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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January/February 2020 Inspectioneering Journal
By Daniel Golub at Hippo CMMS
Computerized Maintenance Management System (CMMS) platforms are a great way to structure, standardize, and streamline maintenance management. But how can you make sure you get a CMMS that effectively delivers on exactly what you need? |
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November/December 2019 Inspectioneering Journal
By Bryan Christiansen at Limble CMMS
This article introduces the P-F Interval and its importance in predictive maintenance, describes methods to detect failures early, and maps out a path to begin an effective Predictive Maintenance program at one’s facility. |
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November/December 2019 Inspectioneering Journal
By Dave Holthaus at Comprehensive Procedure Reviews, LLC (CPR), and Kevin Gaskin at CHS, Inc.
This article helps shine light on some common industry problems that can occur by having inferior UT procedures and practices, while providing several lessons learned through a case study that resulted in nearly $1 million in turnaround repairs. |
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November/December 2019 Inspectioneering Journal
By Steven R. Bolinger at Becht
A refinery or process facility FEMI program consists of eight Pillars that are fundamental to achieve FEMI excellence. This article describes these Pillars in detail and suggests what distinguishes good Pillars from those that are less than adequate. |
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September/October 2019 Inspectioneering Journal
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There are inspection requirements in many construction disciplines, including electrical, welding, coating, and the list goes on, but not for mechanical insulation. The need for a certified mechanical insulation inspection program is long overdue. |
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August 28, 2019 By Alexander Turner at Corrosion Monitoring Services (CMS)
High angle rope inspection can provide immediate inspection and minor repair opportunities, but it’s valuable for long-term planning as well. |
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March/April 2019 Inspectioneering Journal
By Stephen J. Thomas at PK Technology
Creating a proper work scope and developing and executing an effective work plan are essential for a successful turnaround. However, behind the scenes exists the glue that pulls the entire effort together: logistics. |
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May/June 2018 Inspectioneering Journal
By Chad Patschke, CPSA at Ethos Mechanical Integrity Solutions
According to API 570, facilities must have a mechanical integrity program in place for critical check valves. But what criteria determines whether or not a check valve is critical in your process? How should check valves be inspected and by whom? |
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May/June 2018 Inspectioneering Journal
By James R. Widrig at Quest Integrity, and James Wilson at Quest Integrity
As assets age and production demands grow, it becomes increasingly critical to implement sustainable long-term AIM strategies and programs. This article dives into the elements that will help ensure the successful management of assets throughout... |
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May/June 2018 Inspectioneering Journal
By Dheeraj Narang at Haldor Topsoe India Pvt Ltd.
This article intends to use a top-down approach of describing RBI methodology and how it fits in a facility management system. The main idea of this article is to provide a comprehensive picture of RBI methodology in terms of basics, technology... |
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January/February 2018 Inspectioneering Journal
By Jonathan Martinez at PK Technology
Inspection data is vulnerable to flaws in collection and retention. For example, data might be inaccurate, duplicate, or incomplete due to procedural breakdowns. This article introduces Digital Data Management Systems (DDMS) as a response to these... |
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March/April 2017 Inspectioneering Journal
By Ibrahim Kodssi at Independent Consultant
Flare systems provide hydrocarbon facilities with safe and efficient discharge of relief and waste gases by controlled open flame burning. This article provides information on the selection, inspection, and maintenance of various types of flares. |
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January/February 2017 Inspectioneering Journal
By David Aldrich at North Highland, and Teri Mendelovitz at North Highland
This article covers where to start, what to look for, and how to execute a data and systems-focused performance improvement project that can drive large overhead savings. |
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September/October 2016 Inspectioneering Journal
By Tata L.N. Murthy at Gujarat State Petroleum Corporation Ltd
For all operators, a system made up of a variety of equipment must be available to carry out continued operations. Planning plays a vital role in the success of major maintenance projects. Integrating all departments in the maintenance plan can save... |
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July/August 2016 Inspectioneering Journal
By Mike Johnston at T. A. Cook Consultants, Inc.
