Aplicação da manutenção centrada em confiabilidade (RCM) na otimização do programa de manutenção de centrais termonucleares
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Data
2016-07-04
Autores
Quintella, Luciano Confort [UNESP]
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Universidade Estadual Paulista (Unesp)
Resumo
A função manutenção vem sendo considerada como fator estratégico para as empresas, pois através do alinhamento de suas políticas corporativas e integração de seus programas de gestão de ativos, de riscos e de ciclo de vida de suas unidades de negócios, as empresas vêm buscando a constante redução de custos e a melhoria de seus resultados operacionais. E, assim, obtendo maior competitividade. A Manutenção Centrada em Confiabilidade (RCM) é um método já bem disseminado por todo o mundo e que, ao longo dos anos, vem promovendo estes diferenciais estratégicos através de preceitos que possibilitam a elaboração de Programas de Manutenção Preventiva de custo-eficaz, através de um método para a definição de políticas de manutenção mais adequadas, com o foco na manutenção da função dos ativos em seu contexto operacional. Ao longo dos anos, o método RCM vem sendo aplicado em inúmeros estudos de casos em diferentes empresas de diversos seguimentos, onde podem ser observadas novas adaptações ou simplificações do método RCM clássico. Estas adaptações buscam uma maior adequação as particularidades destas empresas e/ou um retorno mais rápido de resultados. O setor nuclear de geração de energia foi um dos pioneiros na adoção e disseminação do RCM, e vem desenvolvendo processos simplificados de aplicação do RCM, como o “Streamlinned RCM” e o “método PMO” (Otimização do Programa de Manutenção, do inglês: Preventive Maintenance Optimization). Estes estudos mostram que o método PMO apresenta uma maior flexibilidade, o que permite a adoção de diferentes estratégias de aplicação que, por sua vez, têm trazido resultados expressivos para as empresas, através da otimização dos Programas de Manutenção já existentes. Com base na literatura, neste trabalho são abordadas questões referentes ao RCM e sua contextualização na área nuclear, estudos sobre os métodos simplificados do RCM e o desenvolvimento do método PMO. Por fim, é realizada uma aplicação prática do método PMO sobre os sistemas relacionados e subsistemas do Sistema de Remoção de Calor Residual (JN), mais especificamente, sobre as Bombas de injeção de segurança do Sistema de Injeção de Alta Pressão (JND) da Usina Nuclear Angra 2. Através dos resultados obtidos com esta aplicação, pretende-se otimizar o Programa de Manutenção da Planta (PMP) referente a estes equipamentos e, assim, validar o método PMO como ferramenta para a melhoria contínua do Programa de Gestão de Ativos e Ciclo de Vida da Usina Nuclear Angra 2.
Corporations tend to consider maintenance work a strategic element. It is through maintenance—especially the alignment between corporate policies and integration of their programs to manage assets, risks, and life cycles of business units—that corporations try to continuously improve their results, reduce their operational costs, and, therefore, increase their competitiveness. Reliability Centered Maintenance (RCM) is a popular method across the world; it has been promoting competitiveness through concepts that allow the design of cost-effective Preventive Maintenance Programs These programs are effective because they entail appropriate maintenance policies that are focused on the preservation of the assets functions in their operational context and on the formation of technical knowledge basis supported by hard data. Throughout the years, RCM has been applied in numerous case studies and in different companies engaged in a variety of market segments. Such diversity in the application of RCM allowed us to observe new adaptations and variations of the classic method. Such adaptations aim to better respond to specific operational contexts in and within production units, as well as achieve faster results. The nuclear power sector has pioneered regarding the adoption and dissemination of RCM; it has been developing simplified versions of RCM, such as the “Streamlined RCM” and the PMO (Preventive Maintenance Optimization). These studies demonstrate that the PMO presents enhanced flexibility, which allows the adoption of different strategies; such enhanced flexibility brings expressive results to corporations as pre-existing maintenance programs are optimized. Based on the currently available literature, this dissertation addresses numerous questions regarding RCM and its application to nuclear power segments. It also addresses studies about simplified versions of RCM and the development of the PMO method. The discussion is supplemented with a practical application of the PMO method regarding auxiliary systems and sub-systems of Removal of Residual Heat System (JN), especially those regarding the security injection pumps of the High Pressure Injection System (JND) at Angra II Nuclear Plant. Through the results obtained from this application, it is possible to optimize the Maintenance Program of these equipments, and therefore, validate the PMO method as a tool of continuous improvement of the Assets and Life Cycle Program of Angra II.
Corporations tend to consider maintenance work a strategic element. It is through maintenance—especially the alignment between corporate policies and integration of their programs to manage assets, risks, and life cycles of business units—that corporations try to continuously improve their results, reduce their operational costs, and, therefore, increase their competitiveness. Reliability Centered Maintenance (RCM) is a popular method across the world; it has been promoting competitiveness through concepts that allow the design of cost-effective Preventive Maintenance Programs These programs are effective because they entail appropriate maintenance policies that are focused on the preservation of the assets functions in their operational context and on the formation of technical knowledge basis supported by hard data. Throughout the years, RCM has been applied in numerous case studies and in different companies engaged in a variety of market segments. Such diversity in the application of RCM allowed us to observe new adaptations and variations of the classic method. Such adaptations aim to better respond to specific operational contexts in and within production units, as well as achieve faster results. The nuclear power sector has pioneered regarding the adoption and dissemination of RCM; it has been developing simplified versions of RCM, such as the “Streamlined RCM” and the PMO (Preventive Maintenance Optimization). These studies demonstrate that the PMO presents enhanced flexibility, which allows the adoption of different strategies; such enhanced flexibility brings expressive results to corporations as pre-existing maintenance programs are optimized. Based on the currently available literature, this dissertation addresses numerous questions regarding RCM and its application to nuclear power segments. It also addresses studies about simplified versions of RCM and the development of the PMO method. The discussion is supplemented with a practical application of the PMO method regarding auxiliary systems and sub-systems of Removal of Residual Heat System (JN), especially those regarding the security injection pumps of the High Pressure Injection System (JND) at Angra II Nuclear Plant. Through the results obtained from this application, it is possible to optimize the Maintenance Program of these equipments, and therefore, validate the PMO method as a tool of continuous improvement of the Assets and Life Cycle Program of Angra II.
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Palavras-chave
Manutenção Centrada em Confiabilidade (RCM), Otimização do Programa de Manutenção (PMO), Usina Nuclear Angra 2, Gestão de Ativos e Ciclo de Vida da Planta, Reliability Centered Maintenance (RCM), Preventive Maintenance Optimization (PMO), Angra 2 Nuclear Power Plant (NPP), Asset Management and Plant Lifecycle