COST OF INSTALLATION AND MAINTENANCE

Roberson (2005) commented on any means of reducing the cost of installation and maintenance while making the best use of skilled labour can produce a competitive advantage..The cost of fines, suspended operations,can far out weights the cost of a leak tubing system and continued by stating that,effective preventive maintenance must be employed on all equipment concerned with emission  controls,including monitoring and compliance of vapour recovery unit (VRU).
He continued that for the environmental reasons, It is essential that vapour recovering equipment be maintained at its optimum performance, and any process equipment as VRU needs regular attention to ensure levels, temperature and flow rates are within normal ranges, Usually a planned  maintenance system is implemented covering details inspections and checks at three,six and twelve months intervals together with daily checks on performance by the operators.

LIMITATION

There were constrains in countered in the process of proper implementation of optimization of maintenance in the oil and gas producing industry and other company. viz:

In the optimization of maintenance cost,effects were observed by non proactive planning and sequence of logistics.
The cost of operation also affected the optimization of maintenance through community integration and environmental quality standard.
The optimization cost was inhibited by lack of orientation and learning and impractical incentive proposition.
The accuracy of the optimization depends on the materials,cost of implementation,instrumentation,but the organizational management was affected by of tooling and incessant delays.
There were limitation to discussions on finding of some inconsequential profiling and testing, which were performed outside the environment.

JUSTIFICATION AND SIGNIFICANCE

To establish a competitive edge and to provide a good customer service.companies must have reliable equipment that respond to customer demand when needed. Equipment must kept reliable without costly work, stoppage and repair, if a company is to remain productive and competitive.
Maintenance is an important factor in quality,which is another basis for successful competition. Inconsistency in equipment leads to variability in products and defective parts that fail to meet the established specification. Beyond just preventive breakdowns,companies must keep equipment operating within specifications that will produce a high level of quality (Milowitz and Madanat,2000),
Most highly trained maintenance workers are required, and the cost of replacement is higher. Poor care of equipment and facility can be very expensive.It allows large investment to deteriorate and  breakdown, To reduce the return that could be earned on the investments.Many challenges make sound maintenance management important to competitive, productive operations.

MONITORING SYSTEM

The plant monitoring system is one common factor that exist in maintenance operations and performance. Jari (2002), emphasised that the maintenance includes various condition and health monitoring systems that monitor both individual field equipment and entire processes,
The method vary with the target to be monitored,condition monitoring system for rotating machines can be used as good early time warning system, for example, a fault in the bearing may cause a malfunction in the turbine.
The comprehensive measurement can be used to monitor turbine and other rotating gas compressors and observe for leakages in areas such as the sumps,bearing and mechanical seals and captured in advance.The integration of data provided by different methods into a power plant information system creates the best possible information foundation for the optimization of plant wide maintenance operations.it will mean that the information supplied must have strong understanding of the power components processes..
Recent experience suggest that nearly all plant encounter irregularities in either their main or sub process machinery.Measurement data ca be used to initiate regulatory actions quickly in the right places and to ensure that operation starts up as planned..

THE OPTIMIZATION MODEL.

The optimization model optimize for a single metric, namely cost,the greater the mean time between maintenance (MTBM) for a given asset,the less the preventive maintenance is being done.Hence the lower the preventive maintenance at same time,the greater the MTBM,the greater the probability of failure,and thus the greater the maintenance repair and replaced cost (Berger,2005).
Berger(2005),illustrates that optimization on the basis of reliability or availability might show that an alternative policy is superior, which might be compared with difference condition based maintenance (CBM) policies that differ in terms of mean time between maintenance.
the condition based maintenance may differ in terms of conditions that trigger a maintenance type(minor versus major) and at which stage of deterioration.Thus a good maintenance program compares policies, from single - runt failure to online continue condition based maintenance, all in the multiple matrices,more sophisticated modeling tools allow progressive outlays of greater and greater functionality, which continuously improves the optimal solutions.The user should be able to:
      - Experiment with effect on several key metrics of changing the maintenance of a given component, equipment, line facility or line of business.
      - Determine the post and benefit of outsourcing one or more maintenance tasks.
      - Understand the trade of in adding hand held or online condition monitoring devices.
      - Determine the effect of changing the maintenance technician skill level.
      - See the effect of giving policy on product quality(damaged or lost items) at different degradation levels.
       -Perform sensitivity analysis to understand the effect of adjustment of various variables, so that strategic trade-offs can be understood.


