Inspectioneering

Integripedia Topic
Maintenance

Explore this topic

Redirected from Preventive Maintenance

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

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.

Predictive Maintenance

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

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

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.

  • Maintenance programs should follow a cradle-to-grave approach and evolve as the facility incorporates new equipment and decommissions aging infrastructure.
  • It’s also important to document all equipment, data, procedures, and facility objectives. All maintenance procedures should be documented in a detailed manner so that successive tasks can be performed efficiently.
  • Establishing clear objectives also helps engineers and inspectors align their decisions to meet facility goals.

Related Topics

Topic Tools

Share this Topic

Contribute to Definition

We welcome updates to this Integripedia definition from the Inspectioneering community. Click the link below to submit any recommended changes for Inspectioneering's team of editors to review.

Contribute to Definition
Articles about Maintenance
July/August 2021 Inspectioneering Journal

This article discusses how composite materials can be used to mitigate light CUI damage and/or repair and restore structural strength to the affected piping system.

Authors: Casey Whalen
July/August 2021 Inspectioneering Journal

Practical steps to mitigate corrosion under insulation (CUI) damage on fixed pressure equipment and commentary on common mitigation techniques and good engineering practices for external insulation or fireproofing system design and application.

May/June 2021 Inspectioneering Journal

This article discusses how Quantitative Reliability Optimization (QRO) can help empower reliability and operations leaders with better data to make smarter and more confident reliability decisions for their facilities.

March/April 2021 Inspectioneering Journal

The manner by which reliability is achieved is experiencing a much-needed paradigm shift in the way it uses data. In this article, we’ll explain how you can leverage this industry shift to implement data-driven reliability at your facility.

Authors: Sean Rosier
January/February 2021 Inspectioneering Journal

Restoring process piping within a short time frame requires an innovative approach. This article discusses how a repair using composite materials proved to be successful and enabled a quick return to operations.

Partner Content

AET is a powerful, non-intrusive inspection technique to verify the structural integrity of pressure vessels, spheres, high-temperature reactors and piping, coke drums, above-ground storage tanks, cryogenic storage tanks, and more.

September/October 2020 Inspectioneering Journal

Understanding asset integrity and its management framework is important to sustaining the integrity of assets in the oil and gas industry. This article will discuss eleven primary elements that make up an asset integrity management program.

Blog

COVID-19 is disrupting all industries including asset management. Here are 6 recommendations to help you align your asset management according to new requirements and turn the challenges into opportunities.

Authors: Frank-Uwe Hess
January/February 2020 Inspectioneering Journal

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?

Authors: Daniel Golub
November/December 2019 Inspectioneering Journal

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.

November/December 2019 Inspectioneering Journal

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.

Partner Content

Equity Engineering Practices® (EEPs) are a collection of detailed & customizable Best Practices integrated with a customizable management system. EEPs include: 650+ branded and customizable Best Practice Documents, 225+ Pre-Engineered &...

November/December 2019 Inspectioneering Journal

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.

Online Article

A systematic approach is required when repairing hot-dip galvanized coatings on structural steel. This article presents a step-by-step process, starting from Surface Preparation, through Application, Inspection, and Completion-verification.

Authors: Nirmal Menon
September/October 2019 Inspectioneering Journal

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.

Authors: Ron King
Blog

High angle rope inspection can provide immediate inspection and minor repair opportunities, but it’s valuable for long-term planning as well.

Authors: Alexander Turner
March/April 2019 Inspectioneering Journal

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.

Authors: Stephen Thomas
Partner Content

Training options to meet your needs. E²G contracts with API to deliver training programs for FFS, Risk–Based Inspection, Damage Mechanisms, and Pressure Relieving Systems. ETI and Customized Training offers specialized courses based on industry...

May/June 2018 Inspectioneering Journal

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?

May/June 2018 Inspectioneering Journal

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...

May/June 2018 Inspectioneering Journal

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...

Authors: Dheeraj Narang
January/February 2018 Inspectioneering Journal

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...

May/June 2017 Inspectioneering Journal

The "simple" process of PWHT is more complicated than it may appear at first glance. Knowledge of the procedures, attention to details, and actual experience are indispensable in preventing failures caused by improper PWHT.

Partner Content

Are you truly prepared for your next Turnaround? Effective work processes are required to successfully plan, manage, review and supervise plant turnarounds. Inspection planning and work scope selection are critical aspects of any turnaround...

Online Article

The Valve World Americas Conference provides an opportunity for people from all sides of the flow control industry to come together to discuss experiences, share insights and work together to resolve common challenges. Sharing knowledge and...

March/April 2017 Inspectioneering Journal

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.

Authors: Ibrahim Kodssi
Online Article

Inspectioneering recently had the opportunity to sit down and chat with Cary Forgeron and Samuel Fisher about the importance of oil analysis to effectively managing the reliability of rotating equipment used in the the O&G and other processing...

Authors: Jeremiah Wooten
January/February 2017 Inspectioneering Journal

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.

September/October 2016 Inspectioneering Journal

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...

Authors: Tata L.N. Murthy
Partner Content

Floodlight Software digitalizes inspection and testing operations and eliminates paper forms, filing cabinets, and spreadsheets. Your inspection forms plus our software equals a user-friendly mobile interface for inspectors and a robust reporting...

