Optimization of test and maintenance of ageing components consisting of multiple items and addressing effectiveness

[EN] There are many models in the literature that have been proposed in the last decades aimed at assessing the reliability, availability and maintainability (RAM) of safety equipment, many of them with a focus on their use to assess the risk level of a technological system or to search for appropriate design and/or surveillance and maintenance policies in order to assure that an optimum level of RAM of safety systems is kept during all the plant operational life. This paper proposes a new approach for RAM modelling that accounts for equipment ageing and maintenance and testing effectiveness of equipment consisting of multiple items in an integrated manner. This model is then used to perform the simultaneous optimization of testing and maintenance for ageing equipment consisting of multiple items. An example of application is provided, which considers a simplified High Pressure Injection System (HPIS) of a typical Power Water Reactor (PWR). Basically, this system consists of motor driven pumps (MDP) and motor operated valves (MOV), where both types of components consists of two items each. These components present different failure and cause modes and behaviours, and they also undertake complex test and maintenance activities depending on the item involved. The results of the example of application demonstrate that the optimization algorithm provide the best solutions when the optimization problem is formulated and solved considering full flexibility in the implementation of testing and maintenance activities taking part of such an integrated RAM model.Authors are grateful to the Spanish Ministry of Science and Innovation for the financial support of this work (research project ENE2013-45540-R) and the Doctoral fellow (BES-2011-043906 and BES-2014-067602).Martón Lluch, I.; Martorell Aigües, P.; Mullor, R.; Sánchez Galdón, AI.; Martorell Alsina, SS. (2016). Optimization of test and maintenance of ageing components consisting of multiple items and addressing effectiveness. Reliability Engineering and System Safety. 153:151-158. https://doi.org/10.1016/j.ress.2016.04.015S15115815

Ageing PSA incorporating effectiveness of maintenance and testing

This paper proposes a new approach to Ageing Probabilistic Safety Assessment (APSA) modelling, which is intended to be used to support risk-informed decisions on the effectiveness of maintenance management programs and technical specification requirements of critical equipment of Nuclear Power Plants (NPP) within the framework of the Risk Informed Decision Making according to R.G. 1.174 principles. This approach focuses on the incorporation of not only equipment ageing but also effectiveness of maintenance and efficiency of surveillance testing explicitly into APSA models and data. An example of application is presented, which centres on a critical safety-related equipment of a NPP in order to evaluate the risk impact of considering different approaches to APSA and the combined effect of equipment ageing and maintenance and testing alternatives along NPP design life. The risk impact of the several alternatives is quantified and the results shows that such risk depends largely on the model parameters, such as ageing factor, maintenance effectiveness, test efficiency.Authors are grateful to the Spanish Ministry of Science and Innovation for the financial support of this work (Research Project ENE2013-45540-R) and the Doctoral Fellow (BES-2011-043906).Martón Lluch, I.; Sánchez Galdón, AI.; Martorell Alsina, SS. (2015). Ageing PSA incorporating effectiveness of maintenance and testing. Reliability Engineering and System Safety. 139:131-140. https://doi.org/10.1016/j.ress.2015.03.022S13114013

After-sales services optimisation through dynamic opportunistic maintenance: a wind energy case study

After-sales maintenance services can be a very profitable source of incomes for original equipment manufacturers (OEM) due to the increasing interest of assets’ users on performance-based contracts. However, when it concerns the product value-adding process, OEM have traditionally been more focused on improving their production processes, rather than on complementing their products by offering after-sales services; consequently leading to difficulties in offering them efficiently. Furthermore, both due to the high uncertainty of the assets’ behaviour and the inherent challenges of managing the maintenance process (e.g. maintenance strategy to be followed or resources to be deployed), it is complex to make business out of the provision of after-sales services. With the aim of helping the business and maintenance decision makers at this point, this paper proposes a framework for optimising the incomes of after-sales maintenance services through: 1) implementing advanced multi-objective opportunistic maintenance strategies that sistematically consider the assets’ operational context in order to perform preventive maintenance during most favourable conditions, 2) considering the specific OEMs’ and users’ needs, and 3) assessing both internal and external uncertainties that might condition the after-sales services’ success. The developed case study for the wind energy sector demonstrates the suitability of the presented framework for optimising the after-sales services.EU Framework Programme Horizon 2020, MSCA-RISE-2014: Marie Skłodowska-Curie Research and Innovation Staff Exchange (RISE) (grant agreement number 645733- Sustain-Owner-H2020-MSCA-RISE-2014) and the EmaitekPlus 2016-2017 Program of the Basque Government

