Operating Environmental Condition Effect on Reliability-Centred Maintenance | ||
| Journal of Mining and Environment | ||
| مقاله 18، دوره 14، شماره 2، تیر 2023، صفحه 667-688 اصل مقاله (543.78 K) | ||
| نوع مقاله: Original Research Paper | ||
| شناسه دیجیتال (DOI): 10.22044/jme.2023.12767.2318 | ||
| نویسندگان | ||
| Ali Nouri Qarahasanlou* 1؛ Abbas Barabadi2؛ Meisam Saleki3 | ||
| 1Department of mining engineering, Faculty of Technical & Engineering, Imam Khomeini International University, Qazvin, Iran | ||
| 2University of Tromsoe, Norway | ||
| 3School of Materials and Minerals Resources Engineering, Universiti Sains Malaysia (USM), Penang, Malaysia | ||
| چکیده | ||
| Implementing maintenance protocols for industrial machinery is essential since a well-thought-out plan may support and improve machinery dependability, production quality, and safety precautions. Implementing a maintenance plan that considers the equipment's actual functional behavior and the effects of failures will be easier and more practical. Engineers must consider environmental conditions when studying in hostile environments such as mine. The major goal of this study is to create a mining equipment maintenance program that is as effective as possible while incorporating risk and performance indicators and taking environmental factors into account. The study uses the “reliability-centered maintenance” method, which combines the reliability operating index and risk. The Cox model also includes the risk factors associated with environmental conditions in the reliability analysis. The proposed approach was implemented in a 5-758 Komatsu dump-truck case study at the Sungun copper mine in Iran. The reliability-centered maintenance approach is implemented for dump-truck in three scenarios based on risk factors: 1- baseline, 2- First semi-annual, cheap maintenance, and 3- second semi-annual, expensive maintenance. All failure modes are low-risk, making corrective maintenance appropriate. In Scenario 1, electrical-electrical, electrical-start, mechanical, and pneumatic-related failures are low-risk, making corrective maintenance suitable. In Scenario 2, corrective maintenance is recommended for pneumatic-related failure. In Scenario 3, the fuel-related failure has a high criticality number and failure intensity, indicating a high-risk situation. Time-based preventive maintenance is the most appropriate strategy for this scenario. | ||
| کلیدواژهها | ||
| Risk؛ Reliability؛ Cox Regression Model؛ Reliability-Centered Maintenance (RCM)؛ The Sungun Copper Mine | ||
| مراجع | ||
|
[1]. Osborne, J. and Dillon, J. (2008). Science Education in Europe: Critical Reflections, London: The Nuffield Foundation, vol. 13.
[2]. Nouri Qarahasanlou, A. Khalokakaie, R. Ataei, M. and Ghodrati, B. (2008). Operating environment-based availability importance measures for mining equipment (case study: sungun copper mine), Journal of Failure Analysis and Prevention, vol. 17, no. 1, pp. 56–67.
[3]. Levkovich, P.E. and Chalenko, N.E. (1969). Use of reliability theory to calculate the required number of reserve longwall faces, Soviet Mining Science, vol. 5, no. 2, pp. 160–165. doi: 10.1007/BF02501894.
[4]. Malakoutikhah, M. (2022). Identifying and prioritizing factors affecting bursting of dump truck tires in mines using fuzzy best-worst method, Journal of Mining and Environment.
[5]. Hoseinie, S.H. Khalokakaie, R. Ataei, M. and Kumar, U. (2011). Reliability-based maintenance scheduling of haulage system of drum shearer, International Journal of Mining and Mineral Engineering, vol. 3, no. 1, pp. 26–37.
[6]. Hoseinie, S.H. Ataei, M. Khalokakaie, R. Ghodrati, B. and Kumar, U. (2012). Reliability analysis of drum shearer machine at mechanized longwall mines, Journal of quality in maintenance engineering, vol. 18, no. 1, pp. 98–119.
[7]. Rahimdel, M.J. Ataei, M. Khalokakaei, R. and Hoseinie, S.H. (2013). Reliability-based maintenance scheduling of hydraulic system of rotary drilling machines, International journal of mining science and technology, vol. 23, no. 5, pp. 771–775.
[8]. Rahimdel, M.J. Ataei, Khalokakaei, M. and Hoseinie, S.H. (2014). Maintenance Plan for a Fleet of Rotary Drill Rigs/Harmonogram Utrzymania I Konserwacji Floty Obrotowych Urządzeń Wiertniczych, Archives of Mining Sciences, vol. 59, no. 2, pp. 441–453.
