Development and application of an off-site maintenance system in the petrochemical industry

Abstract

On-site maintenance (ONSM) is critical to ensuring the safety of equipment in the petrochemical industry. However, many accidents occur during ONSM processes because of unstable equipment, complicated work environment, and human error. To reduce congestion and exposure to hazards during on-site operations and thereby reduce the probability of accidents, off-site maintenance (OFSM) is proposed based on Energy Release Theory (ERT). The information requirements for OFSM are analyzed. A support system for OFSM, which makes use of visualization, information management, and localization capabilities, is developed. A case study utilizing OFSM and its support system for an oil-loading facility of a petrochemical company is conducted. The application results indicated that implementation of OFSM system can significantly reduce the operation risks and can improve the operation efficiency.

Keywords

on-site maintenance / petrochemical industry / safety / off-site maintenance system

References

[1] Adolfo C M, Heguedas A S (2002). Models for maintenance optimization: A study for repairable systems and finite time periods. Reliability Engineering & System Safety, 75(3): 367–377

[2] Attwood D, Khan F, Veitch B (2006). Can we predict occupational accident frequency? Process Safety and Environmental Protection, 84(3): 208–221

[4] Baesi S, Abdolhamidzadeh B, Hassan C, Hamid M D, Reniers G (2013). Application of a multi-plant QRA: A case study investigating the risk impact of the construction of a new plant on an existing chemical plant’s risk levels. Journal of Loss Prevention in the Process Industries, 26(5): 895–903

[7] Ben-Daya M, Duffuaa S O, Raouf A, Knezevic J, Ait-Kadi D (2009). Handbook of Maintenance Management and Engineering. London: Springer

[5] Chien-Ho K (2009). RFID-based building maintenance system. Automation in Construction, 18(3): 275–284

[6] Cong G P (2013). Study on intelligent decision-making of inspection and maintenance based on risk and condition for petrochemical equipment. Dissertation for the Doctoral Degree. Dalian: Dalian University of Technology (in Chinese)

[9] Fabiano B, Curro F (2012). From a survey on accidents in the downstream oil industry to the development of a detailed near-miss reporting system. Process Safety and Environmental Protection, 90(5): 357–367

[10] Gibb A, Isack F (2003). Re-engineering through pre-assembly: Client expectations and drivers. Building Research and Information, 31(2): 146–160

[11] Guo L J, Gao J J, Yang J F, Kang J (2009). Criticality evaluation of petrochemical equipment based on fuzzy comprehensive evaluation and a BP neural network. Journal of Loss Prevention in the Process Industries, 22(4): 469–476

[12] Hipkin I B, De C C (2000). TPM and BPR: Lessons for maintenance management. OMEGA-International Journal of Management Science, 288–292

[13] Ikuma L H, Nahmens I, James J (2011). Use of safety and lean integrated Kaizen to improve performance in modular homebuilding. Journal of Construction Engineering and Management, 137(7): 551–560

[14] Ishekwene I V (2012). Improving the turnaround maintenance of the Escravos Gas Plant. Potchefstroom Campus, South Africa: North-West University

[15] Jaillon L, Poon C S (2009). The evolution of prefabricated residential building systems in Hong Kong: A review of the public and the private sector. Automation in Construction, 18(3): 239–248

[17] Knegtering B, Pasman H J (2009). Safety of the process industries in the 21st century: A changing need of process safety management for a changing industry. Journal of Loss Prevention in the Process Industries, 22(2): 162–168

[18] Konstandinidou M, Nivolianitou Z, Markatos N, Kiranoudis C (2006). Statistical analysis of incidents reported in the Greek Petrochemical Industry for the period 1997–2003. Journal of Hazardous Materials, 135(1–3): 1–9

[19] Li G Z (2013). Research on Maintenance Strategy and Fault Diagnosis of Subway Train Based on RAMS, Dissertation for the Doctoral Degree, Beijing: Beijing Jiaotong University (in Chinese)

[20] Li J R, Khoo L P, Tor S B (2006). Generation of possible multiple components disassembly sequence for maintenance using a disassembly constraint graph. International Journal of Production Economics, 102(1): 51–65

[21] Liu G S (2003). Safety countermeasures for repairing petrochemical plants. Safety Health & Environment, 3(8): 6–7 (in Chinese)

