Reliability and Risk Centered Maintenance: A Novel Method for Supporting Maintenance Management
Abstract
:1. Introduction
2. RCM and RBM Methods as Support for Maintenance
3. The Proposed RRCM Method
3.1. Maintenance Plan Definition and Implementation
- On-condition: it recommends the continuous monitoring of the physical asset condition, for instance through online measurements or periodic inspection routes. In this policy, maintenance tasks are scheduled and performed only when there are signs of degradation that indicate the future occurrence of the failure mode;
- Scheduled restoration or replacement: it recommends preventive maintenance as it comprises a set of pre-scheduled periodic maintenance tasks of replacement or restoration of the item, regardless of its condition, to avoid the occurrence of the failure mode;
- Combination of tasks: it recommends a combination of on-condition and scheduled restoration or replacement tasks;
- Failure finding: it recommends a set of periodic maintenance tasks that seek to verify the occurrence of a hidden failure mode, i.e., a failure mode not perceptible to the system operators;
- No scheduled task; run to failure: it recommends that maintenance tasks only intervene in the physical asset when the failure mode occurs, i.e., when the item does not perform at least one of its functions;
- No scheduled task; redesign may be desirable: it includes a consideration to be made by the maintenance team about a possible update or modification in the physical asset. It is a one-time task to allow other types of policies to be used or to reduce the risk associated with the occurrence of the failure mode;
- Redesign is mandatory: it indicates that none of the previous failure management policies can effectively reduce the risk associated with the failure mode, requiring, therefore, that an asset redesign is carried out to make the risk acceptable according to organizational objectives.
4. Case Study
RRCM Application Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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RCM | RBM | RRCM | ||
---|---|---|---|---|
Item study | Select the item | X | X | X |
Determine the functions and performance standards | X | X | ||
Determine functional failures/failure scenarios | X | X | X | |
Determine the associated failure modes | X | X | ||
Determine the failure effects for each failure | X | X | ||
Determine the failure consequence category (FCC) for the functional failures | X | |||
Risk estimation and evaluation | Perform hazard quantification/impact assessment | X | X | |
Perform a probabilistic assessment | X | X | ||
Estimate/classify the risk | X | X | ||
Set up acceptance risk criteria | X | |||
Compare the assessed risk with acceptance criteria | X | |||
Maintenance planning | Select the failure management policy based on FCC | X | ||
Select the failure management policy based on the failure mode risk classification | X | |||
Apply a decision tree diagram as support for cost-effective decisions | X | X | ||
Determine maintenance tasks and interval | X | X | ||
Determine maintenance plans to reduce risk to items that exceed the acceptance criteria | X | |||
Periodic review | Re-estimate/reclassify the risk | X | X | |
Review the input information and decisions made | X | X |
Item | Functions | Functional Failures | Functional Failure Effects | Failure Modes |
---|---|---|---|---|
2.1. Water intake gates | Allow water intake when the generating unit is in operation | Do not allow the water intake to flow | Water does not flow through the turbine | Gate locked in a closed position |
Inoperative drive system | ||||
Allow a low-intake water flow | Turbine water flow is lower than rated | Gate locked in an intermediary position | ||
Low pressure in the hydraulic drive system | ||||
Ensure the water intake watertightness | Do not ensure water intake watertightness | Residual water flow in the intake system with the unit inoperative | Lack of watertightness in the water intake system when closed | |
Automatically close in case of generating unit overspeed | Do not automatically close when necessary | Water continues to flow through the turbine | Auto-close command not executed | |
Gate locked in an open position | ||||
2.2. Water intake grids | Protect the water intake components and turbine | Do not protect systems from debris carried by the river | Loss of protection of the intake components and turbine | Deformed or ruptured water intake grids |
Allow water intake when the generating unit is in operation | Do not allow the water intake to flow | Water does not flow through the turbine | Water intake grids are completely clogged | |
Allow a lower intake water flow | Turbine water flow is lower than rated | Water intake grids are partially clogged | ||
6.7. Turbine guide bearing | Constrain the radial displacement of the turbine shaft | Do not restrict the radial displacement of the turbine shaft | Excessive shaft vibration | Excessive clearance in the bearing housing |
