Plan de inspección de mantenimiento mecánico para equipos rotativos en caldera de lecho fluidizado

Abstract

This project is developed within the context of a chemical sector company located between the municipalities of Cajicá and Zipaquirá. This company possesses a fluidized bed boiler in its process, which constitutes a fundamental asset for continuous operation. The classification of this equipment as critical is founded on risk matrix analyses and process safety studies conducted in conjunction with operational areas, which determine the severe impact of a functional failure on safety and production. The main objective of this work focuses on the implementation of the Reliability-Centered Maintenance (RCM) methodology applied specifically to the boiler's auxiliary rotating equipment. To this end, Failure Modes and Effects Analyses (FMEA) were developed, focusing the study on failure modes with the highest criticality and probability of occurrence. These analyses were validated and approved by the Process Safety area, ensuring alignment with the company's risk standards. Based on the RCM results, it was determined that the optimal strategy for controlling the identified failures consists of combining condition monitoring via vibration analysis with the execution of rigorous operational parameter inspection routines by maintenance personnel. Consequently, the project establishes appropriate inspection methods, defines optimal intervention frequencies, and presents the design of tracking, traceability, and reporting formats necessary to guarantee the fulfillment of the plan. To evaluate the effectiveness of the implementation, the boiler availability indicator was defined as the primary metric. The study established its baseline through the collection and analysis of failure data and indicators corresponding to the years 2023 and 2024. Subsequently, the designed strategies were implemented during the year 2025. The obtained results evidenced a decrease in unscheduled shutdowns generated by rotating equipment and, therefore, an effective increase in asset availability.