Abstract: In recent years, maintenance optimization has attracted special attention due to the growth of industrial systems complexity. Maintenance costs are high for many systems, and preventive maintenance is effective when it increases operations' reliability and safety at a reduced cost. The novelty of this research is to consider general repair in the modeling of multi-unit series systems and solve the maintenance problem for such systems using the semi-Markov decision process (SMDP) framework. We propose an opportunistic maintenance policy for a series system composed of two main units. Unit 1, which is more expensive than unit 2, is subjected to condition monitoring, and its deterioration is modeled using a gamma process. Unit 1 hazard rate is estimated by the proportional hazards model (PHM), and two hazard rate control limits are considered as the thresholds of maintenance interventions for unit 1. Maintenance is performed on unit 2, considering an age control limit. The objective is to find the optimal control limits and minimize the long-run expected average cost per unit time. The proposed algorithm is applied to a numerical example to compare the effectiveness of the proposed policy (policy Ⅰ) with policy Ⅱ, which is similar to policy Ⅰ, but instead of general repair, replacement is performed. Results show that policy Ⅰ leads to lower average cost compared with policy Ⅱ.
Abstract: In this paper, the joint optimization of the
economic manufacturing quantity (EMQ), safety stock level,
and condition-based maintenance (CBM) is presented for a partially
observable, deteriorating system subject to random failure. The
demand is stochastic and it is described by a Poisson process.
The stochastic model is developed and the optimization problem
is formulated in the semi-Markov decision process framework. A
modification of the policy iteration algorithm is developed to find
the optimal policy. A numerical example is presented to compare
the optimal policy with the policy considering zero safety stock.
Abstract: Power transformers are the most crucial part of power electrical system, distribution and transmission grid. This part is maintained using predictive or condition-based maintenance approach. The diagnosis of power transformer condition is performed based on Dissolved Gas Analysis (DGA). There are five main methods utilized for analyzing these gases. These methods are International Electrotechnical Commission (IEC) gas ratio, Key Gas, Roger gas ratio, Doernenburg, and Duval Triangle. Moreover, due to the importance of the transformers, there is a need for an accurate technique to diagnose and hence predict the transformer condition. The main objective of this technique is to avoid the transformer faults and hence to maintain the power electrical system, distribution and transmission grid. In this paper, the DGA was utilized based on the data collected from the transformer records available in the General Electricity Company of Libya (GECOL) which is located in Benghazi-Libya. The Fuzzy Logic (FL) technique was implemented as a diagnostic approach based on IEC gas ratio method. The FL technique gave better results and approved to be used as an accurate prediction technique for power transformer faults. Also, this technique is approved to be a quite interesting for the readers and the concern researchers in the area of FL mathematics and power transformer.
Abstract: In this paper, we propose a condition-based
maintenance policy for multi-unit systems considering the
existence of economic dependency among units. We consider a
system composed of N identical units, where each unit deteriorates
independently. Deterioration process of each unit is modeled as a
three-state continuous time homogeneous Markov chain with two
working states and a failure state. The average production rate of
units varies in different working states and demand rate of the
system is constant. Units are inspected at equidistant time epochs,
and decision regarding performing maintenance is determined by the
number of units in the failure state. If the total number of units in the
failure state exceeds a critical level, maintenance is initiated, where
units in failed state are replaced correctively and deteriorated state
units are maintained preventively. Our objective is to determine the
optimal number of failed units to initiate maintenance minimizing
the long run expected average cost per unit time. The problem is
formulated and solved in the semi-Markov decision process (SMDP)
framework. A numerical example is developed to demonstrate the
proposed policy and the comparison with the corrective maintenance
policy is presented.
Abstract: This paper presents a maintenance policy for a system
consisting of two units. Unit 1 is gradually deteriorating and is
subject to soft failure. Unit 2 has a general lifetime distribution
and is subject to hard failure. Condition of unit 1 of the system
is monitored periodically and it is considered as failed when its
deterioration level reaches or exceeds a critical level N. At the
failure time of unit 2 system is considered as failed, and unit 2
will be correctively replaced by the next inspection epoch. Unit 1
or 2 are preventively replaced when deterioration level of unit 1
or age of unit 2 exceeds the related preventive maintenance (PM)
levels. At the time of corrective or preventive replacement of unit
2, there is an opportunity to replace unit 1 if its deterioration
level reaches the opportunistic maintenance (OM) level. If unit
2 fails in an inspection interval, system stops operating although
unit 1 has not failed. A mathematical model is derived to find
the preventive and opportunistic replacement levels for unit 1 and
preventive replacement age for unit 2, that minimize the long run
expected average cost per unit time. The problem is formulated and
solved in the semi-Markov decision process (SMDP) framework.
Numerical example is provided to illustrate the performance of the
proposed model and the comparison of the proposed model with an
optimal policy without opportunistic maintenance level for unit 1 is
carried out.
Abstract: In this paper, we present a maintenance model of a
two-unit series system with economic dependence. Unit#1 which is
considered to be more expensive and more important, is subject to
condition monitoring (CM) at equidistant, discrete time epochs and
unit#2, which is not subject to CM has a general lifetime distribution.
The multivariate observation vectors obtained through condition
monitoring carry partial information about the hidden state of unit#1,
which can be in a healthy or a warning state while operating. Only the
failure state is assumed to be observable for both units. The objective
is to find an optimal opportunistic maintenance policy minimizing
the long-run expected average cost per unit time. The problem
is formulated and solved in the partially observable semi-Markov
decision process framework. An effective computational algorithm
for finding the optimal policy and the minimum average cost is
developed, illustrated by a numerical example.
Abstract: In the present article, a new method has been developed to enhance the application of equipment monitoring, which in turn results in improving condition-based maintenance economic impact in an automobile parts manufacturing factory. This study also describes how an effective software with a simple database can be utilized to achieve cost-effective improvements in maintenance performance. The most important results of this project are indicated here: 1. 63% reduction in direct and indirect maintenance costs. 2. Creating a proper database to analyse failures. 3. Creating a method to control system performance and develop it to similar systems. 4. Designing a software to analyse database and consequently create technical knowledge to face unusual condition of the system. Moreover, the results of this study have shown that the concept and philosophy of maintenance has not been understood in most Iranian industries. Thus, more investment is strongly required to improve maintenance conditions.
Abstract: This study adopted previous fault patterns, results of
detection analysis, historical records and data, and experts-
experiences to establish fuzzy principles and estimate the failure
probability index of components of a power transformer. Considering
that actual parameters and limiting conditions of parameters may
differ, this study used the standard data of IEC, IEEE, and CIGRE as
condition parameters. According to the characteristics of each
condition parameter, relative degradation was introduced to reflect the
degree of influence of the factors on the transformer condition. The
method of fuzzy mathematics was adopted to determine the
subordinate function of the transformer condition. The calculation
used the Matlab Fuzzy Tool Box to select the condition parameters of
coil winding, iron core, bushing, OLTC, insulating oil and other
auxiliary components and factors (e.g., load records, performance
history, and maintenance records) of the transformer to establish the
fuzzy principles. Examples were presented to support the rationality
and effectiveness of the evaluation method of power transformer
performance conditions, as based on fuzzy comprehensive evaluation.