IDEAS home Printed from https://ideas.repec.org/a/eee/ejores/v291y2021i1p232-243.html
   My bibliography  Save this article

Condition-based inspection policies for boiler heat exchangers

Author

Listed:
  • Truong-Ba, Huy
  • Cholette, Michael E.
  • Borghesani, Pietro
  • Ma, Lin
  • Kent, Geoff

Abstract

This study considers the inspection and maintenance of boiler heat exchangers, which are examples of a system composed of degrading, non-repairable components in series whose operation can be restored by removing failed components from service (albeit at a performance loss). For such systems, the increased failure risk due to component degradation may be managed through inspections and preventive removal of high failure risk components from service (again at a performance loss for remaining life of systems). In this study, a new joint inspection and preventive maintenance policy is developed, which uses condition information obtained at an inspection to optimize decisions regarding maintenance and future inspections to optimally balance the risks of system failure, future performance losses, and maintenance costs. The policy is optimized using the Markov Decision Process paradigm and is applied to a case study of a boiler heat exchanger operating in an Australian sugar factory. The results show that the proposed policy yields significant savings compared to benchmark policies that represent the factory's current practice.

Suggested Citation

  • Truong-Ba, Huy & Cholette, Michael E. & Borghesani, Pietro & Ma, Lin & Kent, Geoff, 2021. "Condition-based inspection policies for boiler heat exchangers," European Journal of Operational Research, Elsevier, vol. 291(1), pages 232-243.
    • Handle: RePEc:eee:ejores:v:291:y:2021:i:1:p:232-243
    DOI: 10.1016/j.ejor.2020.09.030
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0377221720308341
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ejor.2020.09.030?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Cholette, Michael E. & Yu, Hongyang & Borghesani, Pietro & Ma, Lin & Kent, Geoff, 2019. "Degradation modeling and condition-based maintenance of boiler heat exchangers using gamma processes," Reliability Engineering and System Safety, Elsevier, vol. 183(C), pages 184-196.
    2. Berrade, M.D. & Scarf, P.A. & Cavalcante, C.A.V., 2018. "Conditional inspection and maintenance of a system with two interacting components," European Journal of Operational Research, Elsevier, vol. 268(2), pages 533-544.
    3. Wang, Wei & Wu, Zhiying & Xiong, Junlin & Xu, Yaofeng, 2018. "Redundancy optimization of cold-standby systems under periodic inspection and maintenance," Reliability Engineering and System Safety, Elsevier, vol. 180(C), pages 394-402.
    4. Zhang, Mimi & Gaudoin, Olivier & Xie, Min, 2015. "Degradation-based maintenance decision using stochastic filtering for systems under imperfect maintenance," European Journal of Operational Research, Elsevier, vol. 245(2), pages 531-541.
    5. Sahu, S.G. & Chakraborty, N. & Sarkar, P., 2014. "Coal–biomass co-combustion: An overview," Renewable and Sustainable Energy Reviews, Elsevier, vol. 39(C), pages 575-586.
    6. Cavalcante, C.A.V. & Lopes, R.S. & Scarf, P.A., 2018. "A general inspection and opportunistic replacement policy for one-component systems of variable quality," European Journal of Operational Research, Elsevier, vol. 266(3), pages 911-919.
    7. Yang, Li & Ye, Zhi-sheng & Lee, Chi-Guhn & Yang, Su-fen & Peng, Rui, 2019. "A two-phase preventive maintenance policy considering imperfect repair and postponed replacement," European Journal of Operational Research, Elsevier, vol. 274(3), pages 966-977.
