Availability Analysis of a Steam Boiler in Textile Process Industries Using Failure and Repair Data: A Case Study

2020 ◽  
Author(s):  
Suyog Patil ◽  
Anand Bewoor ◽  
Rajkumar Patil
Keyword(s):  
Preventive Maintenance ◽  
Water System ◽  
Feed Water ◽  
Steam Boiler ◽  
Combustion System ◽  
Blow Down ◽  
Process Industries ◽  
Availability Analysis ◽  
Steam Boilers ◽  
Ram Analysis

Abstract The demand of steam in process industries is increasing rapidly, and this demand can be met by increasing the capacity utilization of steam boilers. Many of the process industries depend on industrial steam boilers as a vital component for their operation. The availability of the boiler can be improved by identifying critical mechanical sub-systems/components concerning failure frequency, reliability, and maintainability and minimizing their likelihood of occurrences. The selection of appropriate technique for data collection and reliability analysis is essential. The time between failure (TBF) and time to repair (TTR) of all components and sub-systems were collected to carry out Reliability, Availability and Maintainability (RAM) analysis. The best-fit distribution and distribution parameters were calculated using ReliaSoft software Weibull++10 after performing trend testing. The preventive maintenance intervals of all components and sub-systems and the availability of the system were evaluated. The analysis reveals that the combustion system, feed-water system, and blow-down system are the critical sub-systems from a reliability perspective and are still the biggest reasons for the boiler downtime. The research study also showed that TTR was longer for the combustion system than the other sub-systems, and thus, to enhance its availability, it is suggested that maintenance resources should be allocated at the appropriate moment to the combustion system. The study also shows the usage of RAM analysis in deciding the preventive maintenance intervals of components/sub-systems of the boiler. It also provides a reference for the preparation of the maintenance plan for the boiler system.

scholarly journals Preventive Maintenance of Boiler: A Case of Kuwait Industry

2019 ◽  
Vol 4 (2) ◽  
pp. 48-58
Author(s):  
Ahmed S Kh R Q Alazemi ◽  
Mohammad Yeakub Ali ◽  
Mohd Radzi Che Daud
Keyword(s):  
Preventive Maintenance ◽  
Oil And Gas ◽  
Safety Concern ◽  
Cost Benefit ◽  
Process Industries ◽  
Benefit Ratio ◽  
Advantages And Disadvantages ◽  
Cost Benefit Ratio ◽  
Steam Boilers ◽  
Industrial Boilers

In Kuwait, industrial boilers are used extensively in food, chemical, oil and gas, textile, pharmaceutical, power plant sectors for generation steam. As a crucial item in industries, its maintenance is of utmost importance. As there are two main maintenance approaches such as reactive maintenance and preventive maintenance, the application of a typical maintenance is definitely based on types of application, safety concern, and cost benefit ratio. If a boiler is down for few days, it may cause huge loss as it interrupts subsequent steps especially in process industries. In this research, the importance of preventive maintenance strategy for steam boilers in Kuwaiti industries has been studied. Based on relative advantages and disadvantages, a proper strategy is proposed for better management and effective maintenance of boilers.

scholarly journals STUDY OF WATER ECONOMIZERS OF STEAM BOILERS AND DEVELOPMENT OF MEASURES FOR EXTENDING THEIR OPERATION

2021 ◽  
Vol 2 (37) ◽  
pp. 64-67
Author(s):  
O. Glushchenko ◽  
I. Sapytsky
Keyword(s):  
Negative Impact ◽  
Combustion Products ◽  
Thermal Calculation ◽  
Feed Water ◽  
Steam Boiler ◽  
Boiler Unit ◽  
Excess Air ◽  
Steam Boilers ◽  
Heat Perception ◽  
Main Components

The operation of the economizer of the P-50 boiler unit, as well as the conditions of its operation have been studied. The economizer is one of the main components of the boiler unit. It works in very difficult conditions. The quality of the feed water supplied to the drum depends on the operation of the economizer. The thermal calculation of steam boiler type P-50 using different values ​​of feed water temperatures at the inlet to the economizer and different coefficients of excess air in the furnace, identified and analyzed factors that negatively affect the operation of the water economizer to conduct a detailed analysis and development of recommendations to improve the operation of the steam boiler as a whole and separately economizing heating surfaces. As a result of the calculations, the dependences of the heat perception of the economizer on the temperature of the feed water at the inlet to the economizer and the dependence of the excess air on the total volume of combustion products are obtained. The paper considers in detail the possible causes of failure of economizers and factors that have a negative impact on the condition of the metal pipes; proposed recommendations that will increase the service life of economizers until the next repair campaign.

scholarly journals Testing and preventive maintenance scheduling optimization for aging systems modeled by generalized renewal process

