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Frontiers of Engineering Management

ISSN 2095-7513

ISSN 2096-0255(Online)

CN 10-1205/N

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Front. Eng    2017, Vol. 4 Issue (2) : 111-126    https://doi.org/10.15302/J-FEM-2017027
RESEARCH ARTICLE
Development and application of an off-site maintenance system in the petrochemical industry
Ruisheng YONG1, Yanbing YE2, Hanbin LUO2(), Lieyun DING2
1. Guangxi Petrochemical of China Petroleum, Qinzhou 535000, China
2. School of Civil Engineering and Mechanics, Huazhong University of Science and Technology, Wuhan 430074, China
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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     
Corresponding Author(s): Hanbin LUO   
Online First Date: 27 June 2017    Issue Date: 17 July 2017
 Cite this article:   
Ruisheng YONG,Yanbing YE,Hanbin LUO, et al. Development and application of an off-site maintenance system in the petrochemical industry[J]. Front. Eng, 2017, 4(2): 111-126.
 URL:  
https://academic.hep.com.cn/fem/EN/10.15302/J-FEM-2017027
https://academic.hep.com.cn/fem/EN/Y2017/V4/I2/111
Fig.1  A typical ONSM process
ItemsOn-site operationOff-site operationBenefits description
Work environmentOn-site, field operationOff-site, workshop operationControllable work environment
Influence of external factorsAffected significantly by external factorsAffected slightly by external factorsImprovement of maintenance quality
High-risk operationMore operation types and workloadLess operation types and workloadReduction of risk
On-site durationLongShortReduction of exposure to hazards
ImplementationMulti-point operation, multi-task interfaceStandardized operationsBetter safety management
Tab.1  Comparative analysis between ONSM and OFSM (Moghadam et al., 2012; Ikuma et al., 2011; Maas and van Eekelen (2004); Jaillon and Poon, 2009; Gibb and Isack, 2003; Rodriguez et al., 2009; Wong et al., 2010)
Fig.2  Flow chart of OFSM model
Fig.3  Information requirements for OFSM
Fig.4  The application model of AVEVA solutions for OFSM
Fig.5  The conceptual framework of applying off-site maintenance system
CapabilitiesDescription
Visualizationl Provide a virtual environment of plant/equipment similar to the real world
l Facilitate the understanding of information that are attached to the corresponding equipment components
l Facilitate identification of dismantling and reinstallation sequences
Information managementl Facilitate information communication among all relevant disciplines
l Provide complete, accurate, and accessible information for maintenance operators
Localizationl Enable accurate identification of maintenance object and fast capture and retrieval of related information
l Facilitate reinstallation operation with spatial coordinates localization
Tab.2  Capabilities of off-site maintenance system
Fig.6  The architecture of off-site maintenance system
Fig.7  Information management module configuration
ObjectAttributeObjectAttribute
EquipmentNameMaintenanceFactory date
RecordsEquipment category
Equipment ID
Size, length, depth
Material, medium
Temperature, pressure		RecordsService life
Warranty period
Maintenance date
Duration
Maintenance cycle
Maintenance team,
Maintenance works
DocumentsOperating procedures
Inspection criteria
Laws and Regulations
Original as-built files
Accident reports
Lesson records		Risk recordsRisk factors
Risk types
Failure causes
Risk level
Risk control measures
Inventory recordsManufacturer/Vendor
Contact
Stock account
Tab.3  Classification of equipment information
Fig.8  Statistical analysis and maintenance warning
Fig.9  Digital data interface of off-site maintenance system
Fig.10  Visualized maintenance control information
Fig.11  Maintenance procedure direction
Fig.12  Visualized safety training and dismantling simulation
Risk factorRisk typeRisk assessmentRisk level
LECLEC
Volatilization of oil and gasFire8552004
Flammable and explosive mediumFire, explosion33151353
Toxic medium leakPoisoning11771
Disorderly toolsObject strikes7531053
Improper personnel positioningMedium splash damage642482
Tab.4  Risk assessment on the ONSM of oil-loading facility
Risk factorRisk typeRisk assessmentRisk level
LECLEC
TransportationVehicle accidents433362
LiftingCrane accident345602
Tab.5  Risk assessment on the OFSM of oil-loading facility
LEC valueRisk levelRisk description
>3205Extremely risky, need to shut down
160-3204Highly risky, need to immediately rectify
70-1603Significantly risky, need to take some measures
20-702Generally risky, need to pay attention
<201Slightly risky, can be accepted
Tab.6  Risk classification criteria
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