  

LITERATURE REVIEW.

Several research work have been conducted to enhance the reliability of maintenance and good performance of plants in the companies, industries, and other production facilities.Some service companies such as airline,production, manufacturing, maintenance experts and many other parastatal  such as petrochemical industry,  oil refinery and production have very high investment in equipment that is vital both for safety and success of the business.Dependability of service is one of the four performance measures by which a company can distinguished itself.
(Robbert,1993) highlights that many manufacturing companies particularly those with just in time inventory or programme (JIT), are operating inventory so low as to offer no protection in the invent of a lenghty equipment failure beyond the cost of idle  equipment, and lost sales that can result from a breakdown. There is a of permanently market shear to a company that are more reliable therefore, It is very important that companies should work very diligently to prevent breakdown.

BACKGROUND OF THE STUDY.

It is important that organization properly map their path to maintenance optimisation or they find themselves inversed in a data, lacking information and direction and find themselves returning to the old maintenance strategy..The project describes a process which may be used to identify the existing resources and to specify advance technology necessary to implement an integrated optimisation of maintenance cost in producing oil and gas company.
The successful implementation of optimisation cost coupled with systematic process change will enable organization to optimise their maintenance programs. The success of this optimisation will lead to reduce maintenance cost and operational outages (Augustine,2003). In today competitive global business climate industries and enterprises are under increasing pressure to reduce cost in order to meet tougher performance and production goals with maximum return on asset investment.
unplanned equipment down time greatly affect the earning of any enterprises and must be minimised, risk should also be minimised as well as the cost of keeping those risks low. Asset maintenance is a significant cost factors for companies to improve and maintain the availability during the asset life cycle. Maintenance is a key factor in succeeding in asset management (BQR,2007).
Asset management is an expert system for maintenance optimisation which allow manufacturer service provider and maintenance repair and overhaul (MRO) organisation to scientifically analyses, improve and optimise all relevant aspect of maintenance strategies.
These strategies involved planning and execution of the following factors:
- Repair or discard
-Corrective, Preventive, and Predictive Maintenance.
-Spare Part Allocation and Procurements
-Support and Test Equipment
-Tools and Materials.
 

MAINTENANCE RESPONSIBILITY.

It is obvious and important that responsibilities assigned to the maintenance department be clearly defined and that the limits of authority and responsibility be established on all concerned.
Maintenance is to ensure installed equipment remains fit for purpose throughout the designed life. It provides maximum overall availability without on hygiene, safety and environment. And it also enhance cost effective operations, optimum use of manpower with less fatigue and more output. It provides means of adequate work preparation, appropriate tools procedures, professionalism and good state of mind. Maintenance is divided into various categories, but the basic concept are:
1.Preventive and 2.Corrective. The preventive maintenance concepts is conducted to reduce either the  probability of failure of an item on the deterioration of a required function. While the corrective maintenance concept are performed after a complete failure had occurred. Others are schedule or periodic, predictive, involving predetermined interval of time, number of operational mileage.

INTRODUCTION: PLANT MAINTENANCE OPTIMIZATION

    Maintenance optimisation is a process that attempts to balance the maintenance requirement (Legislative, Economic, and Technical) etc.and the resources used to carryout the maintenance programme.(peoples,spares,consumptions,equipment; etc.).The goal of the maintenance optimisation is to select the appropriate maintenance technique for each piece of equipment within a system and identifying the periodicity that the maintenance technique should be conducted to achieved availability and cost.(Digiovanni,2003). It is obvious that when maintenance is effectively implemented it will, i)Improve  system availability, ii) Reduce operation maintenance cost iii),Improve equipment reliability and system safety.
The maintenance optimization process will effectively blend predictive,proactive and, corrective maintenance strategies often through the use of reliability centred maintenance techniques. This will allow system maintenance to move from a reactive approach or preventive approach to a planned approach..The planned approach conducts maintenance at the most optimum time, which is often before the equipment fails. Optimising maintenance often seems to be a catchall for many odd activities that no other single department can or wants to handled, but care must be taken not to dilute the primary responsibilities of maintenance with the secondary services. Maintenance must be carefully tailored to suite existing technical, geographical and personnel situations. Basic organizational rules due exist, however, there are some general rules covering specific conditions that govern how the maintenance department is to be structured. It is usually essential that some recognised, formally established relationship exist to layout firm lines of authority and responsibility, Such an organization laced with universal truths, trimmed to fit local structures, and staff with people who interact positively and with a strong spirit of cooperation is the one, which is mostly to succeed, such is the case that exist in most of the professional organization, where the maintenance department is taken as an adhoc implementation and planning department of the organisation or company..  

