ZAKUM Asset Business Unit

Future Major Overhauls On Aging

Plants

Prepared By: OPT(ZK)

Date: 13-May-2015

Future Major Overhauls on Aging

Plants

To ensure the integrity of Aging plants, a holistic approach

in Inspection is suggested covering the below Items.

ZAKUM Asset Business Unit

Piping & Piping Accessories

Structure
Control & Instrumentation
Electricals
Static Equipment
Rotating Equipment
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Piping & Piping Accessories:

Example

ZAKUM Asset Business Unit

Component
Pipe & Pipe fittings
Valves
Flange, Elbow,
Tee etc.
Drain/Vent Inst.
Tapings
Piping Support

Type of Failure
Thickness
Reduction
Erosion
Corrosion
Cracks
Welding failure
Thread failure
Improper Fixing
Spring stiffness
loss
Bent Support

Causes of
Failure
Aging
High Vibration
Damage under
Insulation
Handling
corrosive
material
Operating
Condition

Way forward
Joint Inspection
/ Survey to be
carried out
before
shutdown for
complete piping
system
(Maximo failure
class / Codes
can be used as
reference )
Add in the
Shutdown
scope

Structure:
Example

ZAKUM Asset Business Unit

Component

Beam
Channel

Type of Failure

Structural
deformation

Causes of
Failure
Aging
High Vibration

Grating

Corrosion

Overload

