Performance modeling and assessment of maintenance priorities for steam generation unit of a sugar plant

Purpose: The purpose of this paper is to deal with the performance modeling and assessment of maintenance priorities for steam generation unit of a sugar plant. Design/methodology/approach: The unit comprises of four subsystems, i.e., Bagasse elevator, Bagasse carrier, boiler and feed pump. The Chapman–Kolmogorov equations are generated on the basis of transition diagram and further solved recursively to obtain the performance modeling with the help of normalizing condition using the Markov approach. Findings: Decision matrices are formed with the help of different combinations of failure and repair rates of all subsystems. The performance of steam generation unit is evaluated in terms of availability levels depicted in decision matrices and plots of failure rates and repair rates of various subsystems. The maintenance priorities of various subsystems of steam generation unit are decided on the basis of effect of failure and repair rates of subsystems on the availability of steam generation unit. The key finding is that the boiler subsystem is the most critical subsystem and hence should be kept on top maintenance priority for performance enhancement of the steam generation unit. Originality/value: The acceptance of both performance modeling and maintenance priorities decision by the management of sugar plant will result in the enhancement of unit availability and reduction of maintenance cost.