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Abstract
The unexpected failures, the down time associated with such failures, the loss of production and, the higher maintenance costs are major
problems in any process plant. Risk-based maintenance (RBM) approach helps in designing an alternative strategy to minimize the risk
resulting from breakdowns or failures. Adapting a risk-based maintenance strategy is essential in developing cost-effective maintenance
policies.
The RBM methodology is comprised of four modules: identification of the scope, risk assessment, risk evaluation, and maintenance
planning. Using this methodology, one is able to estimate risk caused by the unexpected failure as a function of the probability and the
consequence of failure. Critical equipment can be identified based on the level of risk and a pre-selected acceptable level of risk. Maintenance
of equipment is prioritized based on the risk, which helps in reducing the overall risk of the plant.
The case study of a power-generating unit in the Holyrood thermal power generation plant is used to illustrate the methodology. Results
indicate that the methodology is successful in identifying the critical equipment and in reducing the risk of resulting from the failure of the
equipment. Risk reduction is achieved through the adoption of a maintenance plan which not only increases the reliability of the equipment
but also reduces the cost of maintenance including the cost of failure.
q 2005 Elsevier Ltd. All rights reserved.
Keywords: Risk assessment; Risk-based maintenance; Maintenance planning; Power plant
1. Introduction
An oil-fired electrical power plant is a complex process
system comprising different types of processing equipment
working under extreme operating conditions. Failure of
such systems can be catastrophic especially during the
winter seasons for the people living in regions having cold
climates and depending on electricity for heating their
homes. Generally, a mix of different maintenance strategies
is used for the maintenance of such systems in order to
increase the availability and to reduce the operating and
maintenance costs of the plant.
Industries worldwide spend a huge amount of money on
maintenance of production machinery. Each year US industry
spends well over $300 billion on plant maintenance and
* Corresponding author. Tel.: C1 709 737 8939; fax: C1 709 737 4042.
E-mail address: fkhan@engr.mun.ca (F. Khan).
0950-4230/$ - see front matter q 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jlp.2005.01.002
70
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
71
72
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Definingrelationship among
components, subsystem and
the main system
Risk Assessment
Hazard identification
Probabilistic failure
analysis
Consequence assessment
Risk quantification
Risk Evaluation
Selecting risk
acceptance criteria
Comparison of assed
risk against acceptable
criteria.
Maintenance Planning
Development of maintenance
plan to reduce the unacceptable
risk to acceptable level
Fig. 1. Architecture of RBM methodology (revised after Khan and Haddara (2003)).
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
System
SubSystems
73
Components
Furnace
Steam generator
Economizer
Steam drum
Super heater
Re-heater
Blow down system
Chemical supply system
Forced draft fan east & west
Turbine
Power plant
(Unit 3)
Generator
Rotating system
Hydrogen supply system
Seal oil supply system
Vacuum system
Condenser
74
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Table 1
Failure parameters of various equipments of Unit 3 (details of Weibull and exponential model is given in Appendix)
Major system
Subsystem/Equipment
Parameter
1. Steam generator
Boiler
Burners
Re-heater
Water walls
Burner piping and valve
Igniters
Boiler control
Controls furnace draft
Steam ins. and control