July/August 2016 Inspectioneering Journal

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.

Authors: Mike Johnston
Blog

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...

March/April 2016 Inspectioneering Journal

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?

March/April 2016 Inspectioneering Journal

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...

January/February 2016 Inspectioneering Journal

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...

Partner Content

TEAM’s integrated touch point corrosion program manages all aspects of the integrity process from screening for damage to permanent repair assuring integrity – every time. TEAM’s unique turn-key approach to touch point corrosion integrity...

January/February 2016 Inspectioneering Journal

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...

Authors: Mike Johnston
January/February 2016 Inspectioneering Journal

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.

Authors: Vipin Nair
November/December 2015 Inspectioneering Journal

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,...

November/December 2015 Inspectioneering Journal

This study provides valuable information for offshore pipeline operators curious about how composite repair systems could be utilized with their assets.

Authors: David A. Hunter
Online Article

Inspectioneering recently had the opportunity to sit down and chat with Brian Fahnestock about heat exchanger issues in the refining and petrochemical sectors and how temporary solutions can help mitigate the damage should a problem arise.

Authors: Jeremiah Wooten
Partner Content

How is reliability affecting your bottom line? Download our Economics of Reliability report, where Pinnacle analysts take data from the oil refining industry and dive into how that key sector is being affected by reliability today.

September/October 2015 Inspectioneering Journal

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...

Authors: Brad Moore
July/August 2015 Inspectioneering Journal

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...

Authors: John Reynolds
July/August 2015 Inspectioneering Journal

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...

May/June 2015 Inspectioneering Journal

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...

March/April 2015 Inspectioneering Journal

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.

Authors: Walt Sanford
Partner Content

Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability.

March/April 2015 Inspectioneering Journal

Rope access allows for a wide variety of work to be performed at high elevations or other hard to reach areas without the use of scaffolding or heavy equipment. It has evolved from techniques used in rock climbing and caving to become an extremely...

Authors: Andy Kates
March/April 2015 Inspectioneering Journal

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...

Authors: Matt Midas
January/February 2015 Inspectioneering Journal

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.

Authors: Clint Rupert
January/February 2015 Inspectioneering Journal

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.

Authors: Matthew Green
Blog

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;...

Authors: Nick Schmoyer
Partner Content

Traditional, paper-based inspection processes can prevent plants from being as effective as they can be. By digitalizing your mechanical integrity process and data with MISTRAS Digital®, plants have realized up to 75% gains in IDMS data entry and...

Online Article

Hydro plants are growing older. Being the first source of renewable power, it is imperative that these plants be kept up-to-date. Traditional issues are becoming refocused as equipment upgrades and new technology come into play. An industry is...

Online Article

Leak related problems in bolted assemblies are an ongoing issue for virtually all facilities in the chemical, petrochemical, and refining industries. From leak detection to leak prevention, operators need knowledgeable and experienced technicians to...

Authors: Jeremiah Wooten
March/April 2013 Inspectioneering Journal

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...

September/October 2012 Inspectioneering Journal

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...

September/October 2011 Inspectioneering Journal

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...

Authors: Barry Snider
Partner Content

Superior inspection results, a best-in-class user interface, great ergonomics and rugged design, unrivaled connectivity options, and much more. The Krautkrämer USM 100 is a revolutionary ultrasonic flaw detector that uncomplicates your...

January/February 2011 Inspectioneering Journal

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...

Authors: John Reynolds
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...

July/August 2004 Inspectioneering Journal

The following is the final part of a 2-part series outlining the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to define an operating envelope.

May/June 2004 Inspectioneering Journal

Corrosion and fouling in HF Alkylation Units are closely linked to feed quality and operating conditions. This article outlines the relationship between key operating parameters and corrosion that has been used to develop a set of guidelines to...

September/October 2000 Inspectioneering Journal

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...

January/February 2000 Inspectioneering Journal

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...

Authors: Gene R. Meyer
January/February 1999 Inspectioneering Journal

One of the greatest challenges facing many of refining, fossil power, and pulp and paper industries is: How to effectively examine their insulated piping?

November/December 1995 Inspectioneering Journal

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.

Authors: David A. Mauney
July/August 1995 Inspectioneering Journal

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.

Authors: Curtis Plumlee
May/June 1995 Inspectioneering Journal

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...

    Companies
    Videos related to Maintenance
      Downloads & Resources related to Maintenance
        Events related to Maintenance
          News related to Maintenance

            Inspectioneering Journal

            Explore over 20 years of articles written by our team of subject matter experts.

            Company Directory

            Find relevant products, services, and technologies.

            Talent Solutions

            Discover job opportunities that match your skillset.

            Case Studies

            Learn from the experience of others in the industry.

            Integripedia

            Inspectioneering's index of mechanical integrity topics – built by you.

            Industry News

            Stay up-to-date with the latest inspection and asset integrity management news.

            Blog

            Read short articles and insights authored by industry experts.

            Expert Interviews

            Inspectioneering's archive of interviews with industry subject matter experts.

            Event Calendar

            Find upcoming conferences, training sessions, online events, and more.

            Downloads

            Downloadable eBooks, Asset Intelligence Reports, checklists, white papers, and more.

            Videos

            Watch educational and informative videos directly related to your profession.

            Acronyms

            Commonly used asset integrity management and inspection acronyms.