Maintenance Activities

Maintenance Activities in

Japanese Refineries

Hiromitsu Saito

Japan Cooperation Center, Petroleum

http://www.cosmo-oil.co.jp

2

Contents

1. Objective & Role of Maintenance

2. Organization of Oil Refinery

3. Maintenance Work

4. Turnaround Maintenance

5. Performance of Maintenance


3

1. Objective & Role of Maintenance 1-1 Objective of Maintenance

Total Productivity with Safety

Objective

Prevent Troubles & Accidents

Keep good Performance & Efficiency

Stable Operation

Safe Operation


4

1-2 Role of Maintenance

Role

Availability of Facilities

Reliability of Equipment

with adequate planning using

Diagnosis for aged plants and

Risk & ReliabilityManagement

by Optimization of maintenance


5

１９５０１９９０

1-3 History of Maintenance Activity

Ａｇｅｓ

Risk-Based Inspection (RBI)

Reliability-Centered Maintenance (RCM)

Breakdown Maintenance Preventive Maintenance

・Time Base Maintenance

・Predictive Maintenance

(Condition Base Maintenance)

QC Activity Productive Maintenance Total Productive Maintenance

(TPM)

Maintenance Technology


6

(Trouble, etc )

Total Cost Optimization Cos

t

Reliability

Cost

Total Impact

Loss

TBM CBM BM

(Planned Maint. Costs)

Reactive Maint.

(unexpected

works)


7

2. Organization of Oil Refinery

2-1 Refineries in Japan JX (Nippon Oil)

Cosmo Oil

Idemitsu

Kosan

JX (Japan Energy)

ExxonMobil Group

Showa-Shell Group

Others

1223

635

640

643

836

515

27 Ref. 4,616 k BPSD

225

335 185

270

180

140

145

5

220 175 220 140

252.5

Tokyo

Nagoya

210 175

160

Kyoto

Osaka

170 156 100 115

400

140 120

127 120 120

136

Sapporo

Hiroshima

Fukuoka

100

TM: Total Productive Maintenance

RC: Reliability Centered Maintenance

RR: Risk and Reliability Management

TR: Total Plant Reliability Risk Based Inspection (Under consideration or started in most refineries)

TM

TM

TM

TM

TM

TR

TR

TR

TR

(RR)

(RR)

(RR)

(RR)

(RR)

RR TM

TM RC

RC

RC

(RC)

TR

TR

Apr. 2011

1964

1972

1965

1971

1950

1975 1964

1963

1970

1971

1973

1973 1964

1969

1964


8

8

Heavy Oil Desulfurization & Cracking in Japan

CDU V/F

VGO-FCC

VGO-HDS FUEL OIL

BLENDER

CDU Resid-HDS

CDU

CDU Resid-HDS Resid-FCC

V/F

Case-2 FUEL OIL

BLENDER

FUEL OIL

BLENDER

FUEL OIL

BLENDER

H-OIL / Coker

AR

VR

VGO

AR

AR

AR

Case-1

Case-3

Case-4

VGO

LS-VGO 1960’s

1990’s

1990’s

1970’s

1980’s


9

Trend of Distillation Capacity and

Crude oil Throughput of Japan

kBPSD

1965 1970 1975 1980 1985 1990 1995 2000 2005

1000

2000

3000

4000

5000

6000

High-growth era Period of stable growth Deregulated era

1st Oil crisis 2nd Oil crisis 3rd Oil crisis

Yom Kippur War Iranian Revolution Gulf War

Topper Capacity

Crude oil

Throughput

2008


10

Directors

Auditors

Refinery Corporate

planning

Technical

HSE

Mechanical Personnel

Admin.

President Chairman

2-2 Organization of Japanese Oil Company

Board of

Directors

Branch


11

2-3 Organization of Oil Refinery

Refinery Manager (Director)

Process Eng.

Product. Control

Quality Control

Inspection

Production

Maintenance &

Engineering

Instrumentation

Electricity

Rotary Machinery

81

Operation

Ope. Sec-1

Ope. Sec-2

Ope. Sec-4

Ope. Sec-3

185

HSE

Safety

Environment

29

Administration

16

Oct. 2010

Human Resource

Deputy

Refinery

Manager

(Production)

Deputy

Refinery

Manager

(HSE)

Deputy

Refinery

Manager

(Operation)

Deputy

Refinery

Manager

(General )

General Affairs

Fire fighting

Oil-Move. Sec

Budget Contr.

