Improvement of System Availability Using Reliability and Maintainability Analysis
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2005:92 LICENTIATE T H E SI S Improvement of System Availability Using Reliability and Maintainability Analysis Javad Barabady Luleå University of Technology Division of Operation and Maintenance Engineering 2005:92|: 02-757|: -c -- 05⁄92 -- Improvement of System Availability Using Reliability and Maintainability Analysis Javad Barabady Division of Operation and Maintenance Engineering Luleå University of Technology December 2005 PREFACE AND ACKNOWLEDGMENTS The research work presented in this thesis has been carried out at the Division of Operation and Maintenance Engineering, under the supervision of Professor Uday Kumar, Head, Divi- sion of Operation and Maintenance Engineering. It was carried out at Luleå University of Technology during the period October 2003 to December 2004. The thesis contains four pa- pers. I wish to express my sincere thanks to my supervisor Professor Uday Kumar for introducing me to the subject area of reliability and availability and maintainability, for his thoughtful su- pervision, steady support, guidance, and for making available critical facilities throughout the course of this work. I am also thankful to Professor Per-Anders Akersten for his comments to improve the manuscript and content of the research work. I am grateful to the government of Iran to provide me with financial support to undertake this research work. I would also like to thank my colleagues Behzad Ghodrati, Aditya Parida, Arne Nissen, to- gether with all other colleagues in my department. They encouraged me through discussions and valuable advice. I would also like to thank my Iranian friends especially to Behzad Ghodrati and his wife Saei- deh for their hospitality during my study in Sweden. I would like to express my thanks to my wife Hamideh and our daughter Maryam, for their endless support and patience. I take this opportunity to express my deep and heartfelt gratitude to my mother Fatemeh and my father Mohammad. They have unselfishly given so much to create the opportunity for me both to grow as a person and to be able to secure an outstanding education. Finally I wish to express my gratitude to all my family members, especially my brothers and my sister for their support, kindness, and encouragement. Javad Barabady December 2005 Luleå, Sweden. i ii ABSTRACT System reliability, maintainability and availability have assumed great significance in recent years due to a competitive environment and overall operating and production costs. Perform- ance of equipment depends on reliability and availability of the equipment used, operating en- vironment, maintenance efficiency, operation process and technical expertise of operators, etc. When the reliability and availability of system are low, efforts are needed to improve them by reducing the failure rate or increasing the repair rate for each component or subsystem. The aim of this research study is to analyse operating reliability and availability for a system with periodically inspected and maintained components subjected to some maintenance strat- egy and find some importance measures that show the criticality of the components or subsys- tems. This analysis has helped to identify the critical and sensitive subsystems or components of the system that need more attention for improvement. In this research work we suggest a methodology for improving the availability of a repairable system. In the methodology, the concept of importance measures must be used to prioritize the components or subsystems for availability improvement processes. Availability importance measures show the criticality of each component based on different points of view such as availability, repair rate, and failure rate of each component. The reliability and availability of repairable systems can be improved by applying appropriate maintenance strategies; therefore a model is developed for selecting the most suitable maintenance strategies on the based of analysis of reliability and maintainability characteristic of the operating system. The empirical data of two crushing plants at the Jajarm bauxite mine of Iran are used as a case study for reli- ability and availability analysis. The study shows that the reliability and maintainability analysis is very useful for deciding maintenance intervals, planning and organizing maintenance. The results show that availabil- ity and reliability importance measures can be used as a guideline for managing the efforts for reliability and availability improvement of a system. Keywords, Reliability, Availability and Maintainability, Maintenance, repairable system, Op- timization, Importance Measure iii iv LIST OF APPENDED PAPERS Paper I: Barabady, J. (2005), “Reliability and maintainability