This article will examine what can occur during the course of a Front Line Supervisor’s day that may hinder the execution of their expected duties, and what can be put in place to overcome those obstacles. |
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Blog
July 8, 2016 By Jeremiah Wooten at Inspectioneering, LLC., and Josh Means at Inspectioneering, LLC
Here are five common misconceptions about RBI that should not prevent you from gaining a more advanced understanding of the true state of your site's equipment. After all, the more we know, the better we can manage equipment integrity and make... |
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March/April 2016 Inspectioneering Journal
By John Reynolds at Intertek, and Mark Bell at Ethos Mechanical Integrity Solutions
We have seen many different inspection recommendation management systems. Most of them struggle to effectively manage all inspection recommendations. However, a few of them are excellent. What makes an effective system? |
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March/April 2016 Inspectioneering Journal
By Greg Fletcher at North Highland Worldwide Consulting, and Josh Arceneaux at North Highland Worldwide Consulting
It is estimated that there have been more than 250,000 layoffs in the oil and gas industry since the price of oil began to drop precipitously in late 2014. With oil not expected to rebound significantly for at least the next year or so, we should be... |
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January/February 2016 Inspectioneering Journal
By Melissa Ramkissoon at Petrotrin
In Part 1 of this 2-part series, published in the July/August 2015 issue of Inspectioneering Journal, I discussed corrosion control methods and some effective techniques for inspecting ASTs, and also identified several root causes of AST failures in... |
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January/February 2016 Inspectioneering Journal
By Mike Johnston at T. A. Cook Consultants, Inc.
It is a generally accepted fact that most Front Line Supervisors (FLS) come up “from the ranks” of the hourly staff. However, most companies provide neither training nor any type of preparation or guidance for the person they have now placed... |
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January/February 2016 Inspectioneering Journal
By Vipin Nair at GE Compliance and Integrity Management
Pipeline management remains fraught with safety risks for operators and the environment. Last year, the Ontario Energy Board determined that a $12 billion oil pipeline proposed by TransCanada Corp. would pose more risks than rewards for the province. |
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November/December 2015 Inspectioneering Journal
By Fernando Vicente at ABB, and Khulani Ndimande at ABB Consulting
This article highlights several benefits of sound reliability and mechanical integrity practices and how they serve as the cornerstone of effective asset management. Moreover, we believe effective asset integrity management is not only important,... |
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November/December 2015 Inspectioneering Journal
By David A. Hunter at Neptune Research, Inc.
This study provides valuable information for offshore pipeline operators curious about how composite repair systems could be utilized with their assets. |
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September/October 2015 Inspectioneering Journal
By Brad Moore at PinnacleART
Operators in all industries are trying to increase equipment availability, yet oftentimes critical process equipment is not available due to planned or unplanned maintenance. To increase equipment availability, steps must be taken to reduce... |
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July/August 2015 Inspectioneering Journal
By John Reynolds at Intertek
Rarely is there a new and unknown cause of a major Fixed Equipment Mechanical Integrity (FEMI) failure in the petrochemical and refining industry. This article briefly summarizes five major fixed equipment mechanical integrity (FEMI) failures from... |
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July/August 2015 Inspectioneering Journal
By Melissa Ramkissoon at Petrotrin
Aboveground Storage Tanks (AST) are essential to any successful oil and gas operation and must be properly managed to ensure operations function in a safe and reliable manner. In this 2-part series, I will identify some common failures related to... |
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May/June 2015 Inspectioneering Journal
By Amanda Nurse at BP, and Josh Havekost at BP
Assessing risk is an integral part of working at a refinery. Infrastructure supporting the miles of piping, process vessels, and the platforms and ladders used in daily unit operations are often taken for granted. The Civil Structures Management... |
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March/April 2015 Inspectioneering Journal
By Walt Sanford at PinnacleART
Today, many managers are finding that they can address the reliability of all types of assets by combining RBI and Reliability Centered Maintenance (RCM) processes together into one comprehensive reliability management process. |
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March/April 2015 Inspectioneering Journal
By Andy Kates at Versa Integrity Group
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March/April 2015 Inspectioneering Journal
By Matt Midas at GenesisSolutions
With the advancements in today’s technology and improvements to Enterprise Asset Management (EAM) systems and Computerized Maintenance Management Systems (CMMS), if we deploy them properly and in line with best practices, it is possible to reach... |
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January/February 2015 Inspectioneering Journal
By Clint Rupert at Engineered Resin Solutions (ERS)
Epoxy products have gone through extensive research and development over the years, and have reached the point that when specified for the correct environment, they should perform exactly as intended. |
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January/February 2015 Inspectioneering Journal
By Matthew Green at Neptune Research, Inc.