Total Number : 316

( 110,000 BPSD Refinery )

15 31 35


12

Section

Manager

(1)

Inspection (10)

Coordinator (Instrumentation &

Electricity, Rotary

Machinery)

Budget Control (2)

Total 15 persons


2-4 Organization of Equipment Control Section in Refinery

Oct. 2010

(2)


13

2-5 Organization of Maintenance Section in Refinery

Section

Manager

(1)

Maintenance (16)

Electricity (3)

Total 31 persons

Rotary Machinery (4)


Oct. 2010

Instrumentation (7)


14

Contractors

・Makers/ Manufactures/

Fabricators

Engineering companies

Institutes

2-6 Maintenance Support System

in Japanese Oil Industries


15

3. Maintenance Work 3-1 Maintenance Work Circle

Maintenance planning

Maintenance Work

Execution

Work Result

Evaluation

Review

PLAN

DO

CHECK

ACTION


16

(1) Basic Maintenance Activities and Flow

MAINTENANCE

PLANNINGEXECUTION

COST

ESTIMATION

JOB SPEC.

PREPARATION

RECORDING &

DATE

COLLECTION

WORK

EVALUATION

COORDINATIONBUDGETARY

PLAN

EXECUTION

PLAN

PURCHASING

PLAN

MAINTENANCE

RECORDMAINTENANCE

REPORT

BUDGET

AUTHORIZATION

EXECUTION

AUTHORIZATIONPURCHASING

COC CEC

Jul.～Aug.

Sep.～Nov

Dec.

COC

HEAD

OFFICE

CEC COC COC

Mar.～Apr. May.～Jun. Jul.

PLAN DO SEE


17

(2) Maintenance Activities and Flow

(Repair & Replacement)

Completion of

Construction

Fixed Asset

Registration

Fixed Asset

Management

Fixing of

Standard

Inspection

PlanInspection

Inspection

Recording

Reporting

Improvement

Evaluation

Work Result

Evaluation

Repair&

Replacement

Plan

Material

Purchasing

Plan

Budget

Design &

Cost

Estimation

Work

SpecificationExecution Recording

Coordination

PLAN DO SEE

Material

Purchasing Storage


18

3-2 Optimization of Maintenance

Reliability Centered Maintenance

-Deciding whether or not implement:

with Cost Benefit Analysis

→ Proactive maintenance work

Risk Based Inspection

-Making inspection plan:

with Risk Assessment (consequences×probability)

→ Inspection plan

(1) Risk and Reliability Management


19

(1) Risk Based Inspection

PR

OB

AB

ILIT

Y

CL

AS

S

HIGH NEGLI GIBLE

S-RBI LOW MED IUM

EXTRE ME

N NEGLI- GIBLE N L M H

N LOW L M H E

L MEDIUM M H E X

L HIGH H E X X

CONSEQUENCES

S-RBI RISK MATRIX

X: INTOLERABLE

E: EXTREME

CRITICALITY

RECTIFY

DETAILED

ANALYSIS

H: HIGH

CRITICALITY

M: MEDIUM

L: LOW

NEGLIGIBLE

RISK NO INSPECTION

REVIEW ONLY INSPECTION PLAN


20

20

Inspection Interval Calculation

Probability of Failure

Consequences of Failure

Matrix

Risk Confidence Factor

Matrix

Interval Factor Remnant Life

Corrosion Allowance

Corrosion Rate

Max. Inspection Interval (in years)

Multiply

X

・Economics

・H&S

・Environment

Inspection

・Accuracy

・Frequency

etc.


21

21

Maximum Inspection Interval

Minimum allowable thickness

×

× ×

Remnant life

Maximum inspection interval

Wall

thickness

T

original

T min

Actual

current

corrosion

allowance

Life ( Year )

Maximum inspection interval = Remnant Life × Interval Factor

N

L

M

H

0.0

Extreme HIGH MED LOW

Confidence factor Risk

Interval Factor

0.8

E

( Example )


22

(2) Reliability Centered Maintenance

Cost Benefit Analysis

Annual cost

with PM

Annual cost

without PM

S-RCM

ＶＳ

Annual cost:

all maintenance cost

(PM(or not),T/A, On-Stream maintenance and others)

+ residual risk / Estimated time


23

3-2 Optimization of Maintenance

Intensive Inspection under same policy

Aged equipment suffer from corrosion and

cracking

(2) Diagnosis for plant

Adequate inspection (method, interval, scope etc)

for each failure mechanism equipment group

Intensive Inspection


24

(1) Subject of Intensive Inspection

1. Trouble experiences in refineries

2. Trouble information in the literature

Gather… Intensive Inspection Subjects

Select Subjects of Intensive Inspection

Inspection Guideline (Purpose, Scope, Method, Interval, Criterion etc)

Do

Plan

Check

Action Planning

Inspection

Look over the

Plan & Guideline

Evaluation


25

1) Corrosion under Insulation

2) Corrosion under Fire Proof Skirt

3) Small Diameter Nozzle (for Instruments etc)

