A Research And Application Of RCM In Optimization Of Maintenance For Nuclear Power Stations

Maintenance Management Optimization in modern industry, especially in nuclear power generation, is a critical part of maintenance and operations. It plays a critical role in improving the dependability of the equipment as well as reducing maintenance expenses & direct operational expenses. Hence for many years maintenance optimization has been one of the most active subjects of research in the maintenance management field. Among the many maintenance optimization methodologies existing, Reliability-centered Maintenance (RCM) is one of the most widely accepted outside China at present. This paper will introduce the RCM developmental history, and how, drawing from experiences of other countries in applying RCM, the Daya Bay Nuclear Power Station (DNMC) RCM implementation program evolved four tools that help structure the application of RCM to local conditions. First this paper will explain that the initial RCM analyses logic applied at DNMC gave rise to conflicts with the established management organization. It became more and more apparent the initial RCM program, as applied, was unable to function fully to our expectation at DNMC and we needed to modify the initial RCM process (to optimize the application) that did not sacrifice the philosophy of RCM. This optimization of the RCM logic diagram made the process more convenient, more logical, more reliable and effective. It also insured economic factors were clearly considered. These clarifications of the RCM logic have reduced the margin for argument, and improvement and have improved the RCM facilitator's effectiveness in choosing the maintenance task that is most sensible and defensible from a total consideration of effectiveness, costs and risk. Also, sub-classification of hidden failures improved equipment management effectiveness. A significant number of examples demonstrated the suitability of our new logic. Secondly, at DNMC, both operations and maintenance management considered identification of sensitive or critical equipment key management priorities. The author provides a definition of the sensitive or critical equipment. He will demonstrate how the limited scope of the initial RCM applied created difficulties in implementing certain aspects of any such program under this RCM method. Combine the characteristic of the nuclear power station of DNMC, research and propose the key and discern the logic picture sensitively ----this system is know as CCM (Critical Component Management, key sensitive equipment control). This CCM program was designed to that it and the RCM logic diagram merge together organically. This method, applied to completed RCM analysis using the information in the RCM database allows quick selection of sensitive and critical equipment and the relevant failure modes. In turn, this allows more effective asset management, which benefits the safe and reliable operation of the power stations. Third, the author established tools and models to analyze the economic benefits achieved by each RCM analysis. The most obvious changes in costs due to applying RCM come from elimination of unnecessary, and even counter-productive maintenance tasks and their associated costs. However, preventing failures, which previously had been allowed to occur, may increase maintenance costs, but due to improved operation the final effect is a reduction in total costs. However, assessing the economic benefits and just how much of improvements in reliability have occurred due to the RCM process itself has always been a difficult point in RCM. This paper discusses different tools developed to help access these sorts of reliability economic benefits based on the type of benefit secured. Adopting this method can help demonstrate the economic benefits made by RCM and justify continued investments in the process. Finally, this paper will discuss the development of a proprietary RCM information database and it's application. RCM is used by many departments, across a large group of equipment, and generates a large amount of information, the management of which is complicated. Effective information technology management is critical to the success in maintaining and applying the results of any RCM program. For this reason, the author puts forward his experience in the development of an RCM equipment information database and the establishment of an RCM based predictive maintenance (on-condition) management system.The paper will introduce the specific details on the critical impact of these databases in establishing a successful RCM program.