[9]. Balaraju, J. Govinda Raj, M. and Murthy, C. (2018). Estimation of reliability-based maintenance time intervals of Load-Haul-Dumper in an underground coal mine, Journal of Mining and Environment, vol. 9, no. 3, pp. 761–770.
[10]. Rahimdel, M.J. Ataei, M. and Khalokakaei, R. (2016). Reliability Analysis and Maintenance Scheduling of the Electrical System of Rotary Drilling Machines, in Current Trends in Reliability, Availability, Maintainability and Safety, pp. 623–632.
[11]. Morshedlou, A. Dehghani, H. and Hoseinie, S.H. (2014). Reliability-based maintenance scheduling of powered supports in Tabas mechanized coal mine, Journal of Mining and Environment, vol. 5, no. 2, pp. 113–120.
[12]. Gharahasanlou, A.N. Ataei, M. Khalokakaie, R. Barabadi, A. and Einian, V. (2017). Risk based maintenance strategy: a quantitative approach based on time-to-failure model, International Journal of System Assurance Engineering and Management, pp. 1–10. doi: 10.1007/s13198-017-0607-7.
[13]. Nouri Qarahasanlou, A. Barabadi, A. Ataei, M. and Einian, V. (2019). Spare part requirement prediction under different maintenance strategies, International Journal of Mining, Reclamation and Environment, vol. 33, no. 3, pp. 169–182.
[14]. Nouri Qarahasanlou, A. Ataei, M. and R. Shakoor Shahabi, R. (2021). Expected Proportional Hazard Model in Preventive Maintenance, Journal of Mining and Environment, vol. 0. doi: 10.22044/jme.2021.10812.2051.
[15]. Wu, C. (1995). Fault tree analysis of spontaneous combustion of sulphide ores and its risk assessment, Journal of Central South University of Technology, vol. 2, no. 2, pp. 77–80.
[16]. Wu, C. and Gu, D. (2000). Fault tree analysis of dust suppression mechanism in a spray system with wetting agent, Journal of Central South University of Technology, vol. 7, no. 3, pp. 117–123.
[17]. Samanta, B. Sarkar, B. and Mukherjee, S.K. (2002). Reliability assessment of hydraulic shovel system using fault trees, Mining Technology, vol. 111, no. 2, pp. 129–135.
[18]. Sharma, R.K. Kumar, D. and Kumar, P. (2005). Systematic failure mode effect analysis (FMEA) using fuzzy linguistic modelling, International journal of quality & reliability management, vol. 22, no. 9, pp. 986–1004.
[19]. Gupta S. and Bhattacharya, J. (2007). Reliability analysis of a conveyor system using hybrid data, Quality and Reliability Engineering International, vol. 23, no. 7, pp. 867–882.
[20]. Beamish, B. Application of fault tree analysis to coal spontaneous combustion, 2010.
[21]. Gharahasanlou, A. N. Mokhtarei, A. Khodayarei, A. and Ataei, M. (2014). Fault tree analysis of failure cause of crushing plant and mixing bed hall at Khoy cement factory in Iran, Case studies in engineering failure analysis, vol. 2, no. 1, pp. 33–38.
[22]. Gilchrist, W. Modelling failure modes and effects analysis, International Journal of Quality & Reliability Management, 1993.
[23]. Gupta, G. Mishra, R.P. and Singhvi, P. (2016). An application of reliability centered maintenance using RPN mean and range on conventional lathe machine, International Journal of Reliability, Quality and Safety Engineering, vol. 23, no. 06, p. 1640010.
[24]. Jahangoshai Rezaee, M. Salimi, A. and Yousefi, S. (2017). Identifying and managing failures in stone processing industry using cost-based FMEA, The International Journal of Advanced Manufacturing Technology, vol. 88, no. 9, pp. 3329–3342.
[25]. Mottahedi A. and Ataei, M. (2019). Fuzzy fault tree analysis for coal burst occurrence probability in underground coal mining, Tunnelling and Underground Space Technology, vol. 83, pp. 165–174, Jan. doi: 10.1016/j.tust.2018.09.029.
[26]. Shahani, N.M. (2019) Fault Tree Analysis and Prevention Strategies for Gas Explosion in Underground Coal Mines of Pakistan. Mining of Mineral Deposits, p. 8.
[27]. Zhai, X.Y. Zhai, Z.P. Lan, Y.Z. Wu, Y.M. Cheng, H.Y. and Zhang, C.C. (2021). System reliability analysis of forage crushing machine based on fuzzy FMECA, IOP Conf. Ser.: Mater. Sci. Eng., vol. 1043, no. 2, p. 022042. doi: 10.1088/1757-899X/1043/2/022042.
