Analysis of Optimal Maintenance Interval on ID Fan Using Reliability Centered Maintenance

Teluk Lembu Gas Power Plant (PLTG) is one type of power plant that uses the power of burning fuel and high pressure air. To be able to meet the needs of electrical energy on the island of Sumatra, especially in the Riau region,electricity production must not experience a decrease in productivity due to equipment damage. Obstacles that arise are frequent downtime unexpectedresulting in the production of electricity is interrupted or even to cause derating caused by damage to the operational when the engine is running. This study aims to provide recommendations for equipment maintenance andtime intervals optimal inspectionin the generator system. The research method used is Reliability Centered Maintenance (RCM) withanalysis quantitative. Where are the stages of implementing the RCM method, namely determining thecomponents criticalin the PLTG generator engine, determining thevalues, determining the Mean Time to Failure (MTTF) and Mean Time to Repair (MTTR)time interval optimal maintenance, and making a table of causes of damage to thecomponents generator engine. After analyzing it, it was found that thecomponent criticalof PLTG Teluk Lembu is the Diesel Motor. This is obtained based on the component with the highest frequency of damage, namely 13 damage during a period of 1 year. From the results of data processing, it is obtained that the MTTF value is 0.92441 hours and the MTTR value is 0.89014 hours. Theinspection time interval optimalis 25 days, so it is advisable to carry out Corrective and Preventive maintenance activities for Diesel Motorcycles periodically every 25 days (PM 25D) in order to increase the reliability of the Diesel Motor

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Evaluasi Manajemen Perawatan dengan Metode Reliability Centered Maintenance (RCM) II pada Mesin Cane Cutter 1 dan 2 di Stasiun Gilingan PG Meritjan - Kediri

Rekayasa ◽

10.21107/rekayasa.v10i2.3611 ◽

2017 ◽

Vol 10 (2) ◽

pp. 99

Author(s):

Cahyo Purnomo Prasetyo

Keyword(s):

Maintenance Cost ◽

Repair Cost ◽

Maintenance Policy ◽

Work Safety ◽

Maintenance Costs ◽

Reliability Centered Maintenance ◽

Optimal Maintenance ◽

Critical Components ◽

Optimal Maintenance Policy ◽

Production Target

Penelitian ini bertujuan untuk menentukan kebijakan perawatan optimal yang dapat mengurangi biaya perbaikan (repair cost) dan biaya konsekwensi operasional (operational consequence cost). Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian ini difokuskan pada mesin Cane Cutter 1 dan 2 dengan pertimbangan beberapa aspek yaitu : pengaruh kegagalan terhadap pencapaian target produksi, resiko keselamatan kerja dan biaya perawatan yang akan ditimbulkan. Dari hasil penelitian dapat diketahui bahwa komponen kritis pada mesin Cane Cutter 1 dan 2 adalah : Pisau dan Baut Pisau. Perawatan yang dilakukan untuk mengantisipasi dan mengatasi kegagalan yang terjadi pada komponen mesin tersebut adalah proactive task yang meliputi : scheduled restoration task dan scheduled discard task. Rata-rata penurunan biaya perawatan total yang didapatkan dengan mengurangkan ‘biaya total pada interval perawatan awal’ dan ‘biaya total pada interval perawatan optimal’ adalah 14,82 %.Kata Kunci: cane cutter, downtime, pabrik gula. ABSTRACTThis research aims to determine the optimal maintenance policy which could reduce repair cost and operational consequence cost. The methods which applied in this research is Reliability Centered Maintenance (RCM) II. This research focuses on Cane Cutter 1 and 2 machines by considering several aspects, such as and effect of any failure on production target achievement, work safety risk and maintenance cost which might be caused by the critical condition. The result showed that some critical components at the Cane Cutter 1 and 2 machines were : Blade and Blade Bolt. The maintenance which could be done to anticipate and deal with any failure occurring in the machine components was called proactive task comprising : scheduled restoration task and scheduled discard task. The average reduction in total maintenance costs which was obtained by subtracting ‘total costs at initial maintenance interval’ and ‘total costs at optimal maintenance interval’ amounted to 14,82 %.Keywords: cane cutter, downtime, sugar factory

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Reliability-Centered Maintenance for Off-Highway Truck: Case Study of Sungun Copper Mine Operation Equipment