4) Root of Support Ring

5) Fin Effect Corrosion

6) Small Diameter K.O Drum

7) AFC Machinery Mount

8) AFC (Air Fin Cooler) Bare Tube

(1) Static Equipment

1) Contact Point with Support

2) Erosion Corrosion at High Velocity

3) Tack Welded Support

(2) Pipe

(2) Subjects of Intensive Inspection

( Example)


26

( Example)

・ Corrosion under Insulation

COVER PLATE

PAINTING or

COATING

INSIDE

INSULATION

STIFFENER RING

SHELL WALL

RAIN WATER

Countermeasure


27

( Example)

・ Corrosion at Contact Point with Support

Structure

Protective plate

or Taping

Structure

Rain water

Countermeasure

Pipe


28

4. Turnaround Maintenance

Ｉｎｔｅｒｖａｌ : 1 year → 2 years

Duration : 30～40 Days

Content of Work: Cleaning , Inspection, Repair, Modification,

Replacement (Equipment, Catalyst)

including Shut Down & Start Up Work

under Government Approval

4 years Continuous Operation

deregulation since 2001


29

4-1 Inspection Intervals for each Equipment

Fire Service Law

High Pressure Gas

Safety Law

Industrial Safety

& Health Law

Electricity Utilities

Industry Law

Oil Storage Tank 7 years≧10,000 KL *1

12 years＜10,000 KL *1

Pressure Equipment 4, 8, 12 years *2

(Process Plant T/A) ( 4 years ） *2

Boiler (for Steam

Generation) 4 years *2

Boiler (for Power

Generation) 4 years *2

*1 Subject to condition of Tank and Foundation ,Interval to be extended more

*2 Need to get certified by Government


30

Maintenance Engineer

Mechanical Engineer

Instrument Engineer

Electrical Engineer

4-2 Organization of Turnaround Maintenance

Head Officer : Refinery Manager

Sub Head : Deputy Refinery Manager

Officer : Manager (Operation, Inspection/Maintenance, HSE)

Maintenance Team for each Plant

Leader : Operation Manager

Staff : Operating Sec.

Maintenance Sec.

Equipment Control Sec.

Contractor

Steering Committee

Health, Safety & Environment

Inspection Engineer


31

HSE Manager

(Site Manager) HSE Council

HSE

Promoter

(Supt.)

HSE

Promoter

(Supt.)

HSE

Promoter

(Supt.)

HSE

Promoter

(Supt.)

HSE

Promoter

(Supt.)

HSE

Promoter

(Supt.)

GM of HSE

(Project Manager) Plant Owner

4-3 HSE Organization of Turnaround Maintenance

Main Contractor

HSE

Promoter

(Supt.)

Chief

Worker

-Electricity-

Chief

Worker

-Instrume

ntation-

Chief

Worker

-Rotary

Machinery-

Chief

Worker

-Inspecti

on-

Chief

Worker

-Equipm

ent-

Chief

Worker

-Piping-

Chief

Worker

-Civil work-

Sub-Contractor


32

4-4 Responsibility for Turnaround Maintenance Work

Contractor

Operation Dep. Maintenance Dep. .

I Turnaround Maintenance Work

1 Maintenance Work

◎ 1) Basic & Detail Plan

◎

2) Work Request ◎

2 Schedule

4)

Outline

◎

5)

Basic

◎ 6)

◎

3 Budget

8)

Estimation

◎

9)

Control

◎

1)

Specification & Procedure

◎

2)

◎

◎

3)

Quotation

◎

1)

Fix & Contract

◎

2) ◎

3)

4)

Item Plant Owner

Work Order 3)

Environment Control

Execution

◎

Gas Tightness Test & Others Test

Inspection

Confirmation of Completion

7)

◎ (Final) (Prelim.)

◎

◎ (Prelim.) (Final)

Detail

Witness Maintenance Work

Supervise Maintenance Work ◎

◎

11)

10)

◎

(Job Specification)


33

▲ 1st Year

▲ T/A

Planning T/A Inspection

On-Stream Inspection (Operator / Inspector)

4-5 Turnaround Maintenance Planning

▲ 2nd Year

▲ 3rd Year

T/A Work should be planned 18 months before the next T/A.

