Synthesis of multilevel quality control panels for complex energy facilities combining reliability, availability, maintainability, and safety indicators

Abstract

The article is devoted to the synthesis of multilevel quality control panels for complex energy facilities, integrating reliability, availability, maintainability, and safety (RAMS) indicators into a single integral quality index suitable for supporting strategic management decisions. The research objective is to develop a methodology and mathematical framework that ensure the transition from fragmented and disjointed control to a hierarchical panel isomorphic to the structure of an energy facility and capable of aggregating heterogeneous operational data in real time. The empirical base consists of archival and streaming monitoring data from twenty-four large energy facilities over a twelve-year observation period (more than 1.5 million state records), including accident logs, reports of structural defects, records of scheduled preventive maintenance, and parameters of equipment failures and restorations. The methodology relies on the principles of qualimetry and reliability theory, cluster and factor analysis, neural network modeling for reconstructing and forecasting availability coefficients, probabilistic and cost-based risk assessments, maintainability evaluation methods based on time tracking and logistics analysis, as well as the convolution of a multidimensional feature space into an integral Energy Quality Index (EQI). It is shown that subsystems of an energy facility differ significantly in availability coefficients, failure intensity, and probability of failure-free operation, necessitating differentiated maintenance strategies; a nonlinear relationship is revealed between mean time to restoration and operational availability, as well as a shift in dominant risks from the area of rare physical disasters to that of high-frequency informational threats (cyberattacks). The proposed model of multilevel synthesis of RAMS indicators makes it possible to implement a “traffic light” mode of visualizing the facility’s condition, reduce personnel response time, form vital trade-offs between reliability, efficiency, and safety, and scale solutions from local substations to major generating units, which makes the developed approach a universal tool for engineering support of operational stability of energy infrastructure.