In the petrochemical industry, effective maintenance management is critical to operational effici... more In the petrochemical industry, effective maintenance management is critical to operational efficiency and safety. Key indicators such as overall equipment effectiveness (OEE), reliability, safety incidents, and maintenance costs are commonly used by management to evaluate maintenance system performance. Increasing equipment availability and product quality can boost OEE and lead to fewer safety incidents and improved overall performance. Studies in Iran's petrochemical sector have shown that investing in maintenance and training can bring significant benefits. For example, data from 42 petrochemical complexes in Iran, covering 2015 to 2021, show an increase in equipment effectiveness and reliability over time. However, there was a slight slowdown in 2021 due to the impact of the Covid-19 pandemic. Improvements in maintenance performance, the use of excellence models along with the necessary training have been associated with increased product realization and productivity growth. Research also shows that increased reliability can positively impact the reduction of safety incidents, environmental issues, and overall operating costs. By prioritizing maintenance excellence and adopting best practices, organizations can strengthen their competitiveness and sustainability in a dynamic business landscape.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department reported an increase in the clearance of the bearings and the beginning of failure. After the technical meetings, the study of the process behavior of equipment and technical and repair data, it was decided to take the equipment apart and its internal parts be inspected.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department reported an increase in the clearance of the bearings and the beginning of failure. After the technical meetings, the study of the process behavior of equipment and technical and repair data, it was decided to take the equipment apart and its internal parts be inspected. Observations inside the equipment during its maintenance process and the results of post-repair analyses showed that the RCM, CM, and Failure Mode Effective Analysis (FMEA) applications are of great importance in care and are well suited for timely diagnosis of defect, and can be used by the above tools and experienced technicians to stop and prevent financial, safety and environmental damage.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
Based on their mission and vision, companies choose different indicators to measure their perform... more Based on their mission and vision, companies choose different indicators to measure their performance. Indicators that are important in the oil, gas, refining and petrochemical industries include safety, health, environment, energy, production, quality, cost, income, exports, stress, risk, maintainability, reliability, availability, replacement cost, commitment, motivation, and profitability. The actual situation assessment and comparison with the target indicators allows identification and analysis and plan the required necessary refining actions. Assessment and control are one of the stages of roadmap for continuous improvement. In this paper 1- Based on key indicators of determining the sensitivity of equipment and their coefficients by Delphi method and the questionnaire and classification of critical equipment in Tabriz petrochemical industry based on it.2- Performing RCM stages on four critical equipment. 3- Looking at maintenance from the perspective of Balance Score Card(BS...
Optimum maintenance of hundreds of thousands of equipment used by each company is one of the main... more Optimum maintenance of hundreds of thousands of equipment used by each company is one of the main challenges of maintenance, operation, and procurement managers. Continuous production and competition in the business environment and resource constraints require that the vital equipment of each company must be controlled, monitored, and considered. To do this, identifying critical and essential equipment is necessary. In this paper, a formula was defined by field surveys and preferences of 75 petrochemical industry experts and managers to determine the equipment sensitivity index. Experts' opinions extracted ten compelling features in determining the sensitivity of the equipment, and the weighting coefficient of each one was obtained by using the group decision-making method, Analytical Hierarchy Process. The introduction of the resistive maintenance index formula represents the capability to use strengths and opportunities and sustainability and resistance against weaknesses and ...
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
In the petrochemical industry, effective maintenance management is critical to operational effici... more In the petrochemical industry, effective maintenance management is critical to operational efficiency and safety. Key indicators such as overall equipment effectiveness (OEE), reliability, safety incidents, and maintenance costs are commonly used by management to evaluate maintenance system performance. Increasing equipment availability and product quality can boost OEE and lead to fewer safety incidents and improved overall performance. Studies in Iran's petrochemical sector have shown that investing in maintenance and training can bring significant benefits. For example, data from 42 petrochemical complexes in Iran, covering 2015 to 2021, show an increase in equipment effectiveness and reliability over time. However, there was a slight slowdown in 2021 due to the impact of the Covid-19 pandemic. Improvements in maintenance performance, the use of excellence models along with the necessary training have been associated with increased product realization and productivity growth. Research also shows that increased reliability can positively impact the reduction of safety incidents, environmental issues, and overall operating costs. By prioritizing maintenance excellence and adopting best practices, organizations can strengthen their competitiveness and sustainability in a dynamic business landscape.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department reported an increase in the clearance of the bearings and the beginning of failure. After the technical meetings, the study of the process behavior of equipment and technical and repair data, it was decided to take the equipment apart and its internal parts be inspected.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department reported an increase in the clearance of the bearings and the beginning of failure. After the technical meetings, the study of the process behavior of equipment and technical and repair data, it was decided to take the equipment apart and its internal parts be inspected. Observations inside the equipment during its maintenance process and the results of post-repair analyses showed that the RCM, CM, and Failure Mode Effective Analysis (FMEA) applications are of great importance in care and are well suited for timely diagnosis of defect, and can be used by the above tools and experienced technicians to stop and prevent financial, safety and environmental damage.
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
Based on their mission and vision, companies choose different indicators to measure their perform... more Based on their mission and vision, companies choose different indicators to measure their performance. Indicators that are important in the oil, gas, refining and petrochemical industries include safety, health, environment, energy, production, quality, cost, income, exports, stress, risk, maintainability, reliability, availability, replacement cost, commitment, motivation, and profitability. The actual situation assessment and comparison with the target indicators allows identification and analysis and plan the required necessary refining actions. Assessment and control are one of the stages of roadmap for continuous improvement. In this paper 1- Based on key indicators of determining the sensitivity of equipment and their coefficients by Delphi method and the questionnaire and classification of critical equipment in Tabriz petrochemical industry based on it.2- Performing RCM stages on four critical equipment. 3- Looking at maintenance from the perspective of Balance Score Card(BS...
Optimum maintenance of hundreds of thousands of equipment used by each company is one of the main... more Optimum maintenance of hundreds of thousands of equipment used by each company is one of the main challenges of maintenance, operation, and procurement managers. Continuous production and competition in the business environment and resource constraints require that the vital equipment of each company must be controlled, monitored, and considered. To do this, identifying critical and essential equipment is necessary. In this paper, a formula was defined by field surveys and preferences of 75 petrochemical industry experts and managers to determine the equipment sensitivity index. Experts' opinions extracted ten compelling features in determining the sensitivity of the equipment, and the weighting coefficient of each one was obtained by using the group decision-making method, Analytical Hierarchy Process. The introduction of the resistive maintenance index formula represents the capability to use strengths and opportunities and sustainability and resistance against weaknesses and ...
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
In this paper, the effective role of and the relationship between reliability centered maintenanc... more In this paper, the effective role of and the relationship between reliability centered maintenance (RCM) and condition monitoring (CM) techniques (vibration analysis, sound, and oil and failure analysis) are considered in one of the vital petrochemical equipment. Given the critical role of MX-840 extruder in the production of the Tabriz Petrochemical Complex, the machine is a critical machine with a degree A and a sensitivity score of 92 to 100. As a result, the RCM method was applied to the machine and was under the care and condition monitoring. By observing the increase in sound and the first failure symptoms, the weekly monitoring of the equipment was placed on the CM unit agenda. By examining the trend of increasing the wearing index in the oil analysis results, the increase of HDm (High Definition Technology) in the data acquisitions of Shock Pulse technology and also the observation of the failure frequency of one of the gears with the mid-shaft harmonics, the CM department r...
Uploads
Papers by safar shasfand