maintenance analysis in determining the policy of<br />treatment and then seek maintenance intervals based on the minimum cost. The results obtained<br />are contained 8 components that have critical categories with each scheduled maintenance policy<br />is age replacement, with this calculation obtained a saving of approximately 44% on inventory<br />costs and increased reliability component approximately 42% -64%.</p>

RCM Analysis for Insulating Switch in Substation

Reliability centered maintenance (RCM) is well known for its widely application in various manufacturing industries, but the study on insulating switches of substation is still blank. In this paper, based on RCM evaluation, fault tree is built according to substation fault data, so as to establish fault assessment model of insulating switches. Corresponding fault and maintenance, RCM evaluation model is set up to assess substation maintenance scheme. After combining with actual data from all substations, a series of calculation is implemented, which lead to improving suggestions. Eventually, optimal reliability and economical efficiency is achieved.

Wind turbine condition monitoring: technical and commercial challenges

ABSTRACTDeployment of larger scale wind turbine systems, particularly offshore, requires more organized operation and maintenance strategies to ensure systems are safe, profitable and cost‐effective. Among existing maintenance strategies, reliability centred maintenance is regarded as best for offshore wind turbines, delivering corrective and proactive (i.e. preventive and predictive) maintenance techniques enabling wind turbines to achieve high availability and low cost of energy. Reliability centred maintenance analysis may demonstrate that an accurate and reliable condition monitoring system is one method to increase availability and decrease the cost of energy from wind. In recent years, efforts have been made to develop efficient and cost‐effective condition monitoring techniques for wind turbines. A number of commercial wind turbine monitoring systems are available in the market, most based on existing techniques from other rotating machine industries. Other wind turbine condition monitoring reviews have been published but have not addressed the technical and commercial challenges, in particular, reliability and value for money. The purpose of this paper is to fill this gap and present the wind industry with a detailed analysis of the current practical challenges with existing wind turbine condition monitoring technology. Copyright © 2012 John Wiley & Sons, Ltd.

Projection Model of Intuitionistic Fuzzy Multiple Attribution Decision Making about Preventive Maintenance Modes in RCMA

In order to increase the validation of preventive maintenance modes decision generally gotten by analyst’s subjective and qualitative judgment in reliability-centered maintenance analysis (RCMA), a projection model of intuitionistic fuzzy multiple attribution decision making for preventive maintenance modes in RCMA was presented. An illustration was used to validate the model of decision making about preventive maintenance modes in RCMA for vehicle equipment. The results indicate that the model is suitable to select the optimum preventive maintenance mode. Compared with the fuzzy comprehensive model that describes fuzzy information only by degree of membership, the intuitionistic fuzzy model more precisely and entirely describes fuzzy information come from RCMA by degree of membership, non-membership and hesitation. Then it is more adequate in group decision making for RCMA. It may be used in developing decision support system for RCMA.

Developing RCM Strategy for Hydrogen Fuel Cells Utilizing On Line E-Condition Monitoring

Fuel cell vehicles are considered to be a viable solution to problems such as carbon emissions and fuel shortages for road transport. Proton Exchange Membrane (PEM) Fuel Cells are mainly used in this purpose because they can run at low temperatures and have a simple structure. Yet high maintenance costs and the inherent dangers of maintaining equipment using hydrogen are two main issues which need to be addressed. The development of appropriate and efficient strategies is currently lacking with regard to fuel cell maintenance. A Reliability Centered Maintenance (RCM) approach offers considerable benefit to the management of fuel cell maintenance since it includes an identification and consideration of the impact of critical components. Technological developments in e-maintenance systems, radio-frequency identification (RFID) and personal digital assistants (PDAs) have proven to satisfy the increasing demand for improved reliability, efficiency and safety. RFID technology is used to store and remotely retrieve electronic maintenance data in order to provide instant access to up-to-date, accurate and detailed information. The aim is to support fuel cell maintenance decisions by developing and applying a blend of leading-edge communications and sensor technology including RFID. The purpose of this paper is to review and present the state of the art in fuel cell condition monitoring and maintenance utilizing RCM and RFID technologies. Using an RCM analysis critical components and fault modes are identified. RFID tags are used to store the critical information, possible faults and their cause and effect. The relationship between causes, faults, symptoms and long term implications of fault conditions are summarized. Finally conclusions are drawn regarding suggested maintenance strategies and the optimal structure for an integrated, cost effective condition monitoring and maintenance management system.

Preliminary Analysis on the RCM Technologies Applied in the High-Speed Train

This paper based on the basic theory of reliability- centered maintenance (RCM) combined with the characteristics of the high speed train products, analysed and elucidated the time and requirements, premise, the content and the output of the RCM analysis that the high-speed train products carry out; put forward the ideas of organization to implement the RCM analysis, which has a great realistic significance on the RCM analysis.

Case Retrieval Mechanism of the Intelligent RCM Analysis System

To improve Reliability Centered Maintenance (RCM) analysis efficiency, the Artificial Intelligence (AI) technology, such as case-based reasoning (CBR) is successfully introduced into RCM analysis process and an intelligent RCM analysis (IRCMA) was studied, and an intelligent RCM analysis system (IRCMAS) was developed. The idea for IRCMAS is based on the fact that the historical records of RCM analysis on similar items can be referenced and used for the current RCM analysis of a new item. Case retrieval is the key part of the IRCMAS, of which mechanism has an importance effect on reasoning efficiency of system. In this paper, the IRCMAS is introduced, retrieval mechanism and process of cases are presented, and nearest neighbor retrieval method based on analytic hierarchy process (AHP) is in detail discussed by an example. Design of case retrieval mechanism lays steady foundation for development and realization of intelligent RCM analysis system.

A framework for intelligent reliability centered maintenance analysis

To improve the efficiency of reliability-centered maintenance (RCM) analysis, case-based reasoning (CBR), as a kind of artificial intelligence (AI) technology, was successfully introduced into RCM analysis process, and a framework for intelligent RCM analysis (IRCMA) was studied. The idea for IRCMA is based on the fact that the historical records of RCM analysis on similar items can be referenced and used for the current RCM analysis of a new item. Because many common or similar items may exist in the analyzed equipment, the repeated tasks of RCM analysis can be considerably simplified or avoided by revising the similar cases in conducting RCM analysis. Based on the previous theory studies, an intelligent RCM analysis system (IRCMAS) prototype was developed. This research has focused on the description of the definition, basic principles as well as a framework of IRCMA, and discussion of critical techniques in the IRCMA. Finally, IRCMAS prototype is presented based on a case study.