Unavailability model for demand-caused failures of safety components addressing degradation by demand-induced stress, maintenance effectiveness and test efficiency

[EN] The reliability, availability and maintainability (RAM) modelling of safety equipment has long been a topic of major concern. Some RAM models have focused on explicitly addressing the effect of component degradation and surveillance and maintenance policies, searching for an optimum level of the safety component RAM by adjusting surveillance and maintenance related parameters. As regards the reliability contribution, these components normally have two main types of failure mode that contribute to the probability of failure on demand (PFD): (1) by demand-caused and (2) standby-related failures. The former is normally associated with a demand failure probability, which is affected by the degradation caused by demand-related stress. Surveillance testing therefore not only introduces a positive effect, but also an adverse one, which it compensates by performing maintenance activities to eliminate or reduce the accumulated degradation. This paper proposes a new model for the demand failure probability that explicitly addresses all aspects of the effect of demand-induced stress (mostly test-induced stress), maintenance effectiveness (PAS or PAR model) and test efficiency. A case study is included on an application to a typical motor-operated valve in a nuclear power plant.The authors are grateful to the Spanish Ministry of Science and Innovation for the financial support received (Research Projects ENE2013-45540-R and ENE2016-80401-R) and the doctoral scholarship awarded (BES-2014-067602). The study also received financial support from the Spanish Research Agency and the European Regional Development Fund.Martorell-Aygues, P.; Martón Lluch, I.; Sánchez Galdón, AI.; Martorell Alsina, SS. (2017). Unavailability model for demand-caused failures of safety components addressing degradation by demand-induced stress, maintenance effectiveness and test efficiency. Reliability Engineering & System Safety. 168:18-27. https://doi.org/10.1016/j.ress.2017.05.044S182716

Parameter Estimation of a Reliability Model of Demand-Caused and Standby-Related Failures of Safety Components Exposed to Degradation by Demand Stress and Ageing That Undergo Imperfect Maintenance

[EN] One can find many reliability, availability, and maintainability (RAM) models proposed in the literature. However, such models become more complex day after day, as there is an attempt to capture equipment performance in a more realistic way, such as, explicitly addressing the effect of component ageing and degradation, surveillance activities, and corrective and preventive maintenance policies. Then, there is a need to fit the best model to real data by estimating the model parameters using an appropriate tool. This problem is not easy to solve in some cases since the number of parameters is large and the available data is scarce. This paper considers two main failure models commonly adopted to represent the probability of failure on demand (PFD) of safety equipment: (1) by demand-caused and (2) standby-related failures. It proposes a maximum likelihood estimation (MLE) approach for parameter estimation of a reliability model of demand-caused and standby-related failures of safety components exposed to degradation by demand stress and ageing that undergo imperfect maintenance. The case study considers real failure, test, and maintenance data for a typical motor-operated valve in a nuclear power plant. The results of the parameters estimation and the adoption of the best model are discussed.The authors are grateful to the Spanish Ministry of Science and Innovation for the financial support received (Research Project ENE2016-80401-R) and the doctoral scholarship awarded (BES-2014-067602). The study also received financial support from the Spanish Research Agency and the European Regional Development Fund.Martorell Alsina, SS.; Martorell-Aygues, P.; Sánchez Galdón, AI.; Mullor, R.; Martón Lluch, I. (2017). Parameter Estimation of a Reliability Model of Demand-Caused and Standby-Related Failures of Safety Components Exposed to Degradation by Demand Stress and Ageing That Undergo Imperfect Maintenance. Mathematical Problems in Engineering. (7042453):1-11. https://doi.org/10.1155/2017/7042453S111704245

Genetic algorithms for condition-based maintenance optimization under uncertainty