analysis of crushing plants in Jajarm bauxite mine of Iran”, Proceedings of the Annual Reliability and Maintainability Sym- posium, P.109 – 115. Paper II: Barabady, J., Kumar, U. (2005), “Reliability analysis of mining equipment: A case study of a crushing plant at the Jajarm bauxite mine of Iran”, Submitted for publication in Journal of Reliability Engineering and System Safety. Paper III: Barabady, J., Kumar, U. (2005), “Maintenance schedule by using reliability analy- sis: A case study at Jajarm bauxite mine of Iran”, 20th World Mining Congress & Expo 2005, 7-11 November, Tehran, Iran. Paper IV: Barabady, J., Kumar, U. (2005), “Availability allocation through importance meas- ures”, Submitted for publication in a Journal. v vi TABLE OF CONTENTS 1 Introduction ……………………………………….…………….….………… 1 1.1 Background ……………………………………………….…………… 1 1.2 Research Problem……………………...……….……………………… 4 1.3 Research Questions ……………………..……….…………….……… 4 1.4 Purpose of the Research Study ……………………………….……… 5 1.5 Objective of the Research Study……………………………………… 5 1.5 Limitation of the Research Study……………………...……….……… 5 1.6 Structure of the Research Study ………..………….……………….… 5 2 Research Approach and Methodology……………..…….…….….………… 7 2.1 Introduction …………………………………………….……………… 7 2.2 Research Purpose …………………………………………………....… 7 2.3 Research Approach ……………………………...……………....…….. 8 2.3.1 Induction, Deduction, or Abduction ...................................…... 8 2.3.2 Qualitative or Quantitative ………………...…….…………… 9 2.4 Research Strategy ………………………………………….…....……. 10 2.5 Data Collection…………………………………………………….…...…….. 11 2.6 Data Analyzing …………………………………………..….………. 12 2.7 Reliability and Validity………………………………………….…… 14 2.8 Research Design ……………………………………………………….. 15 2.7 Research Process …………………………………….………. 15 3 Theoretical frame of reference (Literature Review) ……………………… 17 3.1 Introduction to RAM ……………………………………………....… 17 3.2 Some Basic Definition ……………………………………………….. 19 3.2.1 Reliability………………………………….………………...... 19 3.2.2 Maintainability …………...………………..……………….… 21 3.2.3 Availability ……………………………………..……….…… 23 3.2.4 Maintenance…………………………………….….…….…… 25 3.3 Overview of the RAM Process …………....……………….….….….. 27 vii 3.4 RAM Information System ………………….………………….…….. 29 3.5 Reliability, Availability, Maintainability Improvement …………...... 30 4 Summary of Appended Papers ……….. ……………….….….…… 33 4.1 Paper 1 ………………………………………………………………… 33 4.2 Paper 2 ………………………………………………………………… 33 4.3 Paper 3 ………………………………………………………………… 34 4.4 Paper 4 ………………………………………………………………… 35 5 Result, Discussion and Conclusions ………………..………….….………… 37 5.1 Research Results………………………………………………………. 37 5.2 Discussion ………………..…………………………………………… 37 5.2.1 RAM Improvement ………....………………………………… 37 5.2.2 Concept of Importance Measures ……………………………... 39 5.2.2.1 Reliability Importance Measures …………...……..... 39 5.2.2.2 Availability Importance Measures …………..……… 40 5.2.3 Maintenance Strategy Based on Reliability …………….…….. 42 5.2.4 Self Criticism of the Research ……..…...…………………….. 44 5.3 Conclusions and Future Research ……………………….……….…… 45 5.3.1 Conclusions……………………………...…………………..… 45 5.3.2 Research Contribution ……………..…………...…………….. 46 5.3.2 Suggestion for Further Research …………….....….. 46 References ………………………………………………………………….………… 47 Appended Papers ………………………………………………………….………… 51 viii NOTATION AND ABBREVIATION ΔC Cost needed to improve repair rate of the component i as Δμ μi i i I A Availability importance measure of component i Ci Cost of an inspection λ(t) Failure rate function β Shape parameter I i Availability importance measure of component i based on the failure rate A,λi I i Availability importance measure of component i based on the repair rate A,μi ΔC Cost needed to improve the failure rate of the component i as Δλ λi i i I R Reliability importance measure of the component i ∂C Variation of availability improvement cost with respect to failure rate of component i ∂λi ∂C Variation of availability improvement cost with respect to repair rate of component i ∂μi A (t) Instant availability of system at time t Ai Functional availability or inherent availability Ao Operational availability Aa Achieved availability C Budget for availability improvement CBM Condition based maintenance CM Corrective maintenance ECC Expected cost of corrective maintenance ECI Expected cost of inspection ECP Expected cost of preventive maintenance F(t) Cumulative distribution function (CDF) f(t) Probability density function(PDF) FTM Fixed time maintenance MFTT Mean function test time MTBF Mean time between failures MTTR Mean time to repair PM Preventive maintenance RAM Reliability, Availability and maintainability RAMI Reliability, Availability and maintainability improvement SSC Structure, system or component TBF Time between failures TBM Time based maintenance ix ti Running time at the occurrence of failure