The safety report should address the following points. Through the utilization of various nondestructive testing and measuring techniques, predictive maintenance determines equipment status before a breakdown occurs. Common welding processes, welding procedures, welder qualifications, metallurgical effects from welding, and inspection techniques are described to aid the inspector in fulfilling their role implementing api 510, api 570, std 653, and rp 582. Technical assessments for refinery and petrochemical.
Maintenance, nigerian refineries, manage rotating equipment maintenance strategy. Chemical cleaning and degassing refinery equipment the safe removal of volatile hydrocarbons, hydrogen sulphide gas and pyrophoric iron sulphide from refinery equipment before inspection is indispensable. How valero refinery achieved best maintenance practices paul chandler. Plans had been made to overhaul more than 250 control valves, but only 28 were found to actually need that level of maintenance. The application of the procedure to two specific stages in the maintenance activities of the refinery has shown how the use of riskbased inspection techniques leads to an improvement in the indices which measure maintenance quality table 5, table 7. This new book shows how to remedy this problem through selecting and implementing actions that promote safe, efficient operations and maintenance, improve quality, continuity, profitability and cost control, build upon and record process experience, and promote the concept that operating and maintenance procedures are vital plant components. Pdf development of riskbased inspection and maintenance. Pdf turnaround maintenance management in a processing. Experienced flowserve engineers perform extensive onsite audits to define pump reliability issues and maintenance history, operating. Have written procedures for effective exchange and tracking of safety, operations, and maintenance information. Department of energys federal energy management program femp. The first energy switching and isolation plan is acceptable and meets the intentions of this procedure when they are operating the equipment. Preventive, predictive and corrective maintenance presented by.
Fundamentals of temperature, pressure, flow, level, and analytics calibration and configuration instrument maintenance. Project standards and specifications page 8 of 19 rev. Sizing, selection, and installation of pressurerelieving devices in refineries is an example of a ragagep often used in petroleum refineries. Guidelines for writing effective operating and maintenance. Chapter 5 looks at the different types of maintenance programs and definitions. The state of louisiana is committed to a continuing, aggressive program for maintenance of boiler and machinery equipment, and all other equipment. Everyone needs to know how the maintenance work will be planned, scheduled and executed, and what they will do in the maintenance process.
A maintenance planning and scheduling process needs to be designed. How valero refinery achieved best maintenance practices emerson. Planproposal by project management professional turnarounds. Because of the serious nature of any violation of these rules, you may be suspended or discharged for the following. The application of the procedure to the planned turnaround has. With predictive devices currently available, it is incumbent upon. Edmonton exchanger has over 30 years of onsite maintenance and construction experience in the petrochemical and oil industries. The first is to study the refinery system of the refinery model. Pdf the management of failure analysis has a strategic importance within a. In particular it will be discussed a risk based approach to define the equipment to be included in the turnaround process. Technical assessments for refinery and petrochemical operations. Between 2004 and 2012, the valero wilmington refinery. Maintenance procedures and documentation to provide directions, when appropriate, for. Contributory factors for an assessor to consider concerning maintenance procedures.
First energy is typically the operator of the refinery 8 kv or 69 kv electrical distribution system. Annex a describes a technique for estimating the life remaining for a heater tube. Our experience and expertise range from small maintenance projects to complete turnkey petrochemical plant and re. Proper maintenance of plant systems and equipment supports optimal plant operation, capacity, and productivity. Oil refinery turnaround main goal is to respect the maintenance schedule in terms of times and costs as defined by the management. Pdf turnaround management in an oil refinery researchgate. These interlinks create difficulties in the scheduling procedure that cannot be handled optimally by manual methods.
Tailor your resume by picking relevant responsibilities from the examples below and then add your accomplishments. Review these refinery best practices 3 p etroleum refining is a highly energyintensive process using both purchased energy gas and electricity and byproduct streams from the refining processes. Type and source of feed and unit different operating modes to be specified. Process safety management for petroleum refineries osha. Urbanus technical coordinator reproduction permitted with due acknowledgement concawe brussels october 2000. Predictive maintenance is the complement of preventive maintenance. These procedures are not intended to be used for the design of external piping. Maintenance procedures health and safety executive. The scheduling of necessary operations is made on the basis of risk estimation, cost of the. Valve maintenance valve overhaul can be time consuming and expensive 4. 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 plan is covered in detail in this chapter.