[28]. Xu, J. Yang, M. and Li, S. (2021). Hardware Reliability Analysis of a Coal Mine Gas Monitoring System Based on Fuzzy-FTA, Applied Sciences, vol. 11, no. 22, p. 10616, doi: 10.3390/app112210616.
[29]. Rahimdel M. J. and Ghodrati, B. (2021). Risk Prioritization for Failure Modes in Mining Railcars, Sustainability, vol. 13, no. 11, p. 6195, doi: 10.3390/su13116195.
[30]. Jiskani, I.M. Yasli, F. Hosseini, S.Rehman, A.U. and Uddin, S. (2022). Improved Z-number based fuzzy fault tree approach to analyze health and safety risks in surface mines, Resources Policy, vol. 76, p. 102591, doi: 10.1016/j.resourpol.102591.
[31]. Ghomghale, A. Ataei, M. Khalokakaie, R. Barabadi, A. and Nouri Qarahasanlou, A. (2020). The Application of Frailty Model in Remaining Useful Life Estimation (Case Study: Sungun Copper Mine’s Loading System), Journal of Modeling in Engineering, vol. 18, no. 62, doi: 10.22075/jme.2020.19249.1817.
[32]. Ghomghaleh, A. (2020). Prediction of remaining useful life (RUL) of Komatsu excavator under reliability analysis in the Weibull-frailty model, Plos one, vol. 15, no. 7, p. e0236128.
[33]. Zaki, R. Barabadi, A. Barabadi, J. and Nouri Qarahasanlou, A. (2021). Observed and unobserved heterogeneity in failure data analysis, Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, p. 1748006X211022538.
[34]. Barabadi, R. Ataei, M. Khalokakaie, R. and Nouri Qarahasanlou, A. (2021). Spare-part management in a heterogeneous environment, Plos one, vol. 16, no. 3, p. e0247650.
[35]. Barabadi, A. Qarahasanlou, A.N. Mottahedi, A. Azar, A. R. and Zamani, A. (2021). The effect of risk factors on the resilience of Industrial Equipment, presented at the International Congress and Workshop on Industrial AI, pp. 112–127.
[36]. Chopra, D.A. (2021). Applications and Barriers of Reliability Centered Maintenance (Rcm) in Various Industries: A Review, p. 10.
[37]. Brauer, D.C. and Brauer, G.D. (1987). Reliability-centered maintenance, IEEE transactions on reliability, vol. 36, no. 1, pp. 17–24.
[38]. Islam, H. (2010). Reliability-centered maintenance methodology and application: a case study, Engineering, vol. 2, no. 11, pp. 863–873, doi: 10.4236/eng.2010.211109.
[39]. Barabadi, A. and Markeset, T. (2011). Reliability and maintainability performance under Arctic conditions, Int J Syst Assur Eng Manag, vol. 2, no. 3, pp. 205–217, doi: 10.1007/s13198-011-0071-8.
[40]. Gharahasanlou, A.N. Ataei, M. Khalokakaie, R. and Einian, V. (2016). Throughput capacity analysis (case study: sungun copper mine), JOURNAL OF FUNDAMENTAL AND APPLIED SCIENCES, vol. 8, pp. 1531–1556.
[41]. Barabadi, A. (2013). Reliability model selection and validation using Weibull probability plot-A case study, Electric Power Systems Research, vol. 101, pp. 96–101, doi: 10.1016/j.epsr.2013.03.010.
[42]. Ghodrati, B. (2006). Weibull and Exponential Renewal Models in Spare Parts Estimation: A Comparison, International Journal of Performability Engineering, vol. 2, no. 2, p. 135, doi: 10.23940/ijpe.06.2.p135.mag.
[43]. Jardine, A.K.S. Anderson, P.M. and Mann, D.S. (1987). Application of the weibull proportional hazards model to aircraft and marine engine failure data, Quality and Reliability Engineering International, vol. 3, no. 2, pp. 77–82, doi: 10.1002/qre.4680030204.
[44]. Jiang, R. and Murthy, D.N.P. (1995). Modeling Failure-Data by Mixture of 2 Weibull Distributions: A Graphical Approach, IEEE Transactions on Reliability, vol. 44, no. 3, pp. 477–488, doi: 10.1109/24.406588.
[45]. Gharahasanlou, A.N. Khalokakaie, R. Ataie, M. Jafarie, R. Mokhberdoran, M. and Mokhtarie, A. (2015). Reliability Analysis of Conveyor Belt System of Crushing Department, p. 9.
