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

1-3 History of Maintenance Activity

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
C
o
s
t

Reliability
Cost
Total Impact
Loss
TBM CBM BM
(Planned Maint. Costs)
Reactive
Maint.
(unexpec
ted
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
1960s
1990s
1990s
1970s
1980s
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
1
st
Oil crisis 2
nd
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
PLANNING
EXECUTION
COST
ESTIMATION
JOB SPEC.
PREPARATION
RECORDING &
DATE
COLLECTION
WORK
EVALUATION
COORDINATION
BUDGETARY
PLAN
EXECUTION
PLAN
PURCHASING
PLAN
MAINTENANCE
RECORD
MAINTENANCE
REPORT
BUDGET
AUTHORIZATION
EXECUTION
AUTHORIZATION
PURCHASING
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
Plan
Inspection
Inspection
Recording
Reporting
Improvement
Evaluation
Work Result
Evaluation
Repair&
Replacement
Plan
Material
Purchasing
Plan
Budget
Design &
Cost
Estimation
Work
Specification
Execution 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 (consequencesprobability)
Inspection plan
(1) Risk and Reliability Management
19
(1) Risk Based Inspection
P
R
O
B
A
B
I
L
I
T
Y

C
L
A
S
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

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 I ntensive I nspection
I nspection Guideline (Purpose, Scope, Method, I nterval, 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
: 1 year 2 years
Duration : 3040 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 years10,000 KL *1
12 years10,000 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 AE
SAMPLING
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
N
u
m
b
e
r
PLANT
Number & Ratio of Equipment
opened for T/A maintenance
Total Number
2000
2004
220,000BPSD Refinery

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 Personnel
220,000BPSD
125,000BPSD
100,000BPSD
110,000BPSD
Total
44
The End of Slides

Thank you for your attention
Japan Corporation Center, Petroleum
(JCCP)

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