    8. Scarf, P.A. & Cavalcante, C.A.V. & Lopes, R.S., 2019. "Delay-time modelling of a critical system subject to random inspections," European Journal of Operational Research, Elsevier, vol. 278(3), pages 772-782.
    9. Rusin, Andrzej & Wojaczek, Adam, 2019. "Improving the availability and lengthening the life of power unit elements through the use of risk-based maintenance planning," Energy, Elsevier, vol. 180(C), pages 28-35.
    10. Zhang, Xiaohong & Zeng, Jianchao, 2017. "Joint optimization of condition-based opportunistic maintenance and spare parts provisioning policy in multiunit systems," European Journal of Operational Research, Elsevier, vol. 262(2), pages 479-498.
    11. Hongzhou Wang & Hoang Pham, 2006. "Reliability and Optimal Maintenance," Springer Series in Reliability Engineering, Springer, number 978-1-84628-325-3, February.
    12. Yu, Jungwon & Yoo, Jaeyeong & Jang, Jaeyel & Park, June Ho & Kim, Sungshin, 2017. "A novel plugged tube detection and identification approach for final super heater in thermal power plant using principal component analysis," Energy, Elsevier, vol. 126(C), pages 404-418.
    13. Ferreira, Rodrigo J.P. & de Almeida, Adiel Teixeira & Cavalcante, Cristiano A.V., 2009. "A multi-criteria decision model to determine inspection intervals of condition monitoring based on delay time analysis," Reliability Engineering and System Safety, Elsevier, vol. 94(5), pages 905-912.
    14. Nunes, L.J.R. & Matias, J.C.O. & Catalão, J.P.S., 2016. "Biomass combustion systems: A review on the physical and chemical properties of the ashes," Renewable and Sustainable Energy Reviews, Elsevier, vol. 53(C), pages 235-242.
    15. Zhang, Fengxia & Shen, Jingyuan & Ma, Yizhong, 2020. "Optimal maintenance policy considering imperfect repairs and non-constant probabilities of inspection errors," Reliability Engineering and System Safety, Elsevier, vol. 193(C).
    16. Do, Phuc & Voisin, Alexandre & Levrat, Eric & Iung, Benoit, 2015. "A proactive condition-based maintenance strategy with both perfect and imperfect maintenance actions," Reliability Engineering and System Safety, Elsevier, vol. 133(C), pages 22-32.
    17. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    18. Lam, Ji Ye Janet & Banjevic, Dragan, 2015. "A myopic policy for optimal inspection scheduling for condition based maintenance," Reliability Engineering and System Safety, Elsevier, vol. 144(C), pages 1-11.
    19. Flage, Roger & Coit, David W. & Luxhøj, James T. & Aven, Terje, 2012. "Safety constraints applied to an adaptive Bayesian condition-based maintenance optimization model," Reliability Engineering and System Safety, Elsevier, vol. 102(C), pages 16-26.
    20. Zhang, Nan & Fouladirad, Mitra & Barros, Anne & Zhang, Jun, 2020. "Condition-based maintenance for a K-out-of-N deteriorating system under periodic inspection with failure dependence," European Journal of Operational Research, Elsevier, vol. 287(1), pages 159-167.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Truong-Ba, Huy & Cholette, Michael E. & Rebello, Sinda & Kent, Geoff, 2024. "Joint planning of inspection, replacement, and component decommissioning for a series system with non-identically degrading components," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    2. Li, Guolong & Li, Yanjun & Fang, Chengyue & Su, Jian & Wang, Haotong & Sun, Shengdi & Zhang, Guolei & Shi, Jianxin, 2023. "Research on fault diagnosis of supercharged boiler with limited data based on few-shot learning," Energy, Elsevier, vol. 281(C).

