Expected impact quantification–based reliability assessment methodology for Chilean copper smelting process: A case study

Abstract

Currently, a lack of interpretation tools and methodologies hinders the ability to assess the performance of a single piece of equipment or a total system. Therefore, a reliability, availability, and maintainability analysis must be combined with a quantitative reliability impact analysis to interpret the actual performance and identify bottlenecks and improvement opportunities. This article proposes a novel methodology that uses reliability, availability, and maintainability analysis to quantify the expected impact. The strengths of the failure expected impact methodology include its ability to systematically and quantitatively assess the expected impact in terms of reliability, availability, and maintainability indicators and the logical configuration of subsystems and individual equipment, which show the direct effects of each element on the total system. This proposed analysis complements plant modeling and analysis. Determining the operational effectiveness impact, as the final result of the computation process, enables the quantitative and unequivocal prioritization of the system elements by assessing the associated loss as a ‘‘production loss’’ regarding its unavailability and effect on the system process. The Chilean copper smelting process study provides useful results for developing a hierarchization that enables an analysis of improvement actions that are aligned with the best opportunities.