A mathematical model proposal for maintenance strategies optimization of the most critical electrical equipment groups of hydroelectric power plants

Yıl 2019, Cilt: 25 Sayı: 4, 498 - 506, 28.08.2019

Evrencan Özcan , Tuğba Danışan , Tamer Eren

Öz

Maintenance
is a process that makes a high-level contribution to the sustainability goal of
the manufacturing facilities defined as uninterrupted, high-quality level,
economic, efficient, reliable and environmentally friendly production. The
foremost stage of this important process is the maintenance planning and the
first and indispensable phase of this stage is the maintenance strategy
selection. When considering the maintenance processes which cause the
significant costs due to production downtime, material, time and labor
requirements, assignment of the suitable maintenance strategies especially for
the critical equipment has great importance in terms of avoiding the
unnecessary costs for the generation facility. Furthermore, maintenance
strategy optimization directly effects the goal of sustainable production in
the manufacturing facilities by providing to increase the faultless operating
time of equipment and contribute to realize the reliable and high-quality
manufacturing. In addition to these, this problem becomes more and more
important in the electricity generation plants which are in the group of
continuous production facilities, when the effects of energy on the society are
considered. In this context in this study, among the electrical equipment which
are the most problematic group, the most critical ones in terms of the power
plant are determined by the AHP-TOPSIS combination in one of the big-scale
hydroelectric power plants realize the 20% of Turkey’s electricity generation.
Then, the most appropriate strategy combination from corrective, periodic,
predictive and revision maintenance strategies is obtained by using the
proposed integer programming model for these equipment groups. The use of this
combination has resulted in an 80% improvement in generation downtimes and
associated costs.

Anahtar Kelimeler

Maintenance strategy optimization, Hydroelectric power plants, Integer programming, AHP, TOPSIS

Hidroelektrik santralların en kritik elektriksel ekipman gruplarının bakım stratejilerinin optimizasyonu için matematiksel bir model önerisi

Öz

Bakım,
üretim tesislerinin kesintisiz, kalite düzeyi yüksek, ekonomik, verimli,
güvenilir ve çevreye duyarlı üretim yapması olarak tanımlanan sürdürülebilirlik
hedefine üst düzeyde katkı sağlayan bir prosestir. Bu önemli prosesin en önemli
aşamalarının başında bakım planlaması gelmektedir ve bu fazın ilk ve
vazgeçilmez aşaması ise bakım strateji seçimidir. Bakım proseslerinin üretim
duruşu, malzeme, zaman ve iş gücü gereksinimi nedeniyle önemli maliyetler
doğurması düşünüldüğünde, özellikle kritik ekipmanlara uygun bakım
stratejilerinin atanması, üretim tesisinin gereksiz maliyetlerden kaçınması
açısından büyük önem arz etmektedir. 
Ayrıca, ekipmanın arızasız çalışma süresinin artırılması ile güvenilir
ve kalite düzeyi yüksek üretimin gerçekleştirilmesine sağladığı katkı ile de
bakım strateji optimizasyonu, üretim tesislerinde sürdürülebilir üretim
hedefine direkt olarak etki etmektedir. Bunların yanı sıra, sürekli üretim
tesisleri grubunda yer alan elektrik üretim santrallarında, enerjinin toplum
üzerindeki etkileri de düşünüldüğünde bu problem çok daha önemli bir hal
almaktadır. Bu bağlamda bu çalışmada, Türkiye enerji üretiminin %20’sini
gerçekleştiren hidroelektrik santrallardan büyük ölçekli bir tanesinde, en
problemli ekipman grubu olan elektriksel ekipmanlar arasından santral açısından
en kritik olanlar AHP-TOPSIS kombinasyonu ile belirlenmiştir. Ardından, bu
ekipman grupları için tamir, periyodik, kestirimci ve revizyon bakım
stratejilerinden en uygun kombinasyon önerilen tam sayılı programlama modeli ile
elde edilmiştir. Bu kombinasyonun kullanımı ile üretim duruşları ve bunların
beraberinde getirdiği maliyetlerde %80 oranında bir iyileşme sağlanmıştır.

Anahtar Kelimeler

Bakım strateji optimizasyonu, Hidroelektrik santrallar, Tam sayılı programlama, AHP, TOPSIS

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