بهره‌گيري از رويكرد RCM به‌منظور افزايش همزمان اثربخشي و كارايي در فرايند نگه‌داري و تعميرات (مطالعه‌ي موردي در شركت بهره‌برداري نفت و گاز زاگرس جنوبي)

APPLICATION OF RCM TO ENHANCE THE EFFICIENCY AND EFFECTIVENESS OF MAINTENANCE PROCESS (CASE STUDY: OIL AND GAS PRODUCTION, SOUTH ZAGROS COMPANY OF IRAN)

با وجود گزارش‌هاي متعدد از موفقيت «نگه‌داري مبتني بر اطمينان » (RCM) در كشورهاي پيشرفته‌ي صنعتي، پياده‌سازي آن در ايران و كشورهاي در حال توسعه چندان موفق نبوده است. توجه بيش از اندازه‌ي متخصصين به روش‌هاي اجرايي، و غفلت آنها از مفاهيم زيربنايي و اصول پايه يكي از مشكلات اساسي و موانع پياده‌سازي و اجراي اثربخش RCM متناسب با زيرساخت‌ها و شرايط حاكم بر صنايعِ كشورمان ‌بوده است. در اين نوشتار با بهره‌گيري از مفاهيم زيربنايي RCM و استفاده‌ي تلفيقي از تكنيك‌هاي FMEA‏، نمودار علت و معلول و شبيه‌سازي رايانه‌يي، مدلي اجرايي در پاسخ به محدوديت‌هاي حاكم بر صنايع كشورمان ارايه‌‌شده و عملكرد آن در مطالعه‌ي موردي ارزيابي شده است. ارزيابي نتايج حاكي از افزايش همزمان اثربخشي و كارايي در فرايند نگه‌داري و تعميرات مطابق با اجراي موفقيت‌آميز مدل پيشنهادي است.

Although Reliability Centered Maintenance (RCM) has been successfully implemented in many industries in developed countries, the same record is not clear when it comes to developing countries, like Iran. The excessive specialist tendency to focus on technical aspects, and the negligence of basic principles to maintain available infrastructures, is found to be a significant factor hindering the effective implementation of RCM. This paper reports on a project in an oil and gas company using three key objectives of RCM, i.e. improving the reliability of the system, reducing the consequences of the failures, and minimizing maintenance costs. A variety of techniques was used in an integrated approach. In line with the first principle, the FMEA technique was applied as a sound quantitative evaluation of all critical functions. It helps us to allocate necessary recourses to the most critical functions and equipment. Then, it is necessary to distinguish the possible failures of the equipment to specify their consequences. At this point, the cause and effect diagram was applied concerning the second principle of RCM; to prevent or mitigate the consequences of failures, not to prevent the failures themselves. At the final step, and in line with the third RCM principle, a simulation model was developed to check how it would be possible to reduce maintenance costs by avoiding or removing maintenance actions that are not strictly necessary. The model was applied to a chemical injection pump with a series of operational failures. Failures were characterized by an empirically derived function via the Weibull distribution. Furthermore, the impact of preventive maintenance time cycles was tested in the simulated model to improve system availability, combined with cost benefit analysis. The model was implemented in the case of the South Zagros Oil and Gas Production Company to evaluate performance capabilities. The final results indicated a simultaneous increase in effectiveness and efficiency in the maintenance process through maximizing reliability indicators.