Maintenance is the practice of protecting or restoring equipment in order to maintain function and integrity. As a critical component of an asset integrity management (AIM) program, maintenance engineers and technicians dedicate time to developing and implementing maintenance strategies that optimize production and use cost-effective maintenance techniques.
Typical maintenance techniques include cleaning, inspection, lubrication, testing, replacing, and/or repairing components. Furthermore, the responsibilities of a maintenance engineer may be predictive or preventive. The fundamental difference between predictive and preventive maintenance is that predictive maintenance is a continuous process based on the current condition of equipment whereas preventive maintenance is performed in scheduled intervals based on the age and remaining life of a piece of equipment.
Preventive maintenance depends on the probability of failure and the consequences of a potential failure. The frequency of inspection and maintenance is based on the probability and consequences of failure.
Typically, preventive maintenance is planned and requires engineers and technicians to review past and current inspection and maintenance data in order to predict damage that may result in failure. The purpose is to eliminate unnecessary inspection and repair tasks and reduce maintenance costs. Examples of preventive maintenance may include simple tasks such as cleaning, tightening bolts, changing oil, or lubricating equipment or added parts such as filters to separate dirt and other impurities from contaminating products.
The purpose of predictive maintenance is to prevent unscheduled shutdowns by predicting damage and failures before they occur. This can be done through inspection methods or utilizing sensors to collect data and measure the current condition of equipment during operation. For this reason, predictive maintenance is sometimes called condition-based monitoring. Although installing predictive maintenance measures can be costly, the result of such an investment shows an overall reduction in maintenance costs and facility downtime.
Corrective maintenance is performed on equipment in order to restore a failing piece of equipment back to its operating conditions. Here, it’s important that if maintenance technicians need to replace a component, that they follow specifications and if possible, replace components with original equipment manufacturers. Example of corrective maintenance repairs include welding, sealing, adjusting fixtures, etc.
Reliability centered maintenance (RCM) is a framework that ensures that preventive, predictive, and corrective maintenance tasks are practiced in an efficient, reliable, and safe manner. The benefits of a well organized RCM framework include maintaining the integrity of components, extending the life of equipment, and eliminating unplanned shutdowns.
RCM programs are unique to every company. However, there are several critical factors to consider.
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BP Plc began a planned overhaul on Wednesday of the small gasoline-producing fluidic catalytic cracking unit (FCCU) at its 430,000 barrel-per-day (bpd) Whiting, Indiana, refinery
Total plans to return the 66,000 bpd Diesel Hydrotreater 3, which was shut on Aug. 20, to production later on Monday, sources said. Total has repeatedly pushed back the restart date as repairs have taken longer than expected to complete.
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Dow recently announced it will retrofit proprietary fluidized catalytic dehydrogenation (FCDh) technology into one of its mixed-feed crackers in Plaquemine, Louisiana, to produce on-purpose propylene.
Royal Dutch Shell Plc will begin restarting units at its Norco, Louisiana chemical and refining facilities this week following overhauls.
Motiva Enterprises returned two crude distillation units (CDUs) back to normal operations at its 607,000 barrel per day (bpd) Port Arthur, Texas, refinery over the weekend.
Motiva Enterprises plans to shut the big crude distillation unit (CDU) at its 607,000 barrel-per-day (bpd) Port Arthur, Texas, refinery, the nation’s largest, by Sept. 5 for a 60-day overhaul, said sources familiar with plant operations.
Valero Energy Corp shut a hydrocracking unit (HCU) and sulfur recovery unit (SRU) at its 335,000-barrel-per-day (bpd) Port Arthur, Texas, refinery on Monday.
The government of Aruba said on Monday it will form an advisory committee to decide the future of a 209,000-barrel-per-day refinery that remains idled amid sanctions on operator Citgo Petroleum’s parent company, Petroleos de Venezuela (PDVSA).
United Rentals' charity sporting clays tournament raises $20,000 for local veterans organization Fisher House.
U.S. oil refiners are planning a heavy slate of plant overhauls in the second quarter, with total production this month off 8.5 percent compared with the start of the year, according to data from the U.S. Energy Information Administration.
India’s Mangalore Refinery and Petrochemicals Ltd plans to shut a 60,000 barrels per day (bpd) crude unit and some secondary units for maintenance from mid-April for about a month, a company source said.
Taiwan’s Formosa Petrochemical Corp will raise the throughput at its crude oil refinery from the second-half of April after finishing maintenance at a crude unit, a company spokesman said on Tuesday.
Ecuador will launch an international bidding round for the construction of a new 300,000 barrel per day (bpd) refinery and making upgrades to the 110,000 bpd Esmeraldas Refinery.
Aruba will resume a refurbishment project at a 209,000 barrel-per-day refinery operated by a unit of Citgo Petroleum Corp, the island’s prime minister said on Sunday, after a change to U.S. sanctions on Citgo parent PDVSA last week.
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A planned overhaul of the second-largest crude distillation unit at Exxon Mobil Corp’s 502,500-barrel-per-day (bpd) Baton Rouge, Louisiana, refinery is expected to continue for at least five weeks.
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The U.S. Chemical Safety Board (CSB) has released an animation detailing the events leading up to the February 8, 2017 explosion at the Packaging Corporation of America's DeRidder, Louisiana, pulp and paper mill. The incident killed three contract...
The U.S. Department of Labor's Occupational Safety and Health Administration (OSHA) has released its annual list of the 10 most frequently cited safety and health violations. In 2017 Fall Protection, Hazard Communication, and Scaffolding once again...
The U.S. Chemical Safety Board (CSB) has released a new 8-minute safety video describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers. The video, entitled "Fire in Baton...
The U.S. Chemical Safety Board has released a new safety bulletin covering the November 22, 2016 fire that severely burned four workers at the ExxonMobil refinery in Baton Rouge, Louisiana.
The U.S. Chemical Safety Board (CSB) has released a 3-minute animation describing the events leading to the November 22, 2016 fire at ExxonMobil's Baton Rouge refinery, which severely burned four workers.
Acting Assistant Secretary of State for Oceans and International Environmental and Scientific Affairs Judith G. Garber has issued Presidential permits for three NuStar Logistics, L.P. pipelines.
The U.S. Chemical Safety Board (CSB) has released its findings and a safety bulletin entitled "Key Lessons for Preventing Incidents when Preparing Process Equipment for Maintenance" resulting from the 2015 hydrocarbon release and fire that injured...
Federal investigators found multiple safety violations at a South Dakota ethanol refinery expansion project after a pipefitter suffered fatal burns when ethanol spilled from a process pipe and was ignited by flames from nearby welding operations.
An investigative team from the U.S. Chemical Safety Board (CSB) is deploying to the scene of an incident that injured seven workers – including three critically – that occurred Friday August 12 at the Sunoco Logistics Partners, a terminal...
The US Chemical Safety Board (CSB) has released its draft investigation report into the 2009 massive explosion at the Caribbean Petroleum, or CAPECO, terminal facility near San Juan, Puerto Rico.
