Abstract: This article presents a methodology that improves reliability and cyclability of 2nd-life Li-ion battery system repurposed as energy storage system (ESS). Most of the 2nd-life retired battery systems in market have module/pack-level state of health (SOH) indicator, which is utilized for guiding appropriate depth of discharge (DOD) in the application of ESS. Due to the lack of cell-level SOH indication, the different degrading behaviors among various cells cannot be identified upon reaching retired status; in the end, considering end of life (EOL) loss and pack-level DOD, the repurposed ESS has to be oversized by > 1.5 times to complement the application requirement of reliability and cyclability. This proposed battery grading algorithm, using non-invasive methodology, is able to detect outlier cells based on historical voltage data and calculate cell-level historical maximum temperature data using semi-analytic methodology. In this way, the individual battery cell in the 2nd-life battery system can be graded in terms of SOH on basis of the historical voltage fluctuation and estimated historical maximum temperature variation. These grades will have corresponding DOD grades in the application of the repurposed ESS to enhance the system reliability and cyclability. In all, this introduced battery grading algorithm is non-invasive, compatible with all kinds of retired Li-ion battery systems which lack of cell-level SOH indication, as well as potentially being embedded into battery management software for preventive maintenance and real-time cyclability optimization.
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: Infrastructure maintenance is a great challenge facing sustainable development of infrastructure assets due to the high cost of passive implementation of a sustainable maintenance plan. An assessment model of sustainable maintenance for highway infrastructure projects in Egypt is developed in this paper. It helps in improving the implementation of sustainable maintenance criteria. Thus, this paper has applied the analytical hierarchy processes (AHP) to rank and explore the weight of 26 assessment indicators using three hierarchy levels containing the main sustainable categories and subcategories with related indicators. Overall combined weight of each indicator for sustainable maintenance evaluation has been calculated to sum up to a sustainable maintenance performance index (SMI). The results show that the factor "Preventive maintenance cost" has the highest relative contribution factor among others (13.5%), while two factors of environmental performance have the least weights (0.7%). The developed model aims to provide decision makers with information about current maintenance performance and support them in the decision-making process regarding future directions of maintenance activities. It can be used as an assessment performance tool during the operation and maintenance stage. The developed indicators can be considered during designing the maintenance plan. Practices for successful implementation of the model are also presented.
Abstract: In the past, we could increase profit by increasing product prices. But in the new decade, a competitive market does not let us to increase profit with increase prices. Therefore, the only way to increase profit will be reduce costs. A significant percentage of production costs are the maintenance costs, and analysis of these costs could achieve more profit. Most maintenance strategies such as RCM (Reliability-Center-Maintenance), TPM (Total Productivity Maintenance), PM (Preventive Maintenance) etc., are trying to reduce maintenance costs. In this paper, decreasing the maintenance costs of Concentration Plant of Golgohar Company (GEG) was examined by using of MTBF (Mean Time between Failures) and MTTR (Mean Time to Repair) analyses. These analyses showed that instead of buying new machines and increasing costs in order to promote capacity, the improving of MTBF and MTTR indexes would solve capacity problems in the best way and decrease costs.
Abstract: In the past, we could increase profit by increasing product prices. But in the new decade, a competitive market does not let us to increase profit with increased prices. Therefore, the only way to increase profit will be to reduce costs. A significant percentage of production costs are the maintenance costs, and analysis of these costs could achieve more profit. Most maintenance strategies such as RCM (Reliability-Center-Maintenance), TPM (Total Productivity Maintenance), PM (Preventive Maintenance) and etc., are trying to reduce maintenance costs. In this paper, decreasing the maintenance costs of Concentration Plant of Golgohar Iron Ore Mining & Industrial Company (GeG) was examined by using of MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) analyses. These analyses showed that instead of buying new machines and increasing costs in order to promote capacity, the improving of MTBF and MTTR indexes would solve capacity problems in the best way and decrease costs.
Abstract: This paper studies the optimal maintenance planning of preventive maintenance and renewal activities for components in a single railway track when the available time for maintenance is limited. The rail-track system consists of several types of components, such as rail, ballast, and switches with different preventive maintenance and renewal intervals. To perform maintenance or renewal on the track, a train free period for maintenance, called a possession, is required. Since a major possession directly affects the regular train schedule, maintenance and renewal activities are clustered as much as possible. In a highly dense and utilized railway network, the possession time on the track is critical since the demand for train operations is very high and a long possession has a severe impact on the regular train schedule. We present an optimization model and investigate the maintenance schedules with and without the possession capacity constraint. In addition, we also integrate the social-economic cost related to the effects of the maintenance time to the variable possession cost into the optimization model. A numerical example is provided to illustrate the model.
