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This paper presents a new tool for failure mode and effect analysis developed for a new Integrated Gasification and Combined Cycle plant in an important Italian oil refinery. The methodology is based on the integration between a modified Failure Mode Effect and Criticality Analysis (FMECA) and a Monte Carlo simulation as a method for testing the weights assigned to the measure of the risk priority numbers (RPNs). The RPN proposed consists of a weighted sum of six parameters (safety, machine importance for the process, maintenance costs, failure frequency, downtime length, and operating conditions) multiplied by a seventh factor (the machine access difficulty). Adopting this tool and considering the budget constraints, the best maintenance policy has been selected for each plant facility (about 140 in total). Copyright © 2000 John Wiley & Sons, Ltd.
Bevilacqua et al. (Sat,) studied this question.