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    2. Cavalcante, Cristiano A.V. & Lopes, Rodrigo S. & Scarf, Philip A., 2021. "Inspection and replacement policy with a fixed periodic schedule," Reliability Engineering and System Safety, Elsevier, vol. 208(C).
    3. Alaswad, Suzan & Xiang, Yisha, 2017. "A review on condition-based maintenance optimization models for stochastically deteriorating system," Reliability Engineering and System Safety, Elsevier, vol. 157(C), pages 54-63.
    4. Sinisterra, Wilfrido Quiñones & Cavalcante, Cristiano Alexandre Virgínio, 2020. "An integrated model of production scheduling and inspection planning for resumable jobs," International Journal of Production Economics, Elsevier, vol. 227(C).
    5. Akcay, Alp, 2022. "An alert-assisted inspection policy for a production process with imperfect condition signals," European Journal of Operational Research, Elsevier, vol. 298(2), pages 510-525.
    6. Zhang, Fengxia & Shen, Jingyuan & Liao, Haitao & Ma, Yizhong, 2021. "Optimal preventive maintenance policy for a system subject to two-phase imperfect inspections," Reliability Engineering and System Safety, Elsevier, vol. 205(C).
    7. Wang, Jiantai & Longyan, Tan & Ma, Xiaobing & Gao, Kaiye & Jia, Heping & Yang, Li, 2023. "Prognosis-driven reliability analysis and replacement policy optimization for two-phase continuous degradation," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    8. Sinisterra, Wilfrido Quiñones & Lima, Victor Hugo Resende & Cavalcante, Cristiano Alexandre Virginio & Aribisala, Adetoye Ayokunle, 2023. "A delay-time model to integrate the sequence of resumable jobs, inspection policy, and quality for a single-component system," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    9. Zhao, Yunfei & Smidts, Carol, 2022. "Reinforcement learning for adaptive maintenance policy optimization under imperfect knowledge of the system degradation model and partial observability of system states," Reliability Engineering and System Safety, Elsevier, vol. 224(C).
    10. Truong-Ba, Huy & Cholette, Michael E. & Rebello, Sinda & Kent, Geoff, 2024. "Joint planning of inspection, replacement, and component decommissioning for a series system with non-identically degrading components," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    11. Levitin, Gregory & Finkelstein, Maxim & Dai, Yuanshun, 2020. "Optimal preventive replacement policy for homogeneous cold standby systems with reusable elements," Reliability Engineering and System Safety, Elsevier, vol. 204(C).
    12. Mosayebi Omshi, E. & Grall, A. & Shemehsavar, S., 2020. "A dynamic auto-adaptive predictive maintenance policy for degradation with unknown parameters," European Journal of Operational Research, Elsevier, vol. 282(1), pages 81-92.
    13. Alotaibi, Naif M. & Scarf, Philip & Cavalcante, Cristiano A.V. & Lopes, Rodrigo S. & de Oliveira e Silva, André Luiz & Rodrigues, Augusto J.S. & Alyami, Salem A., 2023. "Modified-opportunistic inspection and the case of remote, groundwater well-heads," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    14. Mosayebi Omshi, E. & Grall, A., 2021. "Replacement and imperfect repair of deteriorating system: Study of a CBM policy and impact of repair efficiency," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    15. Zhang, Wenyu & Zhang, Xiaohong & He, Shuguang & Zhao, Xing & He, Zhen, 2024. "Optimal condition-based maintenance policy for multi-component repairable systems with economic dependence in a finite-horizon," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    16. Xia, Tangbin & Cao, Lei & Xu, Yuhui & Zhang, Kaigan & Chen, Zhen & Pan, Ershun & Xi, Lifeng, 2024. "Multi-level maintenance and inventory joint optimization for a k-out-of-n hyper-system considering the selection of suppliers with incentive discount policies," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    17. Giorgio, Massimiliano & Pulcini, Gianpaolo, 2024. "The effect of model misspecification of the bounded transformed gamma process on maintenance optimization," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    18. Zhang, Fengxia & Liao, Haitao & Shen, Jingyuan & Ma, Yizhong, 2024. "Optimal maintenance over a finite time horizon for a system under imperfect inspection and dynamic working environment," Reliability Engineering and System Safety, Elsevier, vol. 246(C).
    19. de Jonge, Bram, 2019. "Discretizing continuous-time continuous-state deterioration processes, with an application to condition-based maintenance optimization," Reliability Engineering and System Safety, Elsevier, vol. 188(C), pages 1-5.
    20. Finkelstein, Maxim & Cha, Ji Hwan & Langston, Amy, 2022. "Optimal preventive switching of components in degrading systems," Reliability Engineering and System Safety, Elsevier, vol. 219(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:ejores:v:291:y:2021:i:1:p:232-243. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/locate/eor .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.