Designing a Reliability Maintenance Plan for Refinery Plants: A Case Study of a Nigerian-Based Refinery and its Power Systems

Abstract

This study developed a comprehensive and effective reliability maintenance plan for refinery plants. Using a Refinery based in Nigeria as a case study, the research identified key factors affecting the reliability of refinery operations and proposed strategic maintenance measures to enhance operational efficiency and safety. The study utilized reliability centered maintenance (RCM) and failure modes and effect analysis (FMEA). From the evaluation, breaking down the components of the power system in the plant and addressing them individually exposes more vividly the errors in that system. Each failure mode was analyzed in terms of possible consequences on operation, function, or system status. The subject of risk assessment was presented and utilized to develop an approach for implementing the RCM in refinery power systems Finally, a proposed action plan was introduced to reduce the RPN number, thereby increasing the overall reliability and efficiency of the system component. It was observed that by reducing the RPN of each component, the overall efficiency of that component increases saving the company huge maintenance cost.