Volume 15: Safety, Reliability and Risk; Virtual Podium (Posters) ◽

10.1115/imece2013-66355 ◽

2013 ◽

Author(s):

Amin Moniri Morad ◽

Mohammad Pourgol-Mohammad ◽

Javad Sattarvand

Keyword(s):

Block Diagram ◽

Surface Mining ◽

Importance Measure ◽

Mining Equipment ◽

Efficient Operation ◽

Copper Mine ◽

Sungun Copper Mine ◽

Operation And Maintenance ◽

Reliability Centered Maintenance ◽

Optimal Maintenance

Surface mining equipment play an important role in capital investments and operating costs of mining industry. Improvement of the equipment performance leads to improvement of operation cost. Efficient operation and maintenance techniques centered on reliability are the methods of choice. Recent researches promote the necessity of utilization of optimal maintenance methods instead of traditional methods. This study aims in application of optimal maintenance methods for reduction of occurrence of sudden failures and equipment break down. Evaluation of reliability-centered maintenance is demonstrated on mining dump trucks operation and maintenance are utilized for Sungun copper mine. The operation data is used to quantify the failure and maintenance profile for each component required for reliability analysis. The modeling is done by using reliability block diagram and solved by Monte Carlo simulation for assessment of the dynamic behavior of the equipment. The reliability of the system is evaluated and importance of each component is estimated. The importance analysis is used to identify the items which have critical impact on reliability and availability of overall equipment for prioritizing the decision for improvements. The reliability importance measure is computed for the components by weighted importance method. Trend analysis is conducted to select proper model for the maintenance profile. Availability estimations demonstrate overall performance of the equipment on its life span.

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Condition-Based Maintenance of HVAC on a High-Speed Train for Fault Detection

Electronics ◽

10.3390/electronics10121418 ◽

2021 ◽

Vol 10 (12) ◽

pp. 1418

Author(s):

Lorenzo Ciani ◽

Giulia Guidi ◽

Gabriele Patrizi ◽

Diego Galar

Keyword(s):

Decision Making ◽

High Speed ◽

Failure Modes ◽

Air Conditioning System ◽

Suggested Approach ◽

Reliability Centered Maintenance ◽

High Speed Trains ◽

Optimal Maintenance ◽

The Cost ◽

Maintenance Plan

Reliability-centered maintenance (RCM) is a well-established method for preventive maintenance planning. This paper focuses on the optimization of a maintenance plan for an HVAC (heating, ventilation and air conditioning) system located on high-speed trains. The first steps of the RCM procedure help in identifying the most critical items of the system in terms of safety and availability by means of a failure modes and effects analysis. Then, RMC proposes the optimal maintenance tasks for each item making up the system. However, the decision-making diagram that leads to the maintenance choice is extremely generic, with a consequent high subjectivity in the task selection. This paper proposes a new fuzzy-based decision-making diagram to minimize the subjectivity of the task choice and preserve the cost-efficiency of the procedure. It uses a case from the railway industry to illustrate the suggested approach, but the procedure could be easily applied to different industrial and technological fields. The results of the proposed fuzzy approach highlight the importance of an accurate diagnostics (with an overall 86% of the task as diagnostic-based maintenance) and condition monitoring strategy (covering 54% of the tasks) to optimize the maintenance plan and to minimize the system availability. The findings show that the framework strongly mitigates the issues related to the classical RCM procedure, notably the high subjectivity of experts. It lays the groundwork for a general fuzzy-based reliability-centered maintenance method.

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Optimization and Selection of Maintenance Policies in an Electrical Gas Turbine Generator Based on the Hybrid Reliability-Centered Maintenance (RCM) Model

Processes ◽

10.3390/pr8060670 ◽

2020 ◽

Vol 8 (6) ◽

pp. 670

Author(s):

Moath Alrifaey ◽

Tang Sai Hong ◽

Azizan As’arry ◽

Eris Elianddy Supeni ◽

Chun Kit Ang

Keyword(s):

