以可靠性为中心的船舶维修辅助决策系统研究
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摘要
目前,我国船舶设备主要采用是以时间为基础的定期维修制度,这种基于固定维修周期的维修方式为设备正常运行做出了很大贡献。但是伴随着船舶设备结构复杂化程度的上升,定期维修已不能适应新形势的要求,其原因在于许多零部件的故障率曲线并不符合“浴盆曲线”,零部件越多,故障发生的概率就越高。事实上,定期修理还可能将初期的高故障率引入到系统中,从而增加系统的总故障率;定期维修同样也可能会导致部分运行状态较好的设备周期性停运,同时导致某一时间段维修工作量集中,不利于提高维修质量。
随着社会的发展和市场的变化,这样的维修方式已很难满足现在船舶设备的维修要求。鉴于我国船舶企业目前技术与经济条件,以可靠性为中心的维修(Reliability-Centered Maintenance——RCM)足一种较好的选择。这种方法是以设备故障模式和影响效果的系统分析为基础,应用逻辑决断确定设备预防性维修内容。
本文基于以上原因,提出了以可靠性为中心的船舶设备维修的应用研究。其主要研究内容如下:
(1)论证RCM在船舶设备中应用的可行性及有效性,根据RCM实施过程最终得出以可靠性为中心的船舶设备维修大纲,指导今后船舶维修工作。
(2)利用层次分析法对RCM的逻辑决断结果进行反馈验证,使得预防性维修大纲的制定更加科学有效。
(3)开发以可靠性为中心的船舶辅助维修决策系统,系统中包含设备的基本信息管理,RCM分析流程及备件统计管理。
通过对船舶设备RCM分析,相对于现行的维修制度,以可靠性为中心的维修制度能够以最少的资源消耗来保证设备固有可靠性和安全性。基于船舶维修的现有技术水平和条件,全面推行以可靠性为中心的维修理论可能存在一定困难,但目前已有部分船舶的重要设备实现了状态监控,这为RCM在船舶设备维修领域中的运用铺垫了道路。随着科学技术的进步,监控手段的不断成熟,这种以可靠性为中心的维修理论在船舶领域中必将得到全面推广和运用。
At present, time-based maintenance is used in China's Marine equipment maintenance, and which based on the fixed period of maintenance mode have made considerable contribution for the normal operation of equipment. However, with the increasing of marine equipment structure complication, regular maintenance can't meet the requirement of the new situation. The reason is the failure rate in many parts of the curve does not comply with "bathtub curve", parts more failures occur, The higher the probability of failure occurred. In fact, regular repair may introduce the initial high failure rate into the system, thereby increasing the total failure rate of the system; time-based maintenance is bound to lead to some good running equipment cyclical outage, a result of maintenance work focuses on one phase, not conducive to raising the quality of maintenance.
With the development of society and the market changes, such a maintenance mode has been very difficult to meet the requirements of Marine equipment maintenance. In view of our current technical and economic business conditions, RCM (reliability-centered maintenance) is a good choice. This method is based on equipment failure modes and effects of effects of systematic analysis which application of the logical decisions to determine the content of preventive maintenance equipment.
(1) Demonstrate the feasibility and effectiveness of the application of RCM in the marine's equipment, According to RCM implementation process culminated in the reliability-centered maintenance program for marine equipment, which guide future maintenance of the ship.
(2) Using the Analytic Hierarchy Process to feedback and validate the results of RCM logical decision, so as to make the formulation of preventative maintenance outline more scientific and effective.
(3) Development of Reliability Centered Maintenance in Maintenance Decision Support System of Marine Eequipment, This system includes the basic information management of equipment, RCM analysis processes and spare parts statistical management.
Through RCM analysis of ship equipment, compared with existing maintenance system, the reliability-centered maintenance system can ensure the inherent reliability and security of equipment with minimal resource consumption. Based on existing level and condition of ship repair, it may be difficult to fully implement reliability-centered maintenance theory, but some important ship equipments have been in state monitoring, This pave the way for the use of the area. With the development of technology and maturation of monitoring means, the reliability- centered maintenance theory will be fully promoted and used in the field of ship.