CORROSION FORMS AND DEF.ECTS.

The research  in prevention of anti corrosion in maintenance and control of industrial facility, Robert et al, discussed on different types of corrosion and emphasied, that a uniform corrosion is characterised by a literally constant speed of corrosion. typical examples are given by the atmospheric corrosion of galvanised steels - the thicker the zinc coating, the longer the service life or the chalking of paint, which are degraded uniformly by radioactive oxidation in air.Erosion corrosion, uniform corrosion may proceed faster when there is a flow. the flow rate velocity will locally reach high value if turbulent situation occurs, which will prevent the formulation of protective layer on the metals. Abrasive practice in a stream of gas or liquid may mechanically distrupt  the protective surface film and thus enhance corrosion often in a non uniform, localized way.
cavitation  corrosion implies formulation and collapse of tiny gas bundle in a liquid stream, which implies that it can mechanically destroy any protective layer, causing localized corrosion, erosion and cavitation corrosion are control by proper design selection of materials and may help in special case. Galvanic  corrosion often occurs when two different materials are in contact etc. 

CORROSION CAUSES CAN BE CONTROL AND ENVIRONMENTAL SAFETY ENHANCED,

It is obvious  that most corrosion causes can be control, the environmental  safety enhanced and quality improved by means of control measures ,and analysis of factors through dissemination of knowledge, and use of monitoring temperature techniques. A model of interconnection of all groups in the oil and gas production industry with the aim of diminish corrosion risk. Recall that anti corrosion management policy,and quality includes design, manufacture, improvement and control at all stage.

HUMAN FACTORS IN CORROSI0N FAILURES

The human factor is one of the main reason for corrosion failures, anti- corrosion management must be designed in such a manner that human potentials are improved for performance and correct decision. Example of wrong application and use of corrosion prevention measures, such as control of inhibition types and concentration, alloy, coat and technological regime. Insufficient and sometimes  inadequate corrosion monitoring methods may result to ineffective method of controlling corrosion. Ecological impact is one of the indirect cause of corrosion on the environment,because of expensive chemicals, a contamination of technological streams by corrosion product.
less of efficiency, overdesign and shutdown, the corrosion risk is related to environmental pollution by hazardous chemical, fuel and gases, resulting to impossible fire and explosion, damage to people, animal, plant, air, soil and water the causes  of corrosion damage of over-ground storage tank,pipes, heat exchangers, and  other  equipment as well other preventive are analysed.                                                                                           

THE PROBLEM STATEMENT

Many corrosion problems have occured with related process change within the several years of the existence of the oil and gas and refining industry. It is obvious that many corrosion damages or work occured at some of the oil facility, In some oil operating company, corrosion  affects most of their operating facility, and several professional are also provided maintenance work for the upkeep and treatment of the plants. The effluent water and oil/gas are tested for its constituent and are treatment for the best production outcome. The water injection booster pump in one of the oil operating company was inspected by some experts from some of the institutions,which conducted the following case study on water injection unit. Also there are many corrosion experts, and chemical analyst, corrosion magazine, and conferences that are held yearly to eliminate the effect of corrosion and its related damages. A lot of company, manufacture of difference materials and equipment for corrosion control and monitoring had discussed and presented several instructions of this epidemic called corrosion but  the impact of corrosion still persist inspite of numerous trials. It remain one of the main danger to the oil and gas refining and production industry and other operating facility. The main purpose of this work is to conduct the survey of the corrosion situation in the oil and gas industry during the past four years to quantify or estimate cost of corrosion, to define the reason of corrosion  problems and to find the effective measures to solve them, a result to improve their reliability, availability, and the profitability in the oil and gas,  production and manufacturing industry. Every industry and their plant has difference distribution and propagation of corrosion phenomena  that occurs at different interval and frequency, For example distribution of corrosion damages, that occur during the four years and the solution of their preventative measures and methodology. About 75% of all the corrosion failures occurs because of insufficient information and knowledge, as well as adequate interpretation among difference groups responsible for the  acceptance and approval of anti-corrosion discussion.

