Markov-based performance evaluation and availability optimization of the boiler–furnace system in coal-fired thermal power plant using PSO

The appropriate maintenance strategy is essential for maintaining the thermal power plant highly reliable. The thermal power plant is a complex system that consists of various subsystems connected either in series or parallel configuration. The boiler–furnace (BF) system is one of the most critical subsystems of the thermal power plant. This paper presents availability based simulation modeling of the boiler–furnace system of thermal power plant with capacity (500MW). The Markov based simulation model of the system is developed for performance analysis. The differential equations are derived from a transition diagram representing various states with full working capacity, reduced capacity, and failed state. The normalizing condition is used for solving the differential equations. Furthermore, the performance of the system is analyzed for a possible combination of failure rate and repair rate, which revealed that failure of the boiler drum affects the system availability at most, and the failure of reheater affects the availability at least. Based on the criticality ranking, the maintenance priority has been provided for the system.The availability of the boiler–furnace system is optimized using particle swarm optimization method by varying the number of particles. The study results revealed that the maximum system availability level of 99.9845% is obtained. In addition, the optimized failure rate and repair rate parameters of the subsystem are used for suggesting an appropriate maintenance strategy for the boiler–furnace system of the plant. The finding of the study assisted the decision-makers in planning the maintenance activity as per the criticality level of subsystems for allocating the resources

Regression analysis of caterpillar 793D haul truck engine failure data and through-life diagnostic information using the proportional hazards model

Thesis (MScEng)--Stellenbosch University, 2012.ENGLISH ABSTRACT: Physical Asset Management (PAM) is becoming a greater concern for companies in industry today. The widely accepted British Standards Institutes’ specification for optimized management of physical assets and infrastructure is PAS55. According to PAS55, PAM is the “systematic and co-ordinated activities and practices through which an organization optimally manages its physical assets, and their associated performance, risks and expenditures over their life cycle for the purpose of achieving its organizational strategic plan”. One key performance area of PAM is Asset Care Plans (ACP). These plans are maintenance strategies which improve or ensure acceptable asset reliability and performance during its useful life. Maintenance strategies such as Condition Based Maintenance (CBM) acts upon Condition Monitoring (CM) data, disregarding the previous failure histories of an asset. Other maintenance strategies, such as Usage Based Maintenance (UBM), is based on previous failure histories, and does not consider CM data. Regression models make use of both CM data and previous failure histories to develop a model which represents the underlying failure behaviour of the asset under study. These models can be of high value in ACP development due to the fact that Residual Useful Life (RUL) can be estimated and/or the long term life cycle cost can be optimized. The objective of this thesis was to model historical failure data and CM data well enough so that RUL or optimized preventive maintenance instant estimations can be made. These estimates were used in decision models to develop maintenance schedules, i.e. ACPs. Several regression models were evaluated to determine the most suitable model to achieve the objectives of this thesis. The model found to be most suitable for this research project was the Proportional Hazards Model (PHM). A comprehensive investigation on the PHM was undertaken focussing on the mathematics and the practical implementation thereof. Data obtained from the South African mining industry was modelled with the Weibull PHM. It was found that the developed model produced estimates which were accurate representations of reality. These findings provide an exciting basis for the development of futureWeibull PHMs that could result in huge maintenance cost savings and reduced failure occurrences.AFRIKAANSE OPSOMMING: Fisiese Bate Bestuur (FBB) is besig om ’n groter bekommernis vir maatskappye in die bedryf te word. Die Britse Standaarde Instituut se spesifikasie vir optimale bestuur van fisiese bates en infrastruktuur is PAS55. Volgens PAS55 is FBB die “sistematiese en gekoördineerde aktiwiteite en praktyke wat deur ’n organisasie optimaal sy fisiese bates, hul verwante prestasie, risiko’s en uitgawes vir die doel van die bereiking van sy organisatoriese strategiese plan beheer oor hul volle lewensiklus te bestuur”. Een Sleutel Fokus Area (SFA) van FBB is Bate Versorgings Plan (BVP) ontwikkeling. Hierdie is onderhouds strategieë wat bate betroubaarheid verbeter of verseker tydens die volle bruikbare lewe van die bate. Een onderhoud strategie is Toestands Gebasseeerde Onderhoud (TGO) wat besluite baseer op Toestand Monitering (TM) informasie maar neem nie die vorige falingsgeskiedenis van die bate in ag nie. Ander onderhoud strategieë soos Gebruik Gebasseerde Onderhoud (GGO) is gebaseer op historiese falingsdata maar neem nie TM inligting in ag nie. Regressiemodelle neem beide TM data en historiese falings geskiedenis data in ag ten einde die onderliggende falings gedrag van die gegewe bate te verteenwoordig. Hierdie modelle kan baie nuttig wees vir BVP ontwikkeling te danke aan die feit dat Bruikbare Oorblywende Lewe (BOL) geskat kan word en/of die langtermyn lewenssilus koste geoptimeer kan word. Die doelwit van hierdie tesis was om historiese falingsdata en TT data goed genoeg te modelleer sodat BOL of optimale langtermyn lewensiklus kostes bepaal kan word om opgeneem te word in BVP ontwikkeling. Hierdie bepalings word dan gebruik in besluitnemings modelle wat gebruik kan word om onderhoud skedules op te stel, d.w.s. om ’n BVP te ontwikkel. Verskeie regressiemodelle was geëvalueer om die regte model te vind waarmee die doel van hierdie tesis te bereik kan word. Die mees geskikte model vir die navorsingsprojek was die Proporsionele Gevaarkoers Model (PGM). ’n Omvattende ondersoek oor die PGM is onderneem wat fokus op die wiskunde en die praktiese implementering daarvan. Data is van die Suid-Afrikaanse mynbedryf verkry en is gemodelleer met behulp van die Weibull PGM. Dit was bevind dat die ontwikkelde model resultate geproduseer het wat ’n akkurate verteenwoordinging van realiteit is. Hierdie bevindinge bied ’n opwindende basis vir die ontwikkeling van toekomstige Weibull Proporsionele Gevaarkoers Modelle wat kan lei tot groot onderhoudskoste besparings en minder onverwagte falings