MANUAL Published: 29 April 2013

Refinery Inspection and Maintenance


Maintenance and inspection functions in a refinery are the backbone for safe and reliable plant operations and play a pivotal role in efficiently achieving the desired production target and profitability for the company. Maintenance functions in the refinery include mechanical, electrical, instrumentation, and civil functions, which are responsible for monitoring, repair, and maintenance of equipment in the respective defined areas. Inspection is responsible for certification of quality adherence on the repair and maintenance activities through monitoring of static equipment functioning during plant operations. Fulfillment of statutory requirements and liaison with regulatory bodies, failure analysis, and remaining life assessment of plant equipment to establish a repair replacement plan in advance for reliable plant operations, metallurgy upgrading, etc., are also performed by inspection. On the basis of the process condition, on-stream monitoring of all critical equipment is decided by an individual group and monitored religiously. Preventive maintenance, predictive maintenance, a structured repair system, and full-fledged plant shut-down management must be reliable. Each type of maintenance activity that needs to be followed in an operating refinery or when the plant or units have been shut down per plan is covered in detail in this chapter. In case of electrical and instrument equipment, emphasis is placed on explaining the maintenance activities required to be performed on all major equipment along with general guidelines to be followed for making systems more reliable. The chapter covers various methods of inspection techniques being followed in a refinery, including the detailed observations to be made with each piece of equipment. The chapter also includes important sample checklists that are used for recording observations while inspecting equipment or when the maintenance activity is being performed.

Author Information

Kosta, A., L.
Indian Oil Corp. Ltd., New Delhi, IN
Kishore, Keshav
Indian Oil Corp. Ltd., Panipat, IN
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Developed by Committee: D02
Pages: 393–435
DOI: 10.1520/MNL5820131212816
ISBN-EB: 978-0-8031-8681-1
ISBN-13: 978-0-8031-7022-3