COATING - 3

In case of fire-stops,a melting burning plastic pipe must be squeezed together and shut so that there would be no opening for fire to propagate to an otherwise rated wall or floor assembly while the intumescent application is used to achieve passive fire protection for such application as fire stopping,proofing,gasketing,and window casing.But it is important to note that some intumescent are substable to environmental influences such as humanity which reduce or negate their ability to function.protection casing also has some method of evaluating the life prediction of coating and their ability to predict service life real environment and are discussed in the contest of degradation process of coating systems. other experimentation that are conducted to determined the following includes:
1.The ingress of reactants into the steel and coating surface.
2,Accelerated test for performance evaluation ASTM B117 standard practice for operating salt    spray(fog) apparatus.ISO 7253,Testing standard ASTM B117-1939 and B117-1997.
3.Accelerated test for performance evaluation ASTM. G85,standard practice for modified salt spray(fog), testing which includes the following:
-Continuous acetic and acid salt spray test
-Cyclic acidified salt spray test.
-Cyclic sea water acidified test.
-Cyclic So2 salt spray test.
-Dilute electrolyte cyclic fog dry test.
The last item of the modification,the dilute electrolyte cyclic fog dry test was reported to give best correlation without door exposure test and uses a much diluted electrolyte (0-0.5%sodium chloride)
with small amount (0.35%)of ammonium sulphate to represent industrial atmosphere.The test cycle alternate between one hour of fog and one hour of dry off and in each fog drying cycle the fog will gradually increased thus exposing the samples to a water range of salt concentration ASTM D9894 - 96 practice for cyclic salt fog/uv exposure of painted metal.

COMMON USE OF INDUSTRIAL COATING

The most common use of industrial coating is for corrosion control of steel structure such as offshore platforms bridges and underground pipelines.The function of coating industries includes intumescent coating for fire resistance,and polymer which are also used in industrial structure such as polyurethane,epoxy and moisture cure urethane, and fluoropolymer.The process of coating also consist of the following inorganic zinc,phosphate, xylan and PVD coating.Coating also exist in two different types such as soft and hard char being produced with sodium silicates and graphite.And the product are suitable for use in plastic pipe fire-stops as well as exterior fire proofing and structure steel such as in fire-stops pillows and it has low expansion pressure.

RISK ASSOCIATED WITH HUMAN HEALTH TOXICITY ASSESSMENT.-2

Human health benchmark for chronic oral and inhalation exposures were needed to conduct risk assessment characteristics. This section represents the one cancer and cancer benchmark based to evaluate human health effects,that may result to exposure to consistent modeled risk assessment.Human health benchmarks and their sources are discussed.etc

RISK ASSOCIATED WITH HUMAN HEALTH TOXICITY ASSESSMENT

The risk associated to human exposure to the constituent of chemical toxicity information to each chemical stored in the facility or in our operational base,or being used for operations is integrated with the result of the exposure assessment interval.Its ability to cause adverse health effect depends on the toxicity of the chemical.The route of exposure to an individual( either through digestion or inhalation),the duration or extent of exposure,and the dosage(the amount that a human ingests or inhales).The toxicity of a constituent is defined by human health medical analysis  for each route of exposure  and is referred to as the risk assessment.Imperatively medical analysis is a quantitative data,valued on categorization of the medical data analysis and derived from data based on animal  studies or human epidemiological strives.A dose response estimate of adverse health effect to exposure dose are commonly represented by benchmarks. This is because individual chemical causes different heath effects at different doses and the chemical is the benchmark.For further details consult NACE International.

ABSTRACT ON INDUSTRIAL COATING.

Coating work is usually conducted in various areas of the industry periodically to eliminate the formation of oxide on a metallic,and nonmetallic surfaces. The terrain in which such work can be performed include the following activities , industrial flow process ,drilling operation, flowstation,manufacturing industry,and flowlines,machine component and other operating facility.And to eliminate these corrosive or oxides,an industrial coating operation is normally conducted periodically, and the formation of corrosion or oxide on the surface of the pipe emanates through the reaction of oxygen,and moisture.  There are experimental examination that are conducted to determined the extent or integrity of the effect which will enable the specialist company or organization to apply the media or methods of  the composition suitable for the effected surface.
.Although corrosion prevention  coating is  performed to improve the operational life cycle of engineering materials, and there are various steps that are employed in the  application which differs from one location to the other.