PLANT SHUTDOWNS IN REFINERIES

Oil refineries are an integration of different process units made up of a large number of components, the quantity and complexity of which varies in each facility. The long list of these components includes reactors, furnaces, columns, pressure vessels, heat exchangers, pumps, compressors, pipes, fittings, storage tanks, docks, electrical installations and instrumentation, concrete and metal structures, chimneys, flares, and much more. These components are manufactured using different materials, designs, codes, norms, standards, licenses and even, in some cases, specialized laws. This complexity entails certain risks and requires that those responsible for inspection and maintenance be properly trained personnel.

The safe and reliable operation of refineries is based on the application of best maintenance practices, which ensure compliance with production plans, with the aim of transforming crude oil into products of high commercial value such as gasoline, diesel, kerosene, lubricating oils, asphalt, fuel oil, and gas, among others. Otherwise, equipment failures and unscheduled shutdowns have a high cost in terms of lost opportunities and failure to comply with customer plans.

The objective of every refinery is to obtain quality products from crude oil with the best possible profit margin, without compromising the mechanical integrity or safety of the facilities and personnel. Within this objective, both daily routine preventive, predictive, and corrective maintenance, as well as scheduled plant shutdowns intended for major maintenance, play an essential role. As a working premise, those responsible for maintenance must always keep in mind that the work must be done correctly and on time, at a reasonable cost, respecting technical requirements that ensure a good repair and, therefore, safe and reliable operation, to meet the scheduled production plans. Bad repairs and delays in the execution of maintenance work have a high cost due to loss of production days, which significantly affects the margin.

Plant shutdowns are complex jobs that require specialized knowledge and experience from different disciplines. Teamwork and good communication are essential, and the cooperation of the Inspection, Maintenance, Operations, Process Engineering, Economics, and Industrial Safety departments with the Plant Shutdowns organization is essential. This organization needs the contributions of the aforementioned disciplines to carry out the tasks under its charge, which include:

• Developing the annual shutdown plan in conjunction with the Inspection and Economics departments.
• Estimating the costs of each of the activities to be executed and preparing the budget that will be submitted to management for approval.
• Coordinating the preparation of the scope of work, with the support of Equipment Inspection, Process Engineering, and Operations, who have a deciding role.
• Planning each of the activities in detail using computerized applications to estimate the work hours required for each job, as well as the timetable to follow during execution. Identify critical routes and take preventive actions to prevent delays.
• Prepare the list of equipment and materials for the Purchasing department.
• Prepare the contracting packages that will be submitted to the bidding processes, with participation in the clarification process and negotiations with the contractors.
• Supervise the execution of the works by the contracting companies, ensuring not only that they are executed according to the scope and planning, but also respecting the company’s safety standards that prevent unsafe conditions and avoid accidents.
• Manage the administration of the contracts (invoicing, valuations, payments, closing), including additional work not contemplated in the original scope.

The Refinery Plant Shutdowns course includes the explanation of basic concepts of risk-based inspection, equipment inspection technologies and other aspects related to reliability. Tools are also provided to measure the cost-benefit of plant shutdown work and guides to determine whether or not the investment made is in accordance with internationally accepted good management parameters, including the most recommended indicators.

This course will allow participants to learn work methodologies, learn best practices, and discuss examples of real cases in different process units, including accidents caused by poorly executed work or by delays in the execution of maintenance.

For more information: Plant Shutdowns in Refineries