Engineered Composite Repair (ECR) systems are moving into mainstream usage at a faster pace than ever. This increased usage and exposure is working to push them into new frontiers and commands a more demanding understanding of their basic functions. |
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January 6, 2014 By Nick Schmoyer at Inspectioneering
In 2013 Inspectioneering published content covering a wide array of topics, from risk-based inspection, to advanced nondestructive testing methods, to pipeline integrity management systems. Last year, we published more content than any year prior;... |
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Online Article
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Online Article
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March/April 2013 Inspectioneering Journal
By Thomas Fortinberry at Quest Integrity Group, and James R. Widrig at Quest Integrity
Steam reformers are critical assets to many refining and chemical manufacturing plants and facilities, and it is well known that the reformer is one of the most challenging assets to maintain and operate. Common problems in reformer operations... |
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September/October 2012 Inspectioneering Journal
By Abdullah Al-Harbi at Kuwait Oil Company
Since its inception, one of the core businesses of the MS&R (maintenance, safety and reliability) Team for Kuwait Oil Company's NK (North Kuwait) Facilities has included carrying out Preventive Maintenance (PM) activities as directed by the... |
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September/October 2011 Inspectioneering Journal
By Barry Snider at Small Hammer Incorporated
Maintenance has been around since prehistoric man fixed a broken, trusted spear instead of fashioning a new one. One concept of maintenance is any activity that extends the useful life or enhances the performance of an item of interest. A broad... |
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January/February 2011 Inspectioneering Journal
By John Reynolds at Intertek
In the first article in this series entitled How to Put It All Together - Guide to Organizing a Successful PEI Program, (1) I provided an overview of the necessary Management Systems (MS) for a successful program to achieve excellence in pressure... |
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January/February 2007 Inspectioneering Journal
Since the publication of NACE MR0175/ISO 15156, "Petroleum and natural gas industries- Materials for use in H2S-containing environments in oil and gas production," in December 2003, the ISO Maintenance Panel set up to maintain this widely used... |
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September/October 2000 Inspectioneering Journal
By T.C. Ridgeway & Staff at TCRI
In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the... |
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January/February 2000 Inspectioneering Journal
By Gene R. Meyer at The Dow Chemical Company
Part 1 provided a review of RBI for pressure vessels and piping and an introduction to application of RBI to rotating equipment and the differences between approaching the two different types of equipment. As promised, Part 2 will delve more deeply... |
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January/February 1999 Inspectioneering Journal
By Joseph E. Pascente at Lixi, Inc.
One of the greatest challenges facing many of refining, fossil power, and pulp and paper industries is: How to effectively examine their insulated piping? |
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November/December 1995 Inspectioneering Journal
By David A. Mauney at Southwest Research Institute
In the aging portion of an asset's life, the failure rate is exponential. This creates a need for predictive maintenance expenditures to maintain reliability. |
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July/August 1995 Inspectioneering Journal
By Curtis Plumlee at Plumlee Associates, Inc.
One thing is certain - major changes in maintenance programs are being implemented in process plants. These changes are spawned by an increased demand for equipment availability, longer, safer run-times and government and industry compliance. |
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May/June 1995 Inspectioneering Journal
By Paul Pausky at F.B. Dunn & Associates, Inc., and Mark Fitzgerald at F.B. Dunn & Associates, Inc.
Equipment maintenance methods and philosophies continue to evolve. What has taken many by surprise is the rate of change and the sense of urgency that now surrounds issues related to Mechanical Integrity (MI) in the field of maintenance... |
The 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 workers and injured seven.
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 (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. The fire erupted during maintenance...
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News
Reuters, March 20, 2020
Lyondell Basell Industries said maintenance operations were staffed at its Houston refinery to assure safety and reliability. |
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News
Reuters, March 3, 2020
Shell has restarted a catalytic reformer at its 211,270 bpd refinery in Convent, Louisiana after repairing damage caused by a fire on February 16th. |
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Partner Content
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News
Reuters, December 10, 2019
On Monday, Exxon Mobil Corp began restarting the large crude distillation unit (CDU) at its 369,024 barrel-per-day (bpd) Beaumont, Texas, refinery. |
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News
Reuters, December 9, 2019
Vietnam’s $9 billion Nghi Son refinery will be fully operational this week following a shutdown in late October for major maintenance work. |
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News
Reuters, August 13, 2019
Royal Dutch Shell Plc will begin restarting units at its Norco, Louisiana chemical and refining facilities this week following overhauls. |
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News
International Pressure Equipment Integrity Association (IPEIA), August 13, 2019
IPEIA is currently accepting technical presentation abstracts for the 2020 IPEIA Conference and Tradeshow. Abstracts are being accepted up until September 6, 2019. |
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News
Reuters, August 7, 2019
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. |
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News
Inspectioneering Staff, May 22, 2019
United Rentals' charity sporting clays tournament raises $20,000 for local veterans organization Fisher House. |
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News
U.S. Chemical Safety Board, June 11, 2015
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. |
