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Optimizing Maintenance of Heat Transfer Equipment in Petroleum Industry

This presentation by Salamah S. Al-Anizi, an engineering consultant at Saudi Aramco, delves into the maintenance of heat transfer equipment crucial for the petroleum and gas sectors. It covers the objectives of equipment maintenance, frequency considerations, inspection procedures, process types, contractor qualifications, and insightful case studies. Through examples like water tube boilers, reaction furnace shell failures, and sulfur condensers, the importance of proper maintenance practices to ensure equipment integrity, operational continuity, and plant personnel safety becomes evident. The conclusion emphasizes the significance of adequate knowledge, adherence to maintenance frequencies, rigorous inspection and testing, and skilled personnel handling.

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Optimizing Maintenance of Heat Transfer Equipment in Petroleum Industry

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  1. MAINTENANCE Of Heat Transfer Equipment In The Petroleum Industry Presented by : SALAMAH S. AL-ANIZIEngineering Consultant Saudi Aramco

  2. More than 40,000 (forty thousands) tons of heat transfer equipment is manufactured annually for the petroleum and gas industries.

  3. Objective of equipment maintenance Maintenance frequency Inspection and Testing Process types and operational practices Maintenance contractor qualification Case studies Conclusion Outline

  4. Equipment integrity Operation Continuity Plant personnel safety Plant revenues Objective of equipment maintenance

  5. Heat transfer equipment have different maximum maintenance frequencies. Frequencies are based on heat intensity, process type, and equipment reliability. Maintenance Frequency

  6. Inspection prior to maintenance. Inspection records. Inspection log. External Inspection. Internal Inspection. Pressure testing. Inspection and Testing

  7. Process type and operational practices • Equipment handles different types of processes. • Erosion, Corrosion, and fouling. • Normal Operation and abnormalities. • Equipment design limits. • Recommend maintenance friendly design.

  8. Maintenance Contractor Qualification • Repair Certification “R” Stamp per NIBC • Experience. • Good reference list. • Reliability. • Warranty.

  9. Case Studies • Water tube boiler. • Short term overheating. • Insufficient circulation design. • Design Modification of steam drum internals. • Repeat same modification to similar boilers.

  10. Case Studies (cont’d) Reaction Furnace Shell Failure. • Wrong Refractory Design. • Sulfur Dew Condensation behind Refractory. • Complete repair of the Furnace Shell Bottom. • Qualified Contractor for the job.

  11. Case Studies (cont’d) • Sulfur Condenser. • Wrong Shutdown Lay up Procedure. • Sulfuric Acid Formation. • Tube Corrosion. • Complete Retubing of 1654 tubes. • Qualified Contractor for the job.

  12. Case Studies (cont’d) • Burn Pit. • Inadequate Refractory Structure. • Premature Failure. • Structure Redesign.

  13. Conclusion Maintenance of heat transfer equipment requires: • Adequate knowledge of the equipment. • Maximum set forth frequency • Proper Inspection and Testing • Handling by qualified personnel.

  14. THANKS

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