Insufficient lubrication | ||||
Inadequate viscosity of oil | ||||
Overheated lubricating oil | ||||
Damaged bearing components | ||||
Ensure the hydrogenator shaft alignment | Do not ensure the proper hydrogenator shaft alignment | Excessive shaft vibration | Improper bearing elements positioning | |
Prevent oil leakage | Do not prevent oil leakage | Oil leakage to the plant’s facilities and the river | Cracks in the bearing housing |
Level | Description | Functional Failure Impacts on the Environment |
---|---|---|
1 | Very Low | Not enough to cause significant environmental impacts |
2 | Low | May cause minor environmental impacts |
3 | Medium | May cause medium environmental impacts |
4 | High | May cause severe or major environmental impacts |
5 | Very High | May cause catastrophic environmental impacts |
Level | Description | Functional Failure Impacts on Personnel and Facilities’ Safety |
---|---|---|
1 | Very Low | Not enough to cause injury to staff or damage to facilities |
2 | Low | May cause minor injuries to personnel or minor damage to facilities |
3 | Medium | May cause major injury to personnel or serious damage to facilities |
4 | High | May cause severe injury to personnel or critical damage to facilities |
5 | Very High | May cause fatalities or catastrophic damage to facilities |
Level | Description | Functional Failure Impacts on Generating Unit Power Generation and Availability |
---|---|---|
1 | Very Low | The failure does not impact the availability or generation capacity of the generating unit |
2 | Low | Failure does not cause unavailability but affects the operating condition of the generating unit |
3 | Medium | Failure does not cause unavailability but affects the power generation of the generating unit |
4 | High | Failure does not cause unavailability but severely affects the power generation of the generating unit |
5 | Very High | Failure causes the unavailability of the generating unit |
Level | Description | Failure Mode Probability |
---|---|---|
1 | Very Low | Failure rate is very low (up to 1 failure every 60 months) |
2 | Low | Failure rate is low (1 failure between 36 and 48 months) |
3 | Medium | Failure rate is moderate (1 failure between 12 and 24 months) |
4 | High | Failure rate is high (1 failure between 3 and 6 months) |
5 | Very High | Failure rate is very high (1 or more failures every month) |
Item | Functions | Functional Failures | Functional Failure Effects | EnI | PFI | PGAI | FFI | Failure Mode ID | Failure Mode | FMP | FMRL |
---|---|---|---|---|---|---|---|---|---|---|---|
2.1. Water intake gates | Allow water intake when the generating unit is in operation | Do not allow the water intake to flow | Water does not flow through the turbine | 1 | 1 | 5 | 5 | FM.2.1.A | Gate locked in a closed position | 1 | High |
FM.2.1.B | Inoperative drive system | 1 | High | ||||||||
Allow a low-intake water flow | Turbine water flow is lower than rated | 1 | 1 | 4 | 4 | FM.2.1.C | Gate locked in an intermediary position | 1 | Medium | ||
FM.2.1.D | Low pressure in the hydraulic drive system | 2 | High | ||||||||
Ensure the water intake watertightness | Do not ensure water intake watertightness | Residual water flow in the intake system with the unit inoperative | 1 | 2 | 1 | 2 | FM.2.1.E | Lack of watertightness in the water intake system when closed | 2 | Low | |
Automatically close in case of generating unit overspeed | Do not automatically close when necessary | Water continues to flow through the turbine | 1 | 5 | 1 | 5 | FM.2.1.F | Auto-close command not executed | 1 | High | |
FM.2.1.G | Gate locked in an open position | 1 | High | ||||||||
2.2. Water intake grids | Protect the water intake components and turbine | Do not protect systems from debris carried by the river | Loss of protection of the intake components and turbine | 1 | 4 | 4 | 4 | FM.2.2.A | Deformed or ruptured water intake grids | 2 | High |
Allow water intake when the generating unit is in operation | Do not allow the water intake to flow | Water does not flow through the turbine | 1 | 5 | 5 | 5 | FM.2.2.B | Water intake grids are completely clogged | 2 | High | |
Allow a lower intake water flow | Turbine water flow is lower than rated | 1 | 2 | 3 | 3 | FM.2.2.C | Water intake grids are partially clogged | 4 | High | ||
6.7. Turbine guide bearing | Constrain the radial displacement of the turbine shaft | Do not restrict the radial displacement of the turbine shaft | Excessive shaft vibration | 1 | 2 | 4 | 4 | FM.6.7.A | Excessive clearance in the bearing housing | 1 | Medium |
FM.6.7.B | Insufficient lubrication | 2 | High | ||||||||
FM.6.7.C | Inadequate viscosity of oil | 3 | High | ||||||||
FM.6.7.D | Overheated lubricating oil | 2 | High | ||||||||
FM.6.7.E | Damaged bearing components | 1 | Medium | ||||||||
Ensure the hydrogenator shaft alignment | Do not ensure the proper hydrogenator shaft alignment | Excessive shaft vibration | 1 | 1 | 3 | 3 | FM.6.7.F | Improper bearing elements positioning | 1 | Low | |
Prevent oil leakage | Do not prevent oil leakage | Oil leakage to the plant’s facilities and the river | 4 | 2 | 2 | 4 | FM.6.7.G | Cracks in the bearing housing | 1 | Medium |
Failure Mode ID | Failure Mode | FMRL | Failure Mode Management Policy | Maintenance Task | Task Frequency |
---|---|---|---|---|---|
FM.2.1.A | Gate locked in a closed position | High | Scheduled restoration or replacement | Align the gate guides and free them from obstacles. Lubricate moving components | Follow the unit maintenance downtime plan |
FM.2.1.B | Inoperative drive system | High | Scheduled restoration or replacement | Inspect the hydraulic system, retighten gaskets and connections, and replace components such as bearings and seals | Follow the unit maintenance downtime plan |
FM.2.1.C | Gate locked in an intermediary position | Medium | Scheduled restoration or replacement | Align the gate guides and free them from obstacles. Lubricate moving components | Follow the unit maintenance downtime plan |
FM.2.1.D | Low pressure in the hydraulic drive system | High | Scheduled restoration or replacement | Inspect the condition of the hydraulic system and correct leaks. Check the drive oil level and top up if necessary | Follow the inspection route plan |
FM.2.1.E | Lack of watertightness in the water intake system when closed | Low | No scheduled task. Redesign may be desirable | - | - |
FM.2.1.F | Auto-close command not executed | High | Scheduled restoration or replacement | Periodically replace the drive components of the automatic gate-closing system | Follow the unit maintenance downtime plan |
FM.2.1.G | Gate locked in an open position | High | Scheduled restoration or replacement | Align the gate guides and free them from obstacles. Lubricate moving components | Follow the unit maintenance downtime plan |
FM.2.2.A | Deformed or ruptured water intake grids | High | Scheduled restoration or replacement | Check the structural condition of the water intake grids from visual inspections. Carry out repairs when necessary | Follow the unit maintenance downtime plan |
FM.2.2.B | Water intake grids are completely clogged | High | On-condition task | Continuously monitor the water pressure upstream and downstream of the grids and clean them with a hydraulic grate cleaner whenever the pressure difference is significant | Continuous |
FM.2.2.C | Water intake grids are partially clogged | High | On-condition task | Continuously monitor the water pressure upstream and downstream of the grids and clean them with a hydraulic grate cleaner whenever the pressure difference is significant | Continuous |
FM.6.7.A | Excessive clearance in the bearing housing | Medium | Scheduled restoration or replacement | Check the bearing housing fastening elements and retighten or replace them when necessary | Follow the unit maintenance downtime plan |
FM.6.7.B | Insufficient lubrication | High | On-condition task | Continuously monitoring oil flows and levels throughout the bearing lubrication system | Continuous |
FM.6.7.C | Inadequate viscosity of oil | High | On-condition task | Analyze the quality of the oil and replace it in case of contamination | Follow the oil analysis plan |
FM.6.7.D | Overheated lubricating oil | High | On-condition task | Continuously monitoring the inlet and outlet temperatures of the oil in the bearings and heat exchangers | Continuous |
FM.6.7.E | Damaged bearing components | Medium | On-condition task | Continuously monitor turbine shaft vibration. If excessive vibration not associated with other failure modes is observed, check the bearing conditions | Continuous |
FM.6.7.F | Improper bearing elements positioning | Low | Scheduled restoration or replacement | Check the condition of the bearings periodically and reposition their elements when necessary | Follow the unit maintenance downtime plan |
FM.6.7.G | Cracks in the bearing housing | Medium | Failure finding | Check the conditions of the bearing housing and carry out non-destructive tests to verify the presence of cracks | - |
Authors | Method | Item Study | Risk Estimation and Evaluation | Maintenance Planning | Periodic Review |
---|---|---|---|---|---|
Yang et al. (2020) [35] | RCM | The paper presents a study of the items, including their functions, failure modes, failure causes, and Risk Priority Number (RPN). | Although the paper presents the RPN for prioritization of the failure modes, it is not associated with the failure management policy selection. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures review procedures such as reviewing input information and decisions made. |
Fang et al. (2019) [36] | RCM | The paper presents a study of the items, including their functions, failure modes, failure causes, and fault levels. | Although the paper presents the fault level for prioritization of the failure mode, it is not associated with the failure management policy selection. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures review procedures such as reviewing input information and decisions made. |
Umpawanwong and Chutima (2015) [25] | RCM | The paper presents a study of the items, including their functions, functional failures, failure modes, and FCC. | The paper does not present any type of risk estimation or evaluation for the identified failure modes. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures review procedures such as reviewing input information and decisions made. |
Tavares et al. (2012) [37] | RCM | The proposed RRCM includes a broad study of the items, including their functions, functional failures, failure modes, failure effects, and FCC. | The paper does not present any type of risk estimation or evaluation for the identified failure modes. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures review procedures such as reviewing input information and decisions made. |
Deshpande and Modak (2002) [38] | RCM | The paper presents a study of the items, including their functions, functional failures, and failure modes. | The paper does not present any type of risk estimation or evaluation for the identified failure modes. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures review procedures such as reviewing input information and decisions made. |
Lopez and Kolios (2022) [39] | RBM | The paper provides a systematic study of the items, including the identification of failure modes, effects, and causes. | The paper presents risk estimation and evaluation for each failure mode based on risk assessment through a risk matrix. | The paper presents a decision tree to support the selection of an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures for re-estimating or re-classifying risk. |
Masud, Chattopadhyay, and Gunawan (2019) [40] | RBM | The paper provides a study of the items, including the identification of fault events and consequences. | The paper presents risk estimation and evaluation for each failure mode based on risk assessment through a risk matrix. | The paper does not present a support tool to select an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures for re-estimating or re-classifying risk. |
Hu et al. (2009) [41] | RBM | The paper provides a study of the items, including the identification of fault events and consequences. | The paper presents risk estimation and evaluation for each failure mode based on probabilistic risk assessment. | The paper does not present a support tool to select an appropriate failure management policy for each failure mode. | The paper does not specifically mention periodic review procedures for re-estimating or re-classifying risk. |
Dong, Gu, and Chen (2008) [42] | RBM | The paper provides a study of the items, including the identification of fault events and consequences. | The paper presents risk estimation and evaluation for each failure mode based on probabilistic risk assessment. | The paper does not present a support tool to select an appropriate failure management policy for each failure mode. | The paper presents an iterative method that re-evaluates risk after developing a maintenance plan. |
Khan and Haddara (2004) [43] | RBM | The paper provides a study of the items, including the identification of fault events and consequences. | The paper presents risk estimation and evaluation for each failure mode based on probabilistic risk assessment. | The paper does not present a support tool to select an appropriate failure management policy for each failure mode. | The paper presents an iterative method that re-evaluates risk after developing a maintenance plan. |
Proposed method | RRCM | The proposed RRCM includes a broad study of the items, including their functions, functional failures, failure modes, failure effects, and FCC. | The proposed RRCM incorporates the FMRL for the classification of the risk associated with each identified failure mode based on risk assessment. | The proposed RRCM includes different decision trees to support the selection of an appropriate failure management policy according to the FMRL of each failure mode. | The proposed RRCM includes the Risk Review and Assessment of Maintenance Plans’ Effectiveness as necessary processes, which periodically reassess the risks and outcomes of the method. |
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da Silva, R.F.; Melani, A.H.d.A.; Michalski, M.A.d.C.; de Souza, G.F.M. Reliability and Risk Centered Maintenance: A Novel Method for Supporting Maintenance Management. Appl. Sci. 2023, 13, 10605. https://doi.org/10.3390/app131910605
da Silva RF, Melani AHdA, Michalski MAdC, de Souza GFM. Reliability and Risk Centered Maintenance: A Novel Method for Supporting Maintenance Management. Applied Sciences. 2023; 13(19):10605. https://doi.org/10.3390/app131910605
Chicago/Turabian Styleda Silva, Renan Favarão, Arthur Henrique de Andrade Melani, Miguel Angelo de Carvalho Michalski, and Gilberto Francisco Martha de Souza. 2023. "Reliability and Risk Centered Maintenance: A Novel Method for Supporting Maintenance Management" Applied Sciences 13, no. 19: 10605. https://doi.org/10.3390/app131910605