随着社会的发展和市场的变化,这样的维修方式已很难满足现在船舶设备的维修要求。鉴于我国船舶企业目前技术与经济条件,以可靠性为中心的维修(Reliability-Centered Maintenance——RCM)足一种较好的选择。这种方法是以设备故障模式和影响效果的系统分析为基础,应用逻辑决断确定设备预防性维修内容。
本文基于以上原因,提出了以可靠性为中心的船舶设备维修的应用研究。其主要研究内容如下:
(1)论证RCM在船舶设备中应用的可行性及有效性,根据RCM实施过程最终得出以可靠性为中心的船舶设备维修大纲,指导今后船舶维修工作。
(2)利用层次分析法对RCM的逻辑决断结果进行反馈验证,使得预防性维修大纲的制定更加科学有效。
(3)开发以可靠性为中心的船舶辅助维修决策系统,系统中包含设备的基本信息管理,RCM分析流程及备件统计管理。
通过对船舶设备RCM分析,相对于现行的维修制度,以可靠性为中心的维修制度能够以最少的资源消耗来保证设备固有可靠性和安全性。基于船舶维修的现有技术水平和条件,全面推行以可靠性为中心的维修理论可能存在一定困难,但目前已有部分船舶的重要设备实现了状态监控,这为RCM在船舶设备维修领域中的运用铺垫了道路。随着科学技术的进步,监控手段的不断成熟,这种以可靠性为中心的维修理论在船舶领域中必将得到全面推广和运用。
At present, time-based maintenance is used in China's Marine equipment maintenance, and which based on the fixed period of maintenance mode have made considerable contribution for the normal operation of equipment. However, with the increasing of marine equipment structure complication, regular maintenance can't meet the requirement of the new situation. The reason is the failure rate in many parts of the curve does not comply with "bathtub curve", parts more failures occur, The higher the probability of failure occurred. In fact, regular repair may introduce the initial high failure rate into the system, thereby increasing the total failure rate of the system; time-based maintenance is bound to lead to some good running equipment cyclical outage, a result of maintenance work focuses on one phase, not conducive to raising the quality of maintenance.
With the development of society and the market changes, such a maintenance mode has been very difficult to meet the requirements of Marine equipment maintenance. In view of our current technical and economic business conditions, RCM (reliability-centered maintenance) is a good choice. This method is based on equipment failure modes and effects of effects of systematic analysis which application of the logical decisions to determine the content of preventive maintenance equipment.
(1) Demonstrate the feasibility and effectiveness of the application of RCM in the marine's equipment, According to RCM implementation process culminated in the reliability-centered maintenance program for marine equipment, which guide future maintenance of the ship.
(2) Using the Analytic Hierarchy Process to feedback and validate the results of RCM logical decision, so as to make the formulation of preventative maintenance outline more scientific and effective.
(3) Development of Reliability Centered Maintenance in Maintenance Decision Support System of Marine Eequipment, This system includes the basic information management of equipment, RCM analysis processes and spare parts statistical management.
Through RCM analysis of ship equipment, compared with existing maintenance system, the reliability-centered maintenance system can ensure the inherent reliability and security of equipment with minimal resource consumption. Based on existing level and condition of ship repair, it may be difficult to fully implement reliability-centered maintenance theory, but some important ship equipments have been in state monitoring, This pave the way for the use of the area. With the development of technology and maturation of monitoring means, the reliability- centered maintenance theory will be fully promoted and used in the field of ship.
引文
[1]中华人民共和国交通部[EB/OL].[2007-08-03].
