Asset maintenance optimisation approaches in the chemical and process industries – A review

Several plants in Brazil have mature assets or use equipment that comes from decommissioned facilities. In addition, the culture of process safety in Brazil is an under‐researched topic that has only recently begun to attract corporate attention. Since catastrophic accidents are not very common, any accident related to the process can result in very large losses in terms of damage to equipment and loss of human and social capital. In mature process plants, these issues are even more sensitive because their organization may not yet have developed an effective integrity management program. Nevertheless, it is a proven fact that the assets of these plants are often nearing the end of their residual lifetime. Therefore, the present work aims to develop a high‐level checklist to evaluate the mechanical integrity and identify possible failures in the integrity management of vessels and tanks, based in good engineering practices, Regulatory Standard 13 (NR 13), API 579‐1/ASME FFS‐1, API RP 580, API RP 581, HSE (Health and Safety Executive) requirements, and other relevant standards as references. The checklist ts divided into six sections, namely (1) Brazilian Regulatory Standard 13 (NR 13); (2) Design and manufacturing; (3) Operation; (4) Management systems; (5) Deterioration mechanism; and (6) Risk‐based inspection, as the most relevant criteria for evaluating the integrity of mature pressure vessels and tanks.

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“…This provides valuable insight into the effectiveness of the system, allowing for further development and optimization. 25…”

Section: Management Systemmentioning

confidence: 99%

Asset integrity management in mature process plants

Matheus

Correia

Morais

et al. 2023

Process Safety Progress

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“…In order to maintain safe operation of high-pressure pipelines, appropriate maintenance optimisation strategies are required to maximise reliability. A number of such studies can be found in open literature (see for example Castanier and Rausand, 2006;Gong and Zhou, 2018;Chin et al, 2020). As part of future work, a combined approach involving pipeline maintenance optimisation strategies and the current ESDV multi-objective optimisation model would be extremely useful.…”

Section: Multi-objective Optimisation Studymentioning

confidence: 99%

Optimal emergency shutdown valve configuration for pressurised pipelines

Mahgerefteh

2022

Process Safety and Environmental Protection

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Pressurised pipelines are the primary mode of choice for transporting large quantities of hazardous fluids across the globe. The failure of such pipelines can lead to the release of significant amounts of flammable or toxic inventories, which may in turn present significant risks to life, environment and property. In order to mitigate such risks, various types of emergency shutdown valves (ESDVs), including Check Valves (CVs), Automatic Shut-off Valves (ASVs) and Remote Control Valves (RCVs), are installed along such pipelines as the front-line emergency mitigation tool.Accounting for the critically important ensuing in-pipe transient fluid flow, this thesis presents the development and application of a multi-objective optimisation study for selecting the ESDV type, number and spacing as well as its combinations and operational settings for striking a balance between the minimum valve capital cost against the efficacy in minimising and ultimately isolating outflow following pipeline failures.To my parents and brother: Thank you for your never-ending support and motivation.

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“…Another potential benefit of using modular and parallel units is to enhance process reliability which indicates the probability of a system to perform its designated function over a specified time interval. While this topic is beyond the scope of the current paper, we refer the readers to the recent works 53,54 for more information.…”

Section: Operability and Control Challenges In Intensified And Modulamentioning

confidence: 99%

Operability and control in process intensification and modular design: Challenges and opportunities

2021

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In this article, the importance of considering operability and control criteria in the analysis and design of intensified and modular processes is discussed. We first analyze the impact on operability of key factors including: (i) degrees of freedom, (ii) process constraints, (iii) numbering up vs. scaling up, and (iv) dynamic/periodic operation. Comparative examples are presented to showcase the pros and cons in intensified/modular systems vs. their conventional counterparts from operability and control aspects. Then we look into metrics and tools to address these challenges such as: (i) flexibility analysis, (ii) operability‐based design, and (iii) advanced model‐based control. Considering different conceptual design stages as synthesis intensification, steady‐state design, and dynamic operational optimization, we highlight the need to incorporate different levels of operability considerations. Future research opportunities and perspectives are also identified, particularly emphasizing the importance of a holistic strategy for integrated design, operability, and control of intensified and modular process systems.

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Asset maintenance optimisation approaches in the chemical and process industries – A review

Abstract: Graphical abstract

Cited by 31 publications

References 186 publications

Asset integrity management in mature process plants

Asset integrity management in mature process plants

Optimal emergency shutdown valve configuration for pressurised pipelines

Operability and control in process intensification and modular design: Challenges and opportunities

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