Reliability analysis of rodding anode plant in aluminium industry

Yaqoob Al Rahbi, S.M. Rizwan, B.M. Alkali, Andrew Cowell, G. Taneja

Research output: Contribution to journalArticle

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Abstract

The paper presents a reliability analysis of rodding anode plant in aluminum industry. Manufacturing process of raw aluminum passes through eight stations viz., butt shot blast station 1, butt & thimble removal press station 2 with standby arrangement, combined btp (butt & thimble press) station 3, stub straighten station 4, stub shot blast station 5, stub coating and drying station 6, casting station 7, and anode rod inspection station 8. Failure of any of the stations brings the system to a complete halt, except the butt & thimble removal press stations because of the parallel standby arrangement, and does not affect the system operation completely unless both fails. Six years maintenance data on component failures, repairs and associated costs are collected for the purpose of this analysis and various rates are estimated from the data. Measures of system effectiveness such as mean time to plant failure (MTPF), availability of the plant, busy period of repairman and expected number of repair have been obtained. Semi-Markov processes and regenerative point techniques are used in the analysis.
Original languageEnglish
Pages (from-to)5616-5623
Number of pages8
JournalInternational Journal of Applied Engineering Research
Volume12
Issue number16
Publication statusPublished - 30 Sep 2017

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Reliability analysis
Anodes
Repair
Aluminum
Markov processes
Industry
Drying
Casting
Inspection
Availability
Coatings
Costs

Keywords

  • reliability
  • anode plant
  • aluminium industry

Cite this

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title = "Reliability analysis of rodding anode plant in aluminium industry",
abstract = "The paper presents a reliability analysis of rodding anode plant in aluminum industry. Manufacturing process of raw aluminum passes through eight stations viz., butt shot blast station 1, butt & thimble removal press station 2 with standby arrangement, combined btp (butt & thimble press) station 3, stub straighten station 4, stub shot blast station 5, stub coating and drying station 6, casting station 7, and anode rod inspection station 8. Failure of any of the stations brings the system to a complete halt, except the butt & thimble removal press stations because of the parallel standby arrangement, and does not affect the system operation completely unless both fails. Six years maintenance data on component failures, repairs and associated costs are collected for the purpose of this analysis and various rates are estimated from the data. Measures of system effectiveness such as mean time to plant failure (MTPF), availability of the plant, busy period of repairman and expected number of repair have been obtained. Semi-Markov processes and regenerative point techniques are used in the analysis.",
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Reliability analysis of rodding anode plant in aluminium industry. / Al Rahbi, Yaqoob; Rizwan, S.M. ; Alkali, B.M.; Cowell, Andrew; Taneja , G.

In: International Journal of Applied Engineering Research , Vol. 12, No. 16, 30.09.2017, p. 5616-5623.

Research output: Contribution to journalArticle

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AU - Al Rahbi, Yaqoob

AU - Rizwan, S.M.

AU - Alkali, B.M.

AU - Cowell, Andrew

AU - Taneja , G.

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AB - The paper presents a reliability analysis of rodding anode plant in aluminum industry. Manufacturing process of raw aluminum passes through eight stations viz., butt shot blast station 1, butt & thimble removal press station 2 with standby arrangement, combined btp (butt & thimble press) station 3, stub straighten station 4, stub shot blast station 5, stub coating and drying station 6, casting station 7, and anode rod inspection station 8. Failure of any of the stations brings the system to a complete halt, except the butt & thimble removal press stations because of the parallel standby arrangement, and does not affect the system operation completely unless both fails. Six years maintenance data on component failures, repairs and associated costs are collected for the purpose of this analysis and various rates are estimated from the data. Measures of system effectiveness such as mean time to plant failure (MTPF), availability of the plant, busy period of repairman and expected number of repair have been obtained. Semi-Markov processes and regenerative point techniques are used in the analysis.

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