{"id":1176,"date":"2026-02-14T21:28:30","date_gmt":"2026-02-14T21:28:30","guid":{"rendered":"https:\/\/hydrocarbon.sbs\/?p=1176"},"modified":"2026-03-25T15:36:23","modified_gmt":"2026-03-25T15:36:23","slug":"preventive-maintenance-checks-optimization","status":"publish","type":"post","link":"https:\/\/petrostreet.com\/main\/preventive-maintenance-checks-optimization\/","title":{"rendered":"Preventive Maintenance Checks & Optimization"},"content":{"rendered":"\n

In the hydrocarbon industry, if a preventive maintenance which is being performed is not resulting into some insight related to the performance of any equipment or system then that particular preventive maintenance is either not required or not rightly directed. Not a single preventive maintenance should be carried out on any equipment of system which on consecutive occassions does not yield something requiring an action. Data shows that on daily basis, preventive maintenance works are being performed in hydrocarbon industry resulting in checking the boxes, filling in the sheets and updating the system with nothing being picked up. Even revision of these preventive maintenance works is occassional and adjusting their desired frequency has also become an activity rarely done. This calls for optimizing the existing preventive maintenance practices and directing them towards picking up the real issues which can actually occur to a particular equipment and system to ensure they are integral and reliable for continued safe operation.<\/p>\n\n\n\n

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Process safety information is a vital element of any process safety system. This enables availability of all the data related to the assets in any operating facility. Completeness of this data ensures enhanced definition of an asset and from here on, only the applicable and must-to-do preventive maintenance tasks could be performed. Unavailability of this data or incompleteness could result into defining tasks which may not be necessary for that particular asset. Example includes defining additional inspection tasks for a pressure vessel which metallurgy is unknown. Installed material if known resistant to the process can then be optimized for its inspection. Similarly, piping with unknown painting information under insulation would ask for addition inspection however if correct and verified information related to a particular asset would be available, preventive maintenance task could be easily optimized. A life time inspection can be taken off from a heat exchanger having corrosion-resistant metallurgy for its tubing and less severe corrosion environment. All this optimization requires complete process safety information. Not all the heat exchangers installed at a facility are of the same type and for that matter should be having their specific preventive checks. Complete process safety information, if available for all the fire monitors would ensure that the checks are performed in the way intended to provide assurance for its safe operation as and when needed. While collecting the process safety information, this is also to be considered that the original equipment manufacturer\u2019s recommendations and other associated stauatory requirements should also be made part of the package which are concering the preventive maintenance plan to have safe and reliable operation. These are those mandatory checks which if lifted could actually cause major damages in terms of HSE, reputation, legal and finance.<\/p>\n\n\n\n

Historical opertaional and maintenance data is the second importnat thing. For any facility, having all the verified records available for the preventive maintenance along with the analysis report, optimizing the checks in place and to define new ones to enhance safe and reliable operation would become far easier than the facilities lacking these. With computerized maintenance management system taking its place to collect all these records, availability of records has not been a concern in most of the facilities. However, quality of the available records and then the analysis part becomes an issue. There are cases where analysis part is either not done or if done, that requires verification to bring up actions to optimize preventive maintenance checks. When historical data analysis is taken into discussion, at most of the facilities, it is taken as the reliability calculation. That means checking the outcome of all defined preventive maintenance checks whether they were passed, failed & fixed or got failed. This reliabity check is only the feed which helps in analyzing that how existing checks are performing. If that is plotted as well over the years, that would help in optimizing the requirement of that particular check along with its frequency.<\/p>\n\n\n\n

Plant changes play a vital role in how the preventive checks are to be performed. With changes to an asset, the checks are required to be assessed and revised, if required. A change in metallurgy of a piping system could have a potential of eliminating the existing checks being performed earlier or it may ask to introduce more checks if the new metallurgy in inferior to the one existing before. Every change made to the assets and systems has to be reviewed by the respective inspection & maintenance teams performing the preventive checks. Change in product feed could entirely revise the maintenance checks and routines being performed in a particular system. Any change going unnoticed without revieiwng the existing preventive maintenance plan in place would leave the concerned party unnoticed to check of any modifications required.<\/p>\n\n\n\n

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Actual asset failure is the forth area which is required to be reported and analyzed to ensure that the existing preventive maintenance checks in place are fully capable to stop the asset from failing. Several leaks in a particular piping system over a period of time could understandably put a question on the inspection and maintenane being performed for that particular asset. There is a chance that the way that particular piping system is being inspected and maintained is not sufficient.  Heat exchanger tubes are leaking frequently depsite all the inspection checks are being performed to assure its integrity could call for a review of the preventive maintenance checks in place. Issues being faced during activation of emergency shutdown systems could lead to updating the checks being performed or to look for more reliable system in place through introducing a plant change. During this failure analysis, it should be checked if there have been instances where premature failures have been reported. Any failure which may have resulted prior to a planned check as recommended by the original equipment manufacturer is considered as a premature failure. Similarly, all other assets failing before their well risk reviewed and agreed inspection & maintenance date fall in the same category. The quantum of corrective maintenance performed on an asset has to be assessed in order to ascertain the effectiveness of the preventive maintenance plans. That analysis has the potential to actually asks for the changes to be made and optimize.<\/p>\n\n\n\n

With process safety information, historical data of preventive maintenance checks, plant changes review and actual asset failure data, this become simpler to plan for a review round of preventive maintenance checks and look for optimation every 5 years at the maximum. A call can be made before that if on-going data analysis asks for a review. Especially, when unplanned and premature failures are reported, review for that particular unit or a set of assets should be done without delay. Preventive maintenance checks and its optimization review has a potential to address the real risk items and at the same time save the budget being spent on checks not yielding the intended outcome to continue safe and reliable operation.<\/p>\n\n\n\n

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