基于rcm的高炉设备维修工程与实例

上海交通大学硕士学位论文基于RCM的高炉设备维修工程与实例姓名：丁晓东申请学位级别：硕士专业：工业工程指导教师：周炳海;季守军20080601IRCM2#RCMReliabilityCenteredMaintenanceRCMCBMAMRCMRCM2#RCMRCMRCMRCMRCMIIRCMRCM,2#IIIMAINTENANCEPRACTICEFORBLASTFURNACEEQUIPMENTBASEDONRCMTHEORYABSTRACTThisthesisisbasedontheNo.2blastfurnace(BF)oftheBaosteelGroup.Here,weputtheRCMtheoryintopracticeandfulfilleditsuseinthemaintenanceofblastfurnaceequipment.TheBaosteelGroupisthebiggestandmostadvancingiron-steelcompanyinChina.MostoftheBFmaintenancepracticearebasedonthetheoryofCBMandAMnowadays.Althoughtherearemanyobvioustraitsinthiskindofmaintenanceprogram,itisimpossibletogiveattentiontobothsidesofintegrityandcost.However,theRCMmethodcanmeetitverywell.Inthethesis,wefirstlyintroducetheRCMtheory,thenweputittothefulluseofanalysisofequipmentofBaosteelNo.2BF,andlastlywegotawholeRCMprogramonequipmentofBF.Asthecoreoftheironsystem,theBFhasalargenumberofequipment,andsomeadvancedinstrumentsaretechnicalprotected,soitisimpossibletoanalyzeeverypieceofequipmenthere.Providedthiscondition,wejustdiscussthekeypartsofBF.Themaincoverageincludesdustsystem,coolingsystem,gassupplysystem,refractoryetc.Besides,wehasIVcenteredonthecorepartofRCM–decisiontable.Butforthesakeofintegralityofmaintenanceprogram,hereweintroducedtheprinciplesofothernecessaryparts,includingconstructionofthedata,combinationofrepairworks.ButthosearenotonlyappearedinRCMprogram,sothispartofworkisrathersummary.ThroughtheRCManalysisonequipmentofNo.2BFofBaosteel,comparingtheexistpractice,wefoundthatnewmaintenancemethodcannotonlyimprovethereliabilityofequipmentswithdangerousfailureaffect,butalsoprolongtheservicelifeofthewholeequipmentofBFundertheaskedsafety.Keywords:RCM,maintenanceofequipment,maintenanceofBFNo.2BFofBaosteel20086200862008RCMII1RCMII1.1RCM1.1.11.1.1.11.1.1.250601.1.1.370RCMII266RCM1.1.2RCM1.1.2.1RCM.RCMMSG3RCMRCM1974.StanleyNowlan.HowardHeap1978RCMRCMII3RCMMSG-31.1.2.2RCM1978RCM1984RCMRCMSINTEFRCM1.1.2.3RCMIIRCMNowlanHeapRCMMSG-3RCMIIRCMRCMII25000h40000hRCM40%-60%1.2RCMII61ABCDEF4%A2%B5%C7%D14%E68%FRCMIIMTBFWeibullRCMII416Fig.1SixkindsoffailuremodelRCMIIMTBFCRCMIIRCMIIRCMII1.3RCMIIRCMIICBMAMCBMRCMIIAMMTBFRCMIIRCMIIRCMIIRCMII51.41.4.141#2#3#4063m34#4350m31#2#3#80-904#2005415004343601#TPMTotalProductiveMaintenanceCBMConditionBasedMaintenanceAMAdaptiveMaintenanceCBMAMMTBF(meantimebetweenfailure)MTBF2006493601.4.231000/2.4%0.1%434.56150004000/300086.83RCMII61700428005%8.4/1176971.5RCM2#RCMII7RCMII2.1RCMII22RCMIIFig.2AtypicalcensorgroupofRCMIIRCMRCMRCMRCMRCM2.2RCMIIRCMII8RCMIIRCMRCMRCMRCM2.3RCMII7RCM2.3.1RCMIIRCMII3RCMII954433211RCMII10332223RCMfig.3RCMjudgementRCMII112.3.2RCMII11RCMII1990ALADONFFFFM1800L/minXYA1…..