Oil refinery turnaround main goal is to respect the maintenance schedule in. Safety management on a refinery maintenance turnaround. Explain the relevance of iso 9000 standards to maintenance practices and procedures recognize typical calibration needs for systems used in the fdaregulated industries and more you will cover. You need to know how the maintenance work will flow through your company from its request to its completion. Refining operations petroleum refining processes and operations can be separated into five basic areas.
Because of their inherent hazards, especially from explosion, fire, and chemicals, oil refineries are tightly regulated places in which to work. The challenge for executives is to reduce maintenance costs and sustain those cost reductions in an effort to improve razorthin profit margins without. Scgsh0201, lock out tag out loto procedure 2 of 50 1. 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.
Step 1 in the refining process is to remove these contaminants so as. Pbf energy pbf is one of the largest independent petroleum refiners and suppliers of unbranded transportation fuels, heating oil, petrochemical feedstocks, lubricants and other petroleum products in the united states. Inspection and maintenance procedures for an oil refinery. 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. Turnaround maintenance management in a processing industry. 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.
Api 520 covers appropriate relief system size calculations based on process parameters such as flow rate and pressure. Consistent, welldocumented asset operating procedures help. Energy use accounts for approximately 50% of refining costs. Fractionation distillation is the separation of crude oil in atmospheric and vacuum distillation towers into groups of hydrocarbon compounds of. A framework for ensuring a holistic approach to the management of these functions is proposed. Ensure that all findings, recommendations, and action items of the program are communicated effectively to all employees. Best practices for writing operating procedures and trouble. Development of riskbased inspection and maintenance. The lowstress way to find your next refinery maintenance procedure job opportunity is on simplyhired. It was later determined that the crack in the process tower was due to improper contractor welding procedures.
Mechanical maintenance engineer resume samples velvet jobs. Maintenance scheduling for mechanical equipment bureau of. The typical feed and product charateristics for refinery are. Consistent, welldocumented asset operating procedures. How valero refinery achieved best maintenance practices.
Preventive maintenance, predictive maintenance, a structured repair system, and fullfledged plant shutdown management must be reliable. An oil refinery identified 14% of its traps were malfunction ing and. Performing an indepth analysis of any refinery or petrochemical plant system requires the collection of a large amount of historical information and actual current performance data. Experienced flowserve engineers perform extensive onsite audits to define pump. Increase the safety of all staff, as properly maintained equipment is safer equipment. Hundreds of manhours were saved, and there was no delay getting back into production due to valve maintenance. Best practices for writing operating procedures and troubleshooting guides lauren madden, psm manager rec silicon rec silicon and its affiliates shall neither be responsible in any way for the contents of this or any other paper, nor. A chemical cleaning programme reduces downtime and the need for mechanical cleaning i n petroleum refineries, distillation and. If there is reasonable doubt about a situation in which you find yourself, exercise your right to know and make use of whmis to. The mission of femp is to facilitate the federal governments implementation of sound, cost. Plant practices, warnings, and emergency procedures must be observed at all times.
Petroleum refinery process safety management national emphasis. Operational and preventive maintenance frequency daily weekly monthly 3 mo 6 mo yearly as necessary 1 sewage treatment facilities survey for the following conditions. First, daytoday costs for maintaining assets in a petroleum refinery continue to rise. Maintenance is the practice of protecting or restoring equipment in order to maintain function and integrity. Ensure the comfort, health, and safety of building occupants through properly functioning.
Essar oil vadinar refinery mega turnaround septoct 2011. Petroleum and process industry best practices in maintenance. Therefore, backlogs must be kept within reasonable limits. Guide the recruiter to the conclusion that you are the best candidate for the mechanical maintenance engineer job. Toledo refinery plant rules concerning disciplinary suspension and discharge the purpose of these rules is to insure the safety and welfare of our employees in the maintenance of orderly operations. This standard does not give recommendations for tube retirement thickness. As a worker you must depend on the knowledge available from the plant operating and maintenance staff, normally available through your employer. New refinery maintenance procedure careers are added daily on. Policy and procedures guide api committee on refinery equipment. Isa specializes in teaching the latest, proven plant maintenance techniques and. Maintenance customers deserve to have their work performed on a timely basis. Pdf this paper aims at describing the methodologies and the techniques used to manage an oil refinery scheduled maintenance turnaround. Chapter 6 focuses on maintenance technologies, particularly the most accepted predictive technologies.
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