[22] Luan X H (2011). BP US Texas refinery fire explosion. Modern Occupational Safety, 2011(10): 82–83 (in Chinese)

[23] Maas G, van Eekelen B (2004). The Bollard- the lessons learned from an unusual example of off-site construction. Automation in Construction, 13(1): 37–51

[24] Martorell S, Villanueva J F, Carlos S, Nebot Y, Sánchez A, Pitarch J L, Serradell V (2005). RAMS+C informed decision-making with application to multi-objective optimization of technical specifications and maintenance using genetic algorithms. Reliability Engineering & System Safety, 87(1): 65–75

[25] Moghadam M, Al-Hussein M, Al-Jibouri S, Telyas A (2012). Post simulation visualization model for effective scheduling of modular building construction. Canadian Journal of Civil Engineering, 39(9): 1053–1061

[26] Motawa I, Almarshad A (2013). A knowledge-based BIM system for building maintenance. Automation in Construction, 29: 173–182

[27] Murthy D N P, Asgharizadeh E (1999). Optimal decision making in a maintenance service operation. European Journal of Operational Research, 116(2): 259–273

[28] Nivolianitou Z, Konstandinidou M, Kiranoudis C, Markatos N (2006). Development of a database for accidents and incidents in the Greek petrochemical industry. Journal of Loss Prevention in the Process Industries, 19(6): 630–638

[29] Papazoglou I A, Nivolianitou Z, Aneziris O, Christou M D, Bonanos G (1999). Risk-informed selection of a highway trajectory in the neighborhood of an oil-refinery. Journal of Hazardous Materials, 67(2): 111–144

[30] Rodriguez D A, Norrish J, Nicholson A (2009). Robot programming for non repetitive repair operations using vision system. Trends in Welding Research, 671–675

[31] Sherwin D (2000). A review of overall models for maintenance management. Journal of Quality in Maintenance Engineering, 6(3): 138–164

[32] Singh V, Gu N, Wang X Y (2011). A theoretical framework of a BIM-based multi-disciplinary collaboration platform. Automation in Construction, 20(2): 134–144

[33] Skogdalen J E, Vinnem J E (2012). Combining precursor incidents investigations and QRA in oil and gas industry. Reliability Engineering & System Safety, 101: 48–58

[35] Vagliasindi F (2003). Gestire la manutenzione: perché e come. FrancoAngeli

[36] Waeyenbergh G, Pintelon L (2002). A framework for maintenance concept development. International Journal of Production Economics, 77(3): 299–313

[37] Waeyenbergh G, Pintelon L (2009). CIBOCOF: A framework for industrial maintenance concept development. International Journal of Production Economics, 121(2): 633–640

[38] Wang L, Chu J, Wu J (2007). Selection of optimum maintenance strategies based on a fuzzy analytic hierarchy process. International Journal of Production Economics, 107(1): 151–163

[40] Wang Q Z (2003). Responsible Subject of Oil Pollution Damage Caused by Ship Collision and Its Responsibility, Dissertation for the Ph.D degree

[41] Wong C K, Fung I, Tam C M (2010). Comparison of using mixed-integer programming and genetic algorithms for construction site facility layout planning. Journal of Construction Engineering and Management, 136(10): 1116–1128

[42] Xue P L, Zeng W H (2010). Policy issues on the control of environmental accident hazards in China and their implementation. International Conference on Ecological Informatics and Ecosystem Conservation, 2(ISEIS 2010): 440–445

[43] Yuan Z J, Guo Y (2011). Risk identification and control measures of overhaul key operation about natural gas purification equipment. Chemical Engineering of Oil & Gas, 40(4): 429–432 (in Chinese)

[44] Zhang C L (2012). HSE management for inspection and maintenance operations of petrochemical plants. Safety Health & Environment, 12(1): 54–56 (in Chinese)

[45] Zhang D K, Ye Y C (2010). The unsafe factors and countermeasures in petrochemical equipment maintenance. Petrochemical Equipment, 13(4): 57–59 (in Chinese)

[46] Zhao J S, Joas R, Abel J, Marques T, Suikkanen J (2013). Process safety challenges for SMEs in China. Journal of Loss Prevention in the Process Industries, 26(5): 880–886

RIGHTS & PERMISSIONS

2017 The Author(s) 2017. Published by Higher Education Press. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0)