http://www.moc.gov.cn/2006/06jiaotongxw/lishixw/07nian8yue/200708/t20070803_372433.html
[2]吴宗荣.船舶机械修理工艺学[M].北京:人民交通出版社,2000:2-4
[3]刘爱华.基于CWBT的管理信息系统研究[D].武汉:武汉理工大学,2005
[4]史大.船舶维修策略研究及系统开发[D].武汉:武汉理工大学,2004
[5]Wang Y,Jia Y,Jiang W.Early Failure Analysis of Machining Centers:a Case Study[J].Reliability Engineering and System Safety,2001,72:91-97
[6]Rausand Marvin.Reliability-Centered Maintenance.Reliability Engineering and System Safety,1998,60(2):121-132
[7]Zeng Ming.Application of conditional maintenance in thermo power plant.China Electric Power,1998,31:66-68
[8]李志伟.浅谈设备管理与维修.机械管理开发[J],2002,年增刊:132-133
[9]吴刚.减速机械的可靠性维修及其维修决策研究[D].武汉:武汉理工大学,2007
[10]贾希胜.以可靠性为中心的维修决策模型[M].北京:国防工业出版社,2007:14,32
[11]何钟武.浅谈国内外RCM技术的研究与应用[D].成都:洪都航空工业集团六五0所,2006
[12]束洪春.电力系统以可靠性为中心的维修[M].北京:北京工业出版社,2009:27,129,131
[13]金碧辉.系统可靠性工程[M].北京:国防工业出版社,2004:110
[14]Jacobs K.S.Reducing Maintenance Workload through Reliability-Centered Maintenance.Naval Engineers Journal,1998,110(4):87-89
[15]李岐新.设备维修管理的新方法.机电元件[J],2000(1):47-50
[16]胡安定.设备维修与管理的新趋势—97设备维修与管理国际会议(IPEC)综述[J].设备管理,1998,1(19):3-8
[17][葡]A.MONTEIRO ELITE.跨入新千年的现代维修体系(下)[D].北京:中国设备管理,1999,No4
[18]李葆文.设备管理新思维新模式[M].北京:机械工业出版社,2004:210
[19]李晓明.基于RCM的核电站维修优化研究与应用[D].武汉:华中科技大学,2005
[20]冯廷敏.基于状态监测的以可靠性为中心的智能维修系统[D].北京:北京化工大学,2008
[21]Xue Chuang wen,Improving Equipment Management and Meeting the Requirements of Establishing Modem Enterprise System International Journal of Plant Engineering and Management[J],20(x),Vol.3(5):103-120
[22]蒋跃.常州船用电缆有限责任公司RCM体系的建立与实施[D].西安:西安理工大学,2005
[23]Birolini,Alessandro,Reliability engineering:theory and practice,New York:Springer-Veerlag.2004:298-294
[24]Nowlan F S,Heap H F.Reliability Centered Maintenance[M].San Fransisco:United Airl-ines Publications,1978
[25]Cheng Yun,Chung T S.Application of reliability-centered stochastic approach and FMECA to conditional maintenance of electric power plants in China.Proceedings of the 2004 IEEE International Conference on Electric Utility Deregulation.Restructuring and Power Technologies.2004,463-467
[26]Wieslaw tarelko.Control model of maintainability level.Reliability Engineering and System Safety,1995,85-91
[27]Huang G Q,Nie M,Mak K L.Web-based Failure Mode and Effect Analysis(FMEA)[J].Computers & Industrial Engineering,1999,(10)
[28]竹建福.FMECA在船舶主机系统中的应用[D].上海:上海海事大学,2006[29]冯瑞臣.模糊FMECA在船舶主机系统中的应用研究[D].大连:大连海事大学,2008
[30]Jia Xisheng,Hao Jianping.The RCM Analysis for a Complex System.IMA Journal of Mathematics applied in Business and Industry,1995,6(1):135-144