International audienceThis paper proposes and compares different techniques for maintenance optimization based on Genetic Algorithms (GA), when the parameters of the maintenance model are affected by uncertainty and the fitness values are represented by Cumulative Distribution Functions (CDFs). The main issues addressed to tackle this problem are the development of a method to rank the uncertain fitness values, and the definition of a novel Pareto dominance concept. The GA-based methods are applied to a practical case study concerning the setting of a condition-based maintenance policy on the degrading nozzles of a gas turbine operated in an energy production plant

Imperfect Maintenance Models, from Theory to Practice

The role of maintenance in the industrial environment changed a lot in recent years, and today, it is a key function for long-term profitability in an organization. Many contributions were recently written by researchers on this topic. A lot of models were proposed to optimize maintenance activities while ensuring availability and high-quality requirements. In addition to the well-known classification of maintenance activities—preventive and corrective—in the last decades, a new classification emerged in the literature regarding the degree of system restoration after maintenance actions. Among them, the imperfect maintenance is one of the most studied maintenance types: it is defined as an action after which the system lies in a state somewhere between an “as good as new” state and its pre-maintenance condition “as bad as old.” Most of the industrial companies usually operate with imperfect maintenance actions, even if the awareness in actual industrial context is limited. On the practical definition side, in particular, there are some real situations of imperfect maintenance: three main specific cases were identified, both from literature analysis and from experience. Considering these three implementations of imperfect maintenance actions and the main models proposed in the literature, we illustrate how to identify the most suitable model for each real case

Addressing Complexity and Intelligence in Systems Dependability Evaluation

Engineering and computing systems are increasingly complex, intelligent, and open adaptive. When it comes to the dependability evaluation of such systems, there are certain challenges posed by the characteristics of “complexity” and “intelligence”. The first aspect of complexity is the dependability modelling of large systems with many interconnected components and dynamic behaviours such as Priority, Sequencing and Repairs. To address this, the thesis proposes a novel hierarchical solution to dynamic fault tree analysis using Semi-Markov Processes. A second aspect of complexity is the environmental conditions that may impact dependability and their modelling. For instance, weather and logistics can influence maintenance actions and hence dependability of an offshore wind farm. The thesis proposes a semi-Markov-based maintenance model called “Butterfly Maintenance Model (BMM)” to model this complexity and accommodate it in dependability evaluation. A third aspect of complexity is the open nature of system of systems like swarms of drones which makes complete design-time dependability analysis infeasible. To address this aspect, the thesis proposes a dynamic dependability evaluation method using Fault Trees and Markov-Models at runtime.The challenge of “intelligence” arises because Machine Learning (ML) components do not exhibit programmed behaviour; their behaviour is learned from data. However, in traditional dependability analysis, systems are assumed to be programmed or designed. When a system has learned from data, then a distributional shift of operational data from training data may cause ML to behave incorrectly, e.g., misclassify objects. To address this, a new approach called SafeML is developed that uses statistical distance measures for monitoring the performance of ML against such distributional shifts. The thesis develops the proposed models, and evaluates them on case studies, highlighting improvements to the state-of-the-art, limitations and future work

A novel approach for modelling complex maintenance systems using discrete event simulation

Existing approaches for modelling maintenance rely on oversimplified assumptions which prevent them from reflecting the complexity found in industrial systems. In this paper, we propose a novel approach that enables the modelling of non-identical multi-unit systems without restrictive assumptions on the number of units or their maintenance characteristics. Modelling complex interactions between maintenance strategies and their effects on assets in the system is achieved by accessing event queues in Discrete Event Simulation (DES). The approach utilises the wide success DES has achieved in manufacturing by allowing integration with models that are closely related to maintenance such as production and spare parts systems. Additional advantages of using DES include rapid modelling and visual interactive simulation. The proposed approach is demonstrated in a simulation based optimisation study of a published case. The current research is one of the first to optimise maintenance strategies simultaneously with their parameters while considering production dynamics and spare parts management. The findings of this research provide insights for non-conflicting objectives in maintenance systems. In addition, the proposed approach can be used to facilitate the simulation and optimisation of industrial maintenance systems