Procedures are in place for work in the vicinity of underground services and overhead power lines. Contributory factors for an assessor to consider concerning maintenance procedures. Hundreds of manhours were saved, and there was no delay getting back into production due to valve maintenance. Machinery and equipment repair and maintenance checklist. The skills assessment should be based on the critical skills. Specific procedures and rules to be followed by anyone operating on. An oil refinery identified 14% of its traps were malfunction.
Inadequate mechanical integrity and preventive maintenance. How valero refinery achieved best maintenance practices paul chandler. Maintenance is the practice of protecting or restoring equipment in order to maintain function and integrity. The mission of femp is to facilitate the federal governments implementation of sound, cost. How valero refinery achieved best maintenance practices. This program shall include designating personnel who are responsible for specific. The typical feed and product charateristics for refinery are. As noted in the introduction, operations and maintenance procedures for water monitoring and removal have been a recommended practice for over thirty years. Refinery can process 80,000 barrels of highsulfur heavy crude oil per day. Because of the serious nature of any violation of these rules, you. Machinery and equipment repair and maintenance checklist contents. If youve found this article helpful and would like to get your own pdf copy of the article and a supporting presentation that explains the different types of maintenance and when to use them simply click on the link below and leave your details. The characteristics of feed, products and byproducts if necessary shall be specified.
To ensure that all persons involved in the lifting operations are competent and suitably trained in hse matters for the operations to be performed. A petroleum refinery s main job is to split crude oil into its many parts or fractions which are then reprocessed into. On the basis of the process condition, onstream monitoring of all critical. Plans had been made to overhaul more than 250 control valves, but only 28 were found to actually need that level of maintenance. A maintenance skills assessment is a valuable tool in determining the strengths and weaknesses of a given group of employees in order to design a highimpact training program that targets those documented needs. Maintenance procedures health and safety executive. Pdf turnaround management in an oil refinery researchgate. Refining operations petroleum refining processes and operations can be separated into five basic areas. Edmonton exchanger provides plant maintenance and construction services for the petrochemical industry, re.
Department of energys federal energy management program femp. It should be specific and detailed enough so that a qualified maintenance technician who has never before performed the task can do so successfully by reading and following the instructions contained in it. Installation, inspection, maintenance, and repair requirements. Fluor shell maintenance alliance shell geelong refinery. Preventive maintenance, predictive maintenance, a structured repair system, and fullfledged plant shutdown management must be reliable. The complex nature of chemical plants increases the risks for maintenance workers. Inspection and maintenance procedures for an oil refinery. Routine monitoring, inspection, and removal of accumulated sludge are needed to maintain fuel quality, regardless of fuel type. Petroleum refinery process safety management national emphasis. Each hour of effective planning typically returns three to five hours in mechanic time or equivalent savings measured in cost of material and production downtime.
Expertled training with realworld application from a global leader in automation and control training who is isa. Document control specialist receives and checks i n ifc drawings. This process is used for dehydrating and acid gas removal from refinery gases. Safety management on a refinery maintenance turnaround.
Chapter 6 focuses on maintenance technologies, particularly the most accepted predictive technologies. These procedure templates communicate what needs to be done on a routine basis. Maintenance scheduling for mechanical equipment bureau of. Consistent, welldocumented asset operating procedures. How valero refinery achieved best maintenance practices emerson. Project standards and specifications page 8 of 19 rev.
Preventive and predictive maintenance 700zb00102 42 preventivepredictive maintenance the guiding principle of ppm is the regular and systematic application of engineering knowledge and maintenance attention to equipment and facilities to ensure their proper functionality and to. Turnaround maintenance management in a processing industry. Review these refinery best practices 5 recommended installing a small lp package boiler near the dock area with a water softener to feed the boiler. Explain the relevance of iso 9000 standards to maintenance practices and procedures. Scgsh0201, lock out tag out loto procedure 2 of 50 1. The new package boiler isolated the milelong steam supply header. Cleaning of crude oil storage tanks crude oil storage tanks will settle out the long chain and paraffin based materials over time and could lose 5 to 50 % of the tank storage capacity. Chapter 5 looks at the different types of maintenance programs and definitions.
Preventive and predictive maintenance life cycle engineering. Chapter 14 installation, inspection, maintenance, and repair requirements. Guidelines for writing effective operating and maintenance. Voids or supersedes vendor drawings documents and coordinates asbuilt and redlined drawings. Best practice for risk based inspection as a part of plant integrity hse.
Cleaning of crude oil storage tanks oman energy services. Damage mechanisms for refinery equipment a set of tables cataloguing. Pdf the management of failure analysis has a strategic importance within a. Type and source of feed and unit different operating modes to be specified. Procedures, human factors, risk control, process safety management, psm abstract there is no complete, best practice guideline or textbook for writing operating procedures and troubleshooting guides. The safety report should address the following points.
Each type of maintenance activity that needs to be followed in an operating refinery or when the plant or units have been shut down per. Pdf turnaround maintenance management in a processing. Procedures for inspection, maintenance, repair, and. Quick startup and shutdown is a major cause of heat exchanger damage. Revised january 1, 2000 equipment management page 4 each agency is responsible for implementing a viable equipment management maintenance program. In the case of emergency maintenance requirements, we are capable of mobilizing a 1,500 person work force within a short time frame. 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 costeffective maintenance techniques. Maintenance customers deserve to have their work performed on a timely basis. Refinery units maintenance scheduling using integer programming. The repair procedure will depend on the cause of the damage.
Preventive, predictive and corrective maintenance presented by. Facilities instructions, standards, and techniques volume. Maintenance job that has not been done before and has no standard job procedures 1 week maintenance job that has been done before but has no standard job procedures in place 3 days. Sizing, selection, and installation of pressurerelieving devices in refineries is an example of a ragagep often used in petroleum refineries. Fractionation distillation is the separation of crude oil in atmospheric and vacuum distillation towers into groups of hydrocarbon compounds of. Therefore, backlogs must be kept within reasonable limits. Maintenance planner to ensure that equipment affected by those projects is removed from maximo preventive maintenance schedules, plant records, etc. Shutdowns and turnarounds in the oil and gas industry. Pdf this paper aims at describing the methodologies and the techniques used to manage an oil refinery scheduled maintenance turnaround. The effects of unplanned shutdowns or changes to schedules can have a profound impact not only on the company operating the facility but also on. How to design an operating and maintenance procedure management system. Guidelines for writing effective operating and maintenance procedures.
The evaluation of components reliability is a fundamental aspect for proper. Refinery inspection and maintenance astm international. Since the from existing refinery s paperbased operation procedures inconsistent and outdated, the were company made developing a technology solution to enableaccurate proc e. Best practices for writing operating procedures and. Process safety management for petroleum refineries osha. These interlinks create difficulties in the scheduling procedure that cannot be handled optimally by manual methods. This material has been viewed as a waste product over the years, when in fact the paraffin waxes and asphaltenes will. Whether the company maintenance regimes planned, riskbased, reliability centred, condition based or breakdown maintenance are adequate for each plant item which has a safety function. Pdf development of riskbased inspection and maintenance. This paper presents the proven, best approach for developing accurate operating procedures and for ensure the format. Effective planning and execution of shutdowns and turnarounds is essential to maintain product levels and reduce loss of revenue for the oil and gas industry, particularly if improper maintenance leads to an unplanned shutdown. Inspection of unit at regular intervals and as frequently as experience indicates, an examination. A standard maintenance procedure, or smp, is a written set of instructions that specifies how a maintenance procedure is to be performed.
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