2009 ◽  
Vol 29 (3) ◽  
pp. 563-576 ◽  
Author(s):  
Vinícius Correa Damaso ◽  
Pauli Adriano de Almada Garcia
Keyword(s):  
Poisson Process ◽  
Renewal Process ◽  
Point Processes ◽  
Water System ◽  
Actual State ◽  
Feed Water ◽  
Repairable Systems ◽  
Homogeneous Poisson Process ◽  
Availability Analysis ◽  
Non Homogeneous Poisson Process

The use of stochastic point processes to model the reliability of repairable systems has been a regular approach to establish survival measures in failure versus repair scenarios. However, the traditional processes do not consider the actual state in which an item returns to operational condition. The traditional renewal process considers an "as-good-as-new" philosophy, while a non-homogeneous Poisson process is based on the minimal repair concept. In this work, an approach based on the concept of Generalized Renewal Process (GRP) is presented, which is a generalization of the renewal process and the non-homogeneous Poisson process. A stochastic modeling is presented for systems availability analysis, including testing and/or preventive maintenances scheduling. To validate the proposed approach, it was performed a case study of a hypothetical auxiliary feed-water system of a nuclear power plant, using genetic algorithm as optimization tool.

Effect of Process Factors on Pervaporation Dehydration of Isopropanol

2017 ◽  
Vol 68 (6) ◽  
pp. 1302-1305
Author(s):  
Ali A. A. Al Janabi ◽  
Oana Cristina Parvulescu ◽  
Bogdan Trica ◽  
Tanase Dobre
Keyword(s):  
Ceramic Membrane ◽  
Membrane Surface ◽  
Water System ◽  
Surface Model ◽  
Feed Water ◽  
Mixture Flow ◽  
Water Separation ◽  
Membrane Area ◽  
Operation Temperature ◽  
Process Factors

The paper aimed at studying the performances of pervaporation separation of isopropanol-water system using a Pervatech ceramic membrane at various values of feed mixture flow rate (F=1000 kg/hr), feed water mass fraction (xF=0.1-0.2), operation temperature (t=60-90 �C), permeate pressure (pP=1000-9000 Pa) and water separation degree (sW=0.9, 0.95). Membrane total flux and separation factor were predicted applying a second order response surface model with 3 factors, i.e., xF, t and pP. An algorithm for estimating the membrane surface area was presented. Membrane area increased with sW and xF and its lowest values (A=13 m2 for xF=0.1 and A=24 m2 for xF=0.2) were attained for t=60 �C and pP=9000 Pa. These findings could be applied for optimizing the process of isopropanol dehydration by pervaporation.

scholarly journals Vulnerability based management of water resources systems

2004 ◽  
Vol 6 (2) ◽  
pp. 133-156 ◽  
Author(s):  
V. K. Kanakoudis
Keyword(s):  
Water Supply ◽  
Preventive Maintenance ◽  
Water System ◽  
Supply System ◽  
Water Supply System ◽  
Maintenance Policy ◽  
Supply Networks ◽  
Water Resources Systems ◽  
Maintenance Schedule ◽  
Preventive Maintenance Policy

Must the water networks be fail-proof or must they remain safe during a failure? What must water system managers try to achieve? The present paper introduces a methodology for the hierarchical analysis (in time and space) of the preventive maintenance policy of water supply networks, using water supply system performance indices. This is being accomplished through a technical–economic analysis that takes into account all kinds of costs referring to the repair or replacement of trouble-causing parts of the water supply network. The optimal preventive maintenance schedule suggested by the methodology is compared with the empirically based maintenance policy applied to the Athens water supply system.

Refurbishment of Secondary System and High AVT Water Treatment of Genkai #1 and #2

2008 ◽  
Author(s):  
Jun Manabe ◽  
Yasuhiko Shoda ◽  
Tatsushi Yamamura ◽  
Yuuichirou Kusumoto
Keyword(s):  
Water Treatment ◽  
Heat Exchangers ◽  
Copper Alloy ◽  
Iron Concentration ◽  
Management Program ◽  
Feed Water ◽  
Secondary System ◽  
Blow Down ◽  
Scale Adhesion ◽  
Commercial Operation

Kyushu electric co. Genkai #1 and #2 are twin 500 Mw class first generation PWR power stations starting their commercial operation in 1975–1981. The units were recently altered their secondary water treatment from AVT to HAVT (High All Volatile Treatment) operation aiming to suppress erosion in piping and equipment, resulting in feed water iron concentration reduction to around 1 ppb as indication of the effects. The units had been successfully operated from the start of their commercial operation except for scale adhesion to SG and others, degradation of copper alloy material tubes in auxiliary heat exchangers and lower condenser vacuum derived from protective ferrous sulfate coating. Life cycle management program was implemented resulting in the alteration of water treatment to HAVT adopting the SG blow down demineralizing and the replacement of copper alloy tube heat exchangers to stainless steel and titan tubes. Further more the examination results were introduced, of the scale adhesion mechanism in the high temperature region of the secondary system based on actual plants iron characterization data and field examination results of HAVT of Genkai units, expecting HAVT application would be effective for the scale adhesion reduction.

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