[46]. Murthy, D.N.P. Xie, M. and Jiang, R. (2004). Weibull models. in Wiley series in probability and statistics. Hoboken, N.J: J. Wiley.
[47]. Bučar, T. Nagode, M. and Fajdiga, M. (2004). Reliability approximation using finite Weibull mixture distributions, Reliability Engineering & System Safety, vol. 84, no. 3, pp. 241–251, doi: 10.1016/j.ress.2003.11.008.
[48]. Rinne, H. (2008). The Weibull Distribution: A Handbook, 1st edition. Boca Raton: Chapman and Hall/CRC.
[49]. Standard, M. Procedures for Performing a Failure Mode, Effects and Criticality Analysis, Department of Defense, Washington, DC, Standard No. MIL-STD-1629A, p. 80.
[50]. Kumar D. and Klefsjö, B. (1994). Proportional hazards model: a review, Reliability Engineering & System Safety, vol. 44, no. 2, pp. 177–188, doi: https://doi.org/10.1016/0951-8320(94)90010-8.
[51]. Barabadi, A. and Markeset, T. (2011). Reliability and maintainability performance under Arctic conditions, International Journal of System Assurance Engineering and Management, vol. 2, no. 3, pp. 205–217, doi: 10.1007/s13198-011-0071-8.
[52]. Moniri-Morad, A. Pourgol-Mohammad, M. Aghababaei, H. and Sattarvand, J. (2019). Reliability-based covariate analysis for complex systems in heterogeneous environment: Case study of mining equipment, Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, vol. 233, no. 4, pp. 593–604.
[53]. Barabadi, A. (2012). Reliability and Spare Parts Provisioning Considering Operational Environment: A Case Study, International Journal of Performability Engineering, vol. 8, no. 5, pp. 497–506.
[54]. Barabadi, A. Barabady, J. and Markeset, T. (2011). A methodology for throughput capacity analysis of a production facility considering environment condition, Reliability Engineering & System Safety, vol. 96, no. 12, pp. 1637–1646.
[55]. Ghodrati, B. Banjevic, D. and Jardine, A. K. S. (2010). Developing effective spare parts estimations results in improved system availability, presented at the Proceedings - Annual Reliability and Maintainability Symposium. doi: 10.1109/RAMS.2010.5447985.
[56]. Ghodrati, B. (2005). Reliability and operating environment based spare parts planning, PhD Thesis, Luleå tekniska universitet.
[57]. Ghodrati, B. and Kumar, U. (2005). Reliability and operating environment-based spare parts estimation approach: A case study in Kiruna Mine, Sweden, Journal of Quality in Maintenance Engineering.
[58]. Kumar, U.D. Crocker, J. Knezevic, J. and El-Haram, M. (2012). Reliability, Maintenance and Logistic Support: - A Life Cycle Approach. Springer Science & Business Media.
[59]. Rausand M. and Høyland, A. (2004). System reliability theory: models, statistical methods, and applications, vol. 396. John Wiley & Sons.
[60]. Standard, M. (1980). Procedures for performing a failure mode, effects and criticality analysis, Department of Defense, Washington, DC, Standard No. MIL-STD-1629A.
[61]. ISO - ISO 31000 — Risk management, ISO, Dec. 10, 2021. https://www.iso.org/iso-31000-risk-management.html (accessed Feb. 18, 2023).
[62]. Standard for Performing a Failure Mode and Effects Analysis (FMEA) and Establishing a Critical Items List (CIL) (DRAFT), NASA Goddard Space Flight Center, Standard, 2010. [Online]..
[63]. IEC 60812 - Analysis techniques for system reliability – Procedure for failure mode and effects analysis (FMEA), International Electrotechnical Commission, Switzerland, Standard IEC 60812:2006(E), 2006. [Online].
[64]. Lipol L. S. and Haq, J. (2011). Risk analysis method: FMEA/FMECA in the organizations, International Journal of Basic & Applied Sciences, vol. 11, no. 5, pp. 74–82.
[65]. Pillay, A. and Wang, J. (2003). Modified failure mode and effects analysis using approximate reasoning, Reliability Engineering & System Safety, vol. 79, no. 1, pp. 69–85.
[66]. Rausand, M. and Hoyland, A. (2003). System reliability theory: models, statistical methods, and applications, vol. 396. John Wiley & Sons.
[67]. Ebeling, C.E. (2004). An introduction to reliability and maintainability engineering. McGraw-Hill.
| ||
|
آمار تعداد مشاهده مقاله: 859 تعداد دریافت فایل اصل مقاله: 712 |
||