Auxiliary steam and condensate system
Fuel oil management ins. and control
Combustion control
FD fan #1
FD fan #2
FD fan motor #1
FD fan motor #2
Fuel oil transfer system
Fuel oil forwarding system
Fuel oil boosting system
Air pre-heater 1
Air Pre-heater 2
Air extraction system
Air extraction vacuum pumps
Gland seal system
Turbine rotors
Steam turbine aux. ins. and conrole
Turbine bearing #2
Pedestal bearing #1
Hydrogen gas cooling system
Generator brushes
Condenser tubes
Condenser
Feed water piping and support
Condensate make-up system
Condensate make-up system ins. and control
Boiler feed pump 1
Boiler feed pump 2
HP heater 4
HP heater 5
HP heater 6
Feed cycle auxiliary
Boiler feed water ins. and control
Feed water heater ins. and control
De-aerator
bZ1.17, qZ50,853.9 h
bZ1.65, qZ40,215.4 h
lZ1.74!10K5/h
bZ1.27, qZ57,746.9 h
lZ0.17/year
lZ9.51!10K6/h
bZ1.98, qZ49,061.1 h
lZ0.25/year
lZ0.08/year
lZ0.16/year
bZ1.77, qZ52,219.9 h
lZ2.90!10K5/h
bZ1.26, qZ52,523.1 h
lZ3.00!10K5/h
lZ4.90!10K5/h
lZ2.11!10K5/h
lZ0.16/year
lZ0.08/year
bZ2.18, qZ72,895.4 h
lZ1.50!10K5/h
lZ2.00!10K5/h
lZ0.08/year
lZ0.08/year
lZ0.08/year
lZ0.08/year
lZ0.16/year
lZ0.08/year
lZ0.08/year
lZ0.08/year
lZ0.08/year
bZ1.51, qZ74,607 h
lZ1.50!10K5/h
lZ3.10!10K5/h
lZ0.08/year
lZ0.16/year
bZ1.18, qZ33,925.7 h
bZ1.34, qZ34,845.6 h
lZ0.0001/h
bZ2.9, qZ40,607.4 h
lZ0.08/year
lZ0.08/year
bZ2.21, qZ69,743.4 h
lZ0.08/year
lZ0.16/year
4. Turbine
5. Generator
6. Condensate system
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Probability
Improvement
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Minimal path ways
1
5
8
11 12 13
2
3
4
6
7
9
10
9.995466!10
9.990911!10K1
9.990916!10K1
9.990662!10K1
9.990832!10K1
9.990879!10K1
9.990916!10K1
9.990916!10K1
9.990916!10K1
9.990916!10K1
9.990772!10K1
9.995466!10K1
9.995466!10K1
9.995466!10K1
K1
Improvement index
0
0.000000!10
1.821995!10K3
1.819670!10K3
1.921415!10K3
1.853704!10K3
1.834691!10K3
1.819670!10K3
1.819670!10K3
1.819670!10K3
1.819670!10K3
1.877546!10K3
0.000000!100
0.000000!100
0.000000!100
0.000000
9.898002
9.885374
10.438106
10.070265
9.966972
9.885374
9.885374
9.885374
9.885374
10.199786
0.000000
0.000000
0.0000000
75
76
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Description
Hourly rate
Boiler maker
General foreman
Foreman
Fitter/welder
Apprentice 3
Apprentice 2
Apprentice 1
Helper
Foreman
Welder/journeyman
Foreman
Welder/journeyman
Apprentice
Journey
Electrician
$46.21
$44.90
$41.26
$38.04
$32.81
$27.64
$38.04
$45.49
$42.64
$41.47
$40.22
$38.60
$34.64
$25.00
Pipe fitter
Mill wright
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
77
Table 4
Risk analysis results
Rank
Major system
Consequence in
millions
Risk index
1
2
3
4
5
6
7
8
9
10
Steam generator
High pressure feed water system
Air and flue gas system
Generator
Turbine-steam supply
Fuel oil system
Condenser
Turbine rotating system
Low pressure feed water system
Instrument and service air system
3,678,481
2,478,842
2,102,023
1,634,060
1,110,574
1,110,574
874,745
302,053
286,584
25,249
0.9989
0.9999
0.9914
0.9780
0.9999
0.9866
0.9939
0.9999
0.9995
0.9650
3,674,435
2,478,594
2,083,946
1,598,111
1,110,463
1,095,692
869,409
302,023
286,441
24,365
1.837
1.239
1.042
0.799
0.555
0.548
0.403
0.151
0.143
0.012
Subsystems
Risk
value $
Risk
index
Level of
concern
1
2
3
4
5
6
7
8
9
10
2,045,058
1,444,656
1,333,840
1,109,352
1,107,242
1,102,245
918,590
270,734
123,272
108,783
1.0225
0.7278
0.6669
0.5547
0.5536
0.5511
0.4593
0.1354
0.0616
0.0544
High
Medium
108,783
108,658
108,658
79,781
73,312
32,472
19,827
15,374
12,827
12,618
11,568
18,350
8372
8290
7192
7165
6894
0.0544
0.0543
0.0543
0.0399
0.0367
0.0162
0.0099
0.0077
0.0064
0.0063
0.0058
0.0092
0.0042
0.0041
0.0036
0.0036
0.0034
2982
2338
0.0015
0.0016
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Low
Subsystem
Initial risk
factor ($)