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: The performance of the tightening equipment will decline with the working process in manufacturing system. The main manifestations are the randomness and discretization degree increasing of the tightening performance. To evaluate the degradation tendency of the tightening performance accurately, a complexity measurement approach based on Kolmogorov entropy is presented. At first, the states of performance index are divided for calibrating the discrete degree. Then the complexity measurement model based on Kolmogorov entropy is built. The model describes the performance degradation tendency of tightening equipment quantitatively. At last, a study case is applied for verifying the efficiency and validity of the approach. The research achievement shows that the presented complexity measurement can effectively evaluate the degradation tendency of the tightening equipment. It can provide theoretical basis for preventive maintenance and life prediction of equipment.
Abstract: The present study investigated approaches and techniques to enhance strategic management governance and decision making within the framework of a performance-based balanced scorecard. The review of best practices from strategic, program, process, and systems engineering management provided for a holistic approach toward effective outcome-based capability management. One technique, based on factorial experimental design methods, was used to develop an empirical model. This model predicted the degree of capability effectiveness and is dependent on controlled system input variables and their weightings. These variables represent business performance measures, captured within a strategic balanced scorecard. The weighting of these measures enhances the ability to quantify causal relationships within balanced scorecard strategy maps. The focus in this study was on the performance of tangible assets within the scorecard rather than the traditional approach of assessing performance of intangible assets such as knowledge and technology. Tangible assets are represented in this study as physical systems, which may be thought of as being aboard a ship or within a production facility. The measures assigned to these systems include project funding for upgrades against demand, system certifications achieved against those required, preventive maintenance to corrective maintenance ratios, and material support personnel capacity against that required for supporting respective systems. The resultant scorecard is viewed as complimentary to the traditional balanced scorecard for program and performance management. The benefits from these scorecards are realized through the quantified state of operational capabilities or outcomes. These capabilities are also weighted in terms of priority for each distinct system measure and aggregated and visualized in terms of overall state of capabilities achieved. This study proposes the use of interactive controls within the scorecard as a technique to enhance development of alternative solutions in decision making. These interactive controls include those for assigning capability priorities and for adjusting system performance measures, thus providing for what-if scenarios and options in strategic decision-making. In this holistic approach to capability management, several cross functional processes were highlighted as relevant amongst the different management disciplines. In terms of assessing an organization’s ability to adopt this approach, consideration was given to the P3M3 management maturity model.
Abstract: This paper studied the flow shop scheduling problem under machine availability constraints. The machines are subject to flexible preventive maintenance activities. The nonresumable scenario for the jobs was considered. That is, when a job is interrupted by an unavailability period of a machine it should be restarted from the beginning. The objective is to minimize the total tardiness time for the jobs and the advance/tardiness for the maintenance activities. To solve the problem, a genetic algorithm was developed and successfully tested and validated on many problem instances. The computational results showed that the new genetic algorithm outperforms another earlier proposed algorithm.
Abstract: This technical contribution treats of a novel approach
to condition-oriented maintenance as elaborated by Collaborative
Research Centre 653 at the Leibniz University in Hanover. The
objective resides in the targeted analysis of information about a
component's lifecycle for maintenance purposes. The information in
question is collected by means of the Collaborative Research Centre's
innovative technologies. This enables preventive maintenance of
components on the basis of their condition. This contribution initially
explains condition-oriented maintenance, before introducing the
Collaborative Research Centre and finally presenting the
methodology for analyzing the information. The current state of
development is described and an outlook provided for expanding the
methodology.
Abstract: Components with sensory properties such as gentelligent components developed at the Collaborative Research Centre 653 offer a new angle in terms of the full utilization of the remaining service life as well as preventive maintenance. The developed methodology of component status driven maintenance analyzes the stress data obtained during the component's useful life and on the basis of this knowledge assesses the type of maintenance required in this case. The procedure is derived from the case-based reasoning method and will be explained in detail. The method's functionality is demonstrated with real-life data obtained during test runs of a racing car prototype.
Abstract: Vibration analysis of most critical equipment is considered as one of the most challenging activities in preventive maintenance. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of these kinds of equipments are developed too much in recent years. On the other hand, there are too much operation factors like inlet and outlet pressures and temperatures that should be monitored. In this paper, some of the most effective concepts and techniques related to gas turbine vibration analysis are discussed. In addition, a gas turbine SIEMENS 162MW - V94.2 vibration case history related to Iran power industry in Fars province is explained. Vibration monitoring system and machinery technical specification are introduced. Besides, absolute and relative vibration trends, turbine and compressor orbits, Fast Fourier transform (FFT) in absolute vibrations, vibration modal analysis, turbine and compressor start up and shut down conditions, bode diagrams for relative vibrations, Nyquist diagrams and waterfall or three-dimensional FFT diagrams in startup and trip conditions are discussed with relative graphs. Furthermore, Split Resonance in gas turbines is discussed in details. Moreover, some updated vibration monitoring system, blade manufacturing technique and modern damping mechanism are discussed in this paper.
