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Development Ltd
Linking Technology with Success
Contact Details
Risk Based Maintenance for Power Plant
ETD Ltd, 6 Axis Centre Increasingly these days Maintenance Managers are PDM
B o ile r , P r e s s u r ize d
80 B o ile r , G e n e r a l

finding that there is less time (and/or money) PAM 60 T u r b in e


Cleeve Road, Leatherhead, available to do the amount of maintenance that they M a in t e n a n c e B a s is
40
E le c t r ic a l
20
Surrey, KT22 7RD, UK would like to do. The key question that is often asked W a t e r C h e m is t r y
0
A u xilia r y
is
W o r k M e t h o d o lo g y C iv il
"what outage tasks should I give priority to?" The
Tel: + 44 (0)1372 363111 answer is clearly to concentrate on the
T r a in in g
E n g in e e r in g
O p e r a t io n s
P e r fo r m a n c e

Fax:+ 44 (0)1372 363222 "value" Tasks, but how do you identify the critical
Email: etd@etd1.co.uk tasks. There are a number of ways to assess the M a n a g e m e n t P ro g ra m A c c e p t ib le R is k L e ve l

priority that should be given to maintenance or


On the web at: It is important to recognize that identification of
inspection tasks but increasingly a Risk Based
risks does not necessarily require a substantial
www.etd1.co.uk approach is preferred. Although procedures are
financial or resource commitment rather, as the
available for petrochemical and refining plant there
ETD Guideline shows, a simplified system readily
was not one available for Power Plant. To address this
highlights and ranks risk areas for attention.
ETD Services need ETD developed Risk Based Maintenance
Guidelines specifically aimed at generating
The ETD RBM process uses a "Risk Waterfall"
Initially this involves examining how well the plant
equipment.
Training is managed in terms of technical and other programs
The main objective of Risk Based Maintenance is to
and is carried out by comparison with good/best
allow a framework to identify and measure the risk
Inspection Planning areas and thereby allow optimised focusing of practice the attributes (or lack of attributes) of each
program of each area. The output is a numerical
available resources.
Life Extension Information details
indication of the level of risk in different plant
and assessment areas. This is followed by a more detailed
Plant Cycling Programme level accuracy evaluation of the degree of risk by assessing how
increases with effectively the technical programmes are
depth of the
Defect Assessment Implementation level process
implemented and an estimate of the probable
condition of specific components. Finally the
Risk Based Maintenance Component level
maintenance activities to be performed on the
component at the next shutdown are examined in
terms of their (risk based) value and the cost of the
Stress Analysis
Outage Task level activity to prioritize on a value cost basis. This
allows elimination of the low value tasks and hence
Repair Consultancy saving the costs associated with these tasks.

Risk Based Methods for Optimising the Content and Timing of Overhauls
In the current economic climate it is important to not only minimise risk subsequent plant performance can all have a major impact on cost.
levels but to do it at minimum cost. One of the main controllable costs ETD has a suite of risk based methods for optimising the
is maintenance. The time it takes to carry out maintenance, the interval maintenance and overhaul activities.
between outages, the quality and efficiency of the outage work and
Key areas are:
 Optimising the outage content. Risk can be used to define the
value of all of the maintenance and inspection activities. When
this is combined with the cost of the activity a cost/risk optimised
outage program can be defined. As shown opposite the majority
of the plant risk can be captured with a relatively small
percentage of the original planned outage activities.
 Optimising the interval between outages. By assessing the current
condition of plant components and looking at how their risk
levels increase with service it is possible to identify ways of
moderating the risk thereby allowing longer run times between
overhauls.
 Optimising Outage Productivity. By using advanced project
management skills, improved planning support and project risk
identification and mitigation processes a productivity
improvement of 10-20% can be achieved.
ETD can offer these services together with conventional inspection
planning and consultancy on component integrity management
issues.