Failure Mode ◽

Oil And Gas ◽

Analytic Network Process ◽

Processing Plant ◽

Maintenance Policy ◽

Reliability Centered Maintenance ◽

Optimal Maintenance ◽

Electrical Generator ◽

Maintenance Policies ◽

Electrical Generation

The electrical generation industry is looking for techniques to precisely determine the proper maintenance policy and schedule of their assets. Reliability-centered maintenance (RCM) is a methodology for choosing what maintenance activities have to be performed to keep the asset working within its designed function. Current developments in RCM models are struggling to solve the drawbacks of traditional RCM with regards to optimization and strategy selection; for instance, traditional RCM handles each failure mode individually with a simple yes or no safety question in which question has the possibility of major error and missing the effect of a combinational failure mode. Hence, in the present study, a hybrid RCM model was proposed to fill these gaps and find the optimal maintenance policies and scheduling by a combination of hybrid linguistic-failure mode and effect analysis (HL-FMEA), the co-evolutionary multi-objective particle swarm optimization (CMPSO) algorithm, an analytic network process (ANP), and developed maintenance decision tree (DMDT). To demonstrate the effectiveness and efficiencies of the proposed RCM model, a case study on the maintenance of an electrical generator was conducted at a Yemeni oil and gas processing plant. The results confirm that, compared with previous studies, the proposed model gave the optimal maintenance policies and scheduling for the electrical generator in a well-structured plan, economically and effectively.

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A Reliability-Centered Maintenance Study for an Individual Section Forming Machine

10.20944/preprints201809.0494.v1 ◽

2018 ◽

Author(s):

Samuel Okwuobi ◽

Felix Ishola ◽

Oluseyi Ajayi

Keyword(s):

Failure Modes ◽

Special Focus ◽

Effect Analysis ◽

Automated Production ◽

Individual Section ◽

Reliability Centered Maintenance ◽

Maintenance Program ◽

Optimal Maintenance ◽

Critical Components ◽

Functional Components

This study investigated the breakdown trend in an automated production with an aim to recommend the application of Reliability-centered maintenance (RCM) for an improved productivity via a new preventive maintenance (PM) program. Individual Section-forming machine (ISM): a glass blowing machine for making glass bottles was used as the case study of an automated production system. The machine parts and the working mechanisms were analysed with a special focus on methods of processes and procedures that will enable the ISM maintenance department run more effective and achieve its essential goal of ensuring effective machine operation and reducing machine downtime. In this work, information is provided on the steps and procedures to identify critical components of the ISM using Failure Modes and Effect Analysis (FMEA) as a tool to develop an optimal maintenance program based on the reliability data of the equipment’s functional components. A relationship was established between the failure rate of the machine components and the maintenance costs such that using the recommended PM program, an evidence of improvement in the machine’s availability, safety and cost-effectiveness will result into an increase in the company’s profit margin.

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ANALISIS RELIABILITY CENTERED MAINTENANCE (RCM) PADA ALAT BONGKAR MUAT RUBBER TYRE GANTRY CRANE (RTGC) DI PT XXX

Industrika: Jurnal Ilmiah Teknik Industri ◽

10.37090/indstrk.v5i2.357 ◽

2021 ◽

Vol 5 (2) ◽

Author(s):

Rahmatulloh Rahmatulloh ◽

Keyword(s):

Gantry Crane ◽

Maintenance System ◽

Reliability Centered Maintenance ◽

Optimal Maintenance ◽

Cause Of Failure ◽

Selection Decision ◽

Maintenance Systems ◽

Loading And Unloading ◽

Operational Activities ◽

A Company

The loading and Unloading operational activities in port often run into obstacle, because happened malfunction occurrence of the equipment used. Failure to operate the equipment has resulted in downtime decreased of company productivity. Therefore, a system is needed maintenance of planning in order to produce the equipment that can be operated optimally. This research was choosen the company PT. XXX which is a company that enganged in the field maintenance of equipments port operational (quayside container crane, rubber tyre gantry crane, gantry luffing crane, and others) the place where the equipment maintenance system, especially the rubber tyre gantry crane (RTGC) which has been done are still a breakdown maintenance and corrective maintenance. The aim of this research is to analyze by method of reliability centered maintenance (RCM) to able to determined the optimal maintenance and it can be predict steps to overcome the damage that might will happen in the next period based on existing data. From data processing and analysis was obtained that the components most frequently damaged on the equipment of RTGC, cause of failure, selection decision and recommendations for maintenance systems are based on Reliability Centered Maintenance (RCM).

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