Abstract: Vibration monitoring methods of most critical equipment like main turbine and compressors always plays important role in preventive maintenance and management consideration in big industrial plants. There are a number of traditional methods like monitoring the overall vibration data from Bently Nevada panel and the time wave form (TWF) or fast Fourier transform (FFT) monitoring. Besides, Shaft centerline monitoring method developed too much in recent years. There are a number of arguments both in favor of and against this method between people who work in preventive maintenance and condition monitoring systems (vibration analysts). In this paper basic principal of Turbine compressor vibration analysis and rotor movement evaluation by shaft centerline method discussed in details through a case history. This case history is related to main turbine compressor of an olefin plant in Iran oil industry. In addition, some common mistakes that may occur by vibration analyst during the process discussed in details. It is worthy to know that, these mistakes may one of the reasons that sometimes this method seems to be not effective. Furthermore, recent patent and innovation in shaft position and movement evaluation are discussed in this paper.
Abstract: Vibration analysis of screw compressors is one of the most challenging cases in preventive maintenance. This kind of equipment considered as vibration bad actor facilities in industrial plants. On line condition monitoring systems developed too much in recent years. The high frequency vibration of ball bearings, gears, male and female caused complex fast Fourier transform (FFT) and time wave form (TWF) in screw compressors. The male and female randomly are sent to balance shop for balancing operation. This kind of operation usually caused some bending in rotors during the process that could cause further machining in such equipment. This kind of machining operation increased the vibration analysis complexity beside some process characteristic abnormality like inlet and out let pressure and temperature. In this paper mechanical principal and different type of screw compressors explained. Besides, some new condition monitoring systems and techniques for screw compressors discussed. Finally, one of the common behavior of oil injected twin rotary screw compressors called hydraulic unbalance that usually occurred after machining operation of male or female and have some specific characteristics in FFT and TWF discussed in details through a case history related to Iran oil industries.
Abstract: Vibration analysis is the most important factor in preventive maintenance. Gas turbine vibration analysis is also one of the most challenging categories in most critical equipment monitoring systems. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of this kind of equipment developed too much in recent years. On the other hand, too much operation condition consideration in this kind of equipment should be adjusted properly like inlet and outlet pressure and temperature for both turbine and compressor. In this paper the most important tools and hypothesis used for analyzing of gas turbine power plants discussed in details through a real case history related to an Alstom Typhoon gas turbine power plant in Iran oil industries. In addition, the basic principal of vibration behavior caused by mechanical unbalance in gas turbine rotor discussed in details.
Abstract: This paper proposes an effective maintenance method by considering the implementation of the Computerized Maintenance Management System (CMMS) software to plan a maintenance activity in a manufacturing industry. Globally, maintenance is a very important activity in the manufacturing sector to prolong the life span of equipment and machinery; it is also applicable to all household items. It is obvious and well known that apart from giving long life to equipment, it reduces the substantial financial losses for repairs and save the production downtime. In some cases, appropriate maintenance of plant equipment and machinery reduces the tendencies of injuries to personnel in the job floor. But before the maintenance process can be carried out, proper and effective work order planning and scheduling must be in place in other to achieve the set goals and objectives of a maintenance shop. Brief reviews of common planning tools which include the Computerized Maintenance Management System (CMMS) are presented. An interesting outline of analyses on planning and scheduling for effective job planning in a typical manufacturing industry using the CMMS is also presented and discussed. Finally, the steps to adhere to in making job planning effective in a manufacturing industry are also highlighted.
Abstract: This paper presents the results of a preventive maintenance application-based study and modeling of failure rates in breakers of electrical distribution systems. This is a critical issue in the reliability assessment of a system. In the analysis conducted in this paper, the impacts of failure rate variations caused by a preventive maintenance are examined. This is considered as a part of a Reliability Centered Maintenance (RCM) application program. A number of load point reliability indices is derived using the mathematical model of the failure rate, which is established using the observed data in a distribution system.
Abstract: Gas chromatography (GC) is the most widely used
technique in analytical chemistry. However, GC has high initial cost
and requires frequent maintenance. This paper examines the
feasibility and potential of using a neural network model as an
alternative whenever GC is unvailable. It can also be part of system
verification on the performance of GC for preventive maintenance
activities. It shows the performance of MultiLayer Perceptron (MLP)
with Backpropagation structure. Results demonstrate that neural
network model when trained using this structure provides an
adequate result and is suitable for this purpose. cm.
Abstract: The great majority of the electric installations belong
to the first and second category. In order to ensure a high level of
reliability of their electric system feeder, two power supply sources
are envisaged, one principal, the other of reserve, generally a cold
reserve (electric diesel group).
The principal source being under operation, its control can be ideal
and sure, however for the reserve source being in stop, a preventive
maintenance-s which proceeds on time intervals (periodicity) and
for well defined lengths of time are envisaged, so that this source will
always available in case of the principal source failure.
The choice of the periodicity of preventive maintenance of the
source of reserve influences directly the reliability of the electric
feeder system. On the basis of the semi-markovians processes, the
influence of the periodicity of the preventive maintenance of the
source of reserve is studied and is given the optimal periodicity.