Intensive Inspection

▲ T/A

Data evaluation

Result Data

Data


34

(1) Schedule of Turnaround Maintenance Planning

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2

0 M&P Strategy Definition

1 Long Term Business Plan

2 T/A Preliminary Development

3 T/A Work Development

4 T/A Detailed Planning

5 Pre T/A Maintenance Work

6 T/A Maintenance Execution

7 Post T/A Maintenance Review

*Starting Preliminary Discussion with Selected Contractors

*30% Cost Estimate

*Main Job List & Spec. Fixed

*T/A Kick-off Meeting

*Net Work Planning Completed

*10% Cost Estimate

*Job List and S/D Duration Challenging

*Premises Definition Finalized

*Bidding Contract Package Finalized

*Contract Awarded

*Planning, Scheduling and Optimization

*Final Approved S/D Scheduling

*Final Pre-T/A Meeting

*T/A Maintenance

*Joint Final Report

M&P : Maintenance & Procurement

*Budget Approval


35

4-5 Work Flow of Turnaround Maintenance

Selection of

maintenance

items

Planning of

T/A

Preparation of

maintenance work

specifications

Quotation and

contract

Preparation of

T/A

Safety review

before shut down

Hot

work

Safety review before

starting up

Shut down

operation

Starting up

operation

Evaluation of

result

Review the

plan


36

MAY JUNE HOT WORK TOTAL

NVP

2TP/VP

HDS

1HP

4UF

FCC

COB

SR/TGT

10DDS

10HP

2RF

2RS

14 12 18 9

14 17 25 11

17 15 20 11

16 16 20 11

15 9 15 10

16 13 19 10

11 18 20 10

13 9 18 8

17 15 20 10

14 16 20 10

24 11 19 15

24 11 19 15

28

22

21 33

20 31

22 37

22 34

21 24

18 35

18 33

18 29

44 22

22 44

17

33

Normal Operation

Maintenance Period (Hot Work)

Shutting Down

4-6 Turnaround Maintenance Schedule

( 220,000 BPSD Refinery in 2004 )


37

The number of workers during a SDM period

Nor.

Operation. Shut down TA Execution Normal

Operation Start up

Contractor Plant Owner Others

Number

Date


38

38

TIME ITEMS TIME ITEMS

7:30 Morning Meeting (each group) 13:00 Short Meeting (each group)

8:00 Morning Meeting (all member) Work

・Stretch Exercise,Safety Notice,Instruction Safety Patrol

8:15 TBM (Tool Box Meeting) 15:00 Recess

Gas Monitoring (Ope./HSE/Contr.) Maintenance Meeting (Maint./Ope./HSE/Contr)

KYK(Work Risk Assessment) at the site ・Safety Notice,Work Adjustment,Schedule Confirmation

Work Countermeasure Decision Meeting

10:00 Recess (Managers of Maint./Ope./HSE)

Work Work

Safety Patrol 17:00 Finish (field work)

12:00 Recess Completion Comfirmation (Maint./Contr)

4-6 Daily Work Flow of Turnaround Maintenance

cooperation with Plant Owner and Contractor


39

PT

MT EVA

Non magnetic ○ ○ ○ ○

magnetic ○ ○ ○ ○

○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

Inside ○ ○ 　　 ○ ○

Outside ○ ○ ○

Inside ○ ○ ○ ○

Outside ○ ○ ○ ○ ○ ○ ○ ○

SM AESAMPLING

VI RT

Boiler tube

Furnace

Side& Top plate

ET

Heat exchanger

Tank

Tower & vessel

Bottom plate

UT SUMP

Piping

Tube

With insulation

No insulation

Tube sheet

Shell

4-7 Inspection Techniques for Equipments

VI: visual inspection, SM: strain measurement, SUMP: replica method, EVA: extreme value analysis,

AE: acoustic emission


40

40

Maintenance Works

& Inspection Activities


41

0

50

100

150

200

250

Num

ber

PLANT

Number & Ratio of Equipment

opened for T/A maintenance

Total Number

2000

2004

220,000BPSD Refinery

５５％

７８％

５５％

７０％

5. Performance of Maintenance 5-1 Change in the Ratio of Equipment opened

for T/A maintenance

44%

63%

45%

65%

55%

75%

44%

76%

38%

76%

26%

77%

36%

56%

43%

49%


42

Maintenance Cost = Opening, Cleaning, Inspection, Repair & Replacement Cost

excluding Company Maintenance Personnel Cost

5-2 Trend of Maintenance Cost


43

Maintenance Personnel ：Maintenance Department Engineers

( Inspection, Budget Control, Maintenance, Mechanical, Instrument & Electrical Engineers )

5-3 Trend for the number of

Maintenance Personnel

0

50

100

150

200

250

300

350

1998 1999 2000 2001 2002 2003 2004 2005 2006

Number

Year

Number of Maintenance Personnel220,000BPSD

125,000BPSD

100,000BPSD

110,000BPSD

Total


44

The End of Slides

Thank you for your attention

Japan Corporation Center, Petroleum

(JCCP)

Maintenance Activities

Documents