[31]季守军.基于RCM的高炉设备维修工程与实例[D].上海:上海交通大学,2008
[32]李美芳,刘家科,杜清玲.机械设备预防维修周期的确定[J].机床与液压,2000,(6):92-95
[33]田世林.远洋船舶维修保养管理系统[D].大连:大连海事大学,2003
[34]李晓明.基于RCM的核电站维修优化研究与应用[D].武汉:华中科技大学,2005
[35]Shimizu,Sugawara.Decision-Making Support Systems for Reliability-Centered Maintenance.Journal of Nuclear Science and Technology,1993,30(6):505-515
[36]杨清.变电设备维修的应用研究[D].昆明:昆明理工大学,2007
[37]T.L萨蒂著.层次分析法[M].北京:煤炭工业出版社,1986
[38]刘豹.层次分析法[M].北京:科学出版社,1986:28
[39]李祝清.船舶机舱设备维修分类研究[D].大连:大连海事大学,2006
[40]Whittington H W,Flynn B W.High Reliability Condition Monitoring System.British Journal of NDT,1993,35(11):648-654
[41]邱朋辉.船舶动力装置的安全管理及其信息化[D].武汉:武汉理工大学,2007
[42]王健,张琦,雷霆等.基于COM组件的工程机械集成化故障诊断系统研究[J].建筑机械,2005(2):61-64
[43]范世东,钟骏杰,陈俊.基于Web的设备维修方式决策系统开发[J].交通与计算机,2001,(5):35-37
[44]程中华.基于C/S模式的RCM分析决策系统的设计与实现[J].开发研究与设计技术,2004:174-177
[45]林杰,薛华成.基于WEB和数据仓库的信息系统构架[J].计算机工程,2001(2):39-40
[46]张健沛.数据库原理及应用系统开发[M].北京:中国水利水电出版社,1999
[47]王芸.设备维修管理及决策支持系统的研究与设计[D].西安:西安理工大学,2006
[48]林杰,薛华成.基于WEB和数据仓库的信息系统构架[J].计算机工程,2001(2):39-40
[49]刘福明,顾文涓,李莉等.基于MTS的三层结构的研究与实现[J].计算机应用研究,2002,
[50]黄梯云,智能决策支持系统[M].北京:电子工业出版社,2001
[51]阂庆海,巫世晶,向农.发电设备维修管理信息系统的研究与开发[J].中国设备工程,2002,(6):10-11
[52]陈文伟.决策支持系统及其开发[M].北京:清华大学出版社,2000
[53]李晓林.阂华清,张彦铎.基于三层结构的设备管理信息系统开发技术及其实现[J].计算机应用,2001,8(21):222-223
http://www.moc.gov.cn/2006/06jiaotongxw/lishixw/07nian8yue/200708/t20070803_372433.html
[2]吴宗荣.船舶机械修理工艺学[M].北京:人民交通出版社,2000:2-4
[3]刘爱华.基于CWBT的管理信息系统研究[D].武汉:武汉理工大学,2005
[4]史大.船舶维修策略研究及系统开发[D].武汉:武汉理工大学,2004
[5]Wang Y,Jia Y,Jiang W.Early Failure Analysis of Machining Centers:a Case Study[J].Reliability Engineering and System Safety,2001,72:91-97
[6]Rausand Marvin.Reliability-Centered Maintenance.Reliability Engineering and System Safety,1998,60(2):121-132
[7]Zeng Ming.Application of conditional maintenance in thermo power plant.China Electric Power,1998,31:66-68
[8]李志伟.浅谈设备管理与维修.机械管理开发[J],2002,年增刊:132-133
[9]吴刚.减速机械的可靠性维修及其维修决策研究[D].武汉:武汉理工大学,2007
[10]贾希胜.以可靠性为中心的维修决策模型[M].北京:国防工业出版社,2007:14,32
[11]何钟武.浅谈国内外RCM技术的研究与应用[D].成都:洪都航空工业集团六五0所,2006
[12]束洪春.电力系统以可靠性为中心的维修[M].北京:北京工业出版社,2009:27,129,131
[13]金碧辉.系统可靠性工程[M].北京:国防工业出版社,2004:110
[14]Jacobs K.S.Reducing Maintenance Workload through Reliability-Centered Maintenance.Naval Engineers Journal,1998,110(4):87-89
[15]李岐新.设备维修管理的新方法.机电元件[J],2000(1):47-50
[16]胡安定.设备维修与管理的新趋势—97设备维修与管理国际会议(IPEC)综述[J].设备管理,1998,1(19):3-8
[17][葡]A.MONTEIRO ELITE.跨入新千年的现代维修体系(下)[D].北京:中国设备管理,1999,No4
[18]李葆文.设备管理新思维新模式[M].北京:机械工业出版社,2004:210
[19]李晓明.基于RCM的核电站维修优化研究与应用[D].武汉:华中科技大学,2005