….…..…….….…..RCMII1990ALADONFFFFMHSEOH1S1O1N1H2S2O2N2H3S3O3N3H4H5S41A1…………….….…..….….….…RCMII122.3.3103RCMIIHSEONl3H1H2H3H4H532.3.4HSEO2.3.4.1HABABABBAAAABAAB4RCMII134Fig.4JudgeprocessonConcealedworks2.3.4.2SE3RCMRCMRCMII142.3.4.3ORCM5RCMII155Fig.5Judgeprocessonoperatingcharacteristicresults2.3.4.4……RCMII166EYO76Fig.6RecordoffailureresultsinjudgmentbillHYSHNH1SNESYS1EYS1ENOOYO1ONN1RCMII177Fig.7Scheduleoffailureresults2.3.4.5810H1S1O1N1H2S2O2N2FFFFMHSEO3A1N5B2YY2C4YNY1A5YNNY1B3YNNN…………………RCMII18H3S3O3N38H1S1O1N1H2S2O2N2H3S3O3N3YP-FP-FP-FNYNNY8Fig.8JudgmentoffeasibilityY2.3.4.6H4H5S43393RCMII19FFFFMHSEOH1S1O1N1H2S2O2N2H3S3O3N3H4H5S43A1NNNNY44BC42NNNNNNNNNNYNH452BA25YYYYNNNNNNYN11AB53YYNNNNYNNNNNNN9Fig.9JudgeprocessoftemporaryproblemsRCMII202.3.4.72.3.4.8P-F,XYYXRCMII212.3.4.9RCMIIRCM2.4RCM2.4.110RCMII221210Fig.10Translationbetweenjudgmentbillandmaintainplan2.4.2RCMII232.4.322…………………………………RCMII242.5RCMII2.5.12.5.1.12.5.1.22.5.1.32.5.1.4RCMII25CRCMRCMRCMRCMRCM2.5.2RCMRCMRCMII2633/MTTFMTBF/P-FSPCP-FRCMII27C/1%-2%MTBFRCMII28RCMIIRCMII2#RCMII8RCMRCMRCMRCMRCMRCMIIRCMRCMII3.12#11112#Fig.11Equipmentlistof2#BF2#RCMII29RCMIIL123456781L-01-013.2RCMII3.2.16121#L01--012#L-01-023#L-01-034#L-01-045#L-01-056#L-01-062#SRCMII3012Fig.12Equipmentlistofventilationandfiltrationsystem3.2.2645RCMII4RCMIIL-012007-71L-01-062007-7112A31B1SRCMII31212240A4035RCMIIL-012007-71L-01-012007-711A211B21A21232B….…….….RCMII323.2.3RCMIIRCMIIRCMIIRCMIIYN66RCMIIL-012007-71L-01-062007-71H1H2H3S1S2S3O1O2O3FFFFMHSEON1N2N3H4H5S41YNYY12YNYY1A3YNYY11NY11B2YNNYY11YNNNY12YNNNY12A3YNNNY1RCMRCM1/hRCMII331-B-22/h2/h4/h77RCMIIL-012007-71L-01-012007-71H1H2H3S1S2S3H4H5S4O1O2O3FFFFMHSEON1N2N31YYY1A2YYY11YYY11B2NY11YNNYY12A2YNNYY1………..………………………………3.2.4RCMIIRCMII34RCMII3.3RCMII1313Fig.13ThreegradesofequipmentrecordsystemonBFRCMIIRCMRCMRCM2#RCMII35RCMIIRCM3.3.1RCM811:8RCMIIL-022007-71L-02-01-012007-7112341A51A2280B1RCMII369RCMIIL-022007-71L-02-01-012007-71H1H2H3S1S2S3O1O2O3FFFFMHSEON1N2N3H4H5S41YNNYY12YNNYY13YNNYY14YNNYY11A5YNNNY11YNNNY1A2YNNNY12B1YNNNY1RCMII3710RCMIIL-022007-71L-02-01-022007-71A11B211C212A3280B1RCMII3811RCMIIL-022007-71L-02-01-022007-71H1H2H3S1S2S3O1O2O3FFFFMHSEON1N2N3H4H5S4A1NNNNY111YNYY1B2YNYY11YNYY11C2NNNNY11011YNYY12NY1A3NYY312B1NY1RCMII393.3.2121712RCMIIL-022007-71L-02-02-012007-7112A31B113RCMIIL-022007-71L-02-02-012007-71H1H2H3S1S2S3O1O2O3FFFFMHSEON1N2N3H4H5S4RCMII401NY