Life cycle maintenance planning method in consideration of operation and maintenance integration

Abstract

In this article, we propose a maintenance planning method that takes into account the interrelation between maintenance and operations. In the proposed system, the maintenance plan is evaluated in terms of losses related to operations as well as maintenance. Operational losses include production losses due to both failure and maintenance operations. Maintenance losses include inspection costs, repair costs and other losses, such as those incurred due to operator injury. In addition, the system evaluates the risk of fatal failure. We have developed a prototype system that evaluates these losses using Monte Carlo simulation. The effectiveness of the system is demonstrated by applying the prototype to a heating furnace used in the direct desulphurisation facility of an oil refinery plant.

Keywords:

• maintenance planning
• O&M integration
• Monte Carlo simulation
• oil refinery plant
• creep rupture

Acknowledgements

Our heartfelt appreciation goes to H. Ishimaru, M. Iwata and I. Kawamura whose comments and suggestions were innumerably valuable throughout the course of our study.