[20]冯廷敏.基于状态监测的以可靠性为中心的智能维修系统[D].北京:北京化工大学,2008
[21]Xue Chuang wen,Improving Equipment Management and Meeting the Requirements of Establishing Modem Enterprise System International Journal of Plant Engineering and Management[J],20(x),Vol.3(5):103-120
[22]蒋跃.常州船用电缆有限责任公司RCM体系的建立与实施[D].西安:西安理工大学,2005
[23]Birolini,Alessandro,Reliability engineering:theory and practice,New York:Springer-Veerlag.2004:298-294
[24]Nowlan F S,Heap H F.Reliability Centered Maintenance[M].San Fransisco:United Airl-ines Publications,1978
[25]Cheng Yun,Chung T S.Application of reliability-centered stochastic approach and FMECA to conditional maintenance of electric power plants in China.Proceedings of the 2004 IEEE International Conference on Electric Utility Deregulation.Restructuring and Power Technologies.2004,463-467
[26]Wieslaw tarelko.Control model of maintainability level.Reliability Engineering and System Safety,1995,85-91
[27]Huang G Q,Nie M,Mak K L.Web-based Failure Mode and Effect Analysis(FMEA)[J].Computers & Industrial Engineering,1999,(10)
[28]竹建福.FMECA在船舶主机系统中的应用[D].上海:上海海事大学,2006[29]冯瑞臣.模糊FMECA在船舶主机系统中的应用研究[D].大连:大连海事大学,2008
[30]Jia Xisheng,Hao Jianping.The RCM Analysis for a Complex System.IMA Journal of Mathematics applied in Business and Industry,1995,6(1):135-144
[31]季守军.基于RCM的高炉设备维修工程与实例[D].上海:上海交通大学,2008
[32]李美芳,刘家科,杜清玲.机械设备预防维修周期的确定[J].机床与液压,2000,(6):92-95
[33]田世林.远洋船舶维修保养管理系统[D].大连:大连海事大学,2003
[34]李晓明.基于RCM的核电站维修优化研究与应用[D].武汉:华中科技大学,2005
[35]Shimizu,Sugawara.Decision-Making Support Systems for Reliability-Centered Maintenance.Journal of Nuclear Science and Technology,1993,30(6):505-515
[36]杨清.变电设备维修的应用研究[D].昆明:昆明理工大学,2007
[37]T.L萨蒂著.层次分析法[M].北京:煤炭工业出版社,1986
[38]刘豹.层次分析法[M].北京:科学出版社,1986:28
[39]李祝清.船舶机舱设备维修分类研究[D].大连:大连海事大学,2006
[40]Whittington H W,Flynn B W.High Reliability Condition Monitoring System.British Journal of NDT,1993,35(11):648-654
[41]邱朋辉.船舶动力装置的安全管理及其信息化[D].武汉:武汉理工大学,2007
[42]王健,张琦,雷霆等.基于COM组件的工程机械集成化故障诊断系统研究[J].建筑机械,2005(2):61-64
[43]范世东,钟骏杰,陈俊.基于Web的设备维修方式决策系统开发[J].交通与计算机,2001,(5):35-37
[44]程中华.基于C/S模式的RCM分析决策系统的设计与实现[J].开发研究与设计技术,2004:174-177
[45]林杰,薛华成.基于WEB和数据仓库的信息系统构架[J].计算机工程,2001(2):39-40
[46]张健沛.数据库原理及应用系统开发[M].北京:中国水利水电出版社,1999
[47]王芸.设备维修管理及决策支持系统的研究与设计[D].西安:西安理工大学,2006
[48]林杰,薛华成.基于WEB和数据仓库的信息系统构架[J].计算机工程,2001(2):39-40
[49]刘福明,顾文涓,李莉等.基于MTS的三层结构的研究与实现[J].计算机应用研究,2002,
[50]黄梯云,智能决策支持系统[M].北京:电子工业出版社,2001
[51]阂庆海,巫世晶,向农.发电设备维修管理信息系统的研究与开发[J].中国设备工程,2002,(6):10-11
[52]陈文伟.决策支持系统及其开发[M].北京:清华大学出版社,2000
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