Target
probability
Risk
reduction
in dollars
1
2
3
Steam generator
Air and flue gas system
HP feed water system
3,674,434
2,083,945
2,478,594
0.54
0.85
0.80
1,984,194
1,771,353
1,982,875
78
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Table 7
Maintenance schedule
S. No.
Components
Steam generator
Boiler
Furnace
Economizer
Steam drum
Super heater
Re-heater
Water walls
Blow down system
Chemical supply system
Auxiliary steam supply system
Igniter
Burners
Retractable soot blowers
Rotary soot blowers
Cleaning of ash
Manual door in furnace
Refractory lining in furnace door
Economizer tubes
Water supply header
Vent valve
Globe valve
Cleaning of excessive scaling
Cyclone separator
Feed water control system
Level indicating transmitters (LIT)
Steam drum
Clogged down comer nozzles
Worn gaskets and leakage
Safety valves
Plate dryers
Liners
Secondary super heater (SS)
Primary super heater (PS)
SS inlet and outlet headers
PS inlet and outlet headers
Safety valves
Temperature indicating transmitters
Steam and control system
Attemperator
Control valve
Pressure indicating transmitters
Boiler control
Combustion control
Fuel oil management and control
Spray nozzle
Globe valve
By pass valve
Primary re-heater
Re-heater inlet and outlet headers
Secondary re-heater
Control system (attemperator)
Control valve
Nozzle
Globe valve
By-pass valve
TITs
1.1
Furnace
1.2
Economizer
1.3
Steam drum
1.4
Super heater
1.5
Re-heater
393
223
90
174
84
84
84
135
152
380
2501
266
219
21
109
555
119
145
116
174
152
89
152
175
175
4167
4167
47
102
77
4167
101
123
79
32
253
103
106
120
37
41,669
37
59
73
71
76
86
74
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
79
Table 7 (continued)
S. No.
Components
1.6
1.7
2.1
2.2
2.3
2.4
144
22
48
182
179
47
187
182
48
211
535
44
60
324
320
388
435
364
588
154
217
365
200
109
118
217
157
517
157
175
2403
196
years
years
months
months
months
months
months
years
months
months
months
months
months
months
months
months
months
months
year
months
months
months
year
months
months
months
months
year
months
months
months
months
months
months
months
months
months
year
year
months
months
year
year
year
year
year
year
months
months
year
year
year
months
months
months
year
months
months
years
months
80
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
Table 7 (continued)
S. No.
Components
2.5
Acknowledgements
References
Appendix
Exponential distribution. Failures due to completely
random or chance events will follow exponential distribution. It models reliability during useful life of a system or
component. The probability density function is given as
f tZ l eKlt , where l is failure rate.
failure probability is given as FtZ
t Cumulative Klt
f
tdtZ
1K
e
Z 1K Rt.
0
Thus,
reliability
function is given as RtZ
N
Klt
f
tdtZ
e
.
t
Weibull distribution. Failure events for non-constant
hazard rate functions with respect to time are best
represented by Weibull distribution. The Weibull distribution is one of the most widely used model because of it
versatility to represent different failure depending upon
value of the shape parameter. It is expressed as
b t bK1
lt Z
;
q q
where q is characteristic life and b is shape parameter of the
failure model.
L. Krishnasamy et al. / Journal of Loss Prevention in the Process Industries 18 (2005) 6981
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