Optimal Maintenance Policy for Welded Plate Heat Exchangers Using Monte Carlo Simulation

• Julio M. Carrillo Palma Departamento de Ingeniería Mecánica, Facultad de Ingeniería, Universidad del Zulia, Núcleo Costa Oriental del Lago, Cabimas, Venezuela https://orcid.org/0009-0000-0606-5188

DOI: https://doi.org/10.22209/rt.v47a02

Keywords: costs, reliability, sterilization, Weibull distribution

Abstract

Welded plate heat exchangers are fundamental equipment for sterilization processes in the pharmaceutical industry, which is why it is crucial to design effective maintenance plans to avoid failures that may compromise the reliability of these processes. The goal of this research was to determine, through Monte Carlo simulation, an optimal maintenance policy for these exchangers. A descriptive, applied, and cross-sectional methodology based on a field design was used. Seven heat exchangers in a pharmaceutical plant were studied, serving as both population and sample. Data collection instruments included the review of existing records and validation by experts. The study demonstrated that the Weibull distribution is a useful tool for modeling the failure times of the exchangers and revealed that the optimal replacement time is approximately 1.7 years, with an associated minimum cost of US$2,139. These findings are essential for effective planning of maintenance and replacement of equipment, as well as for the optimization of economic resources. However, the need for a larger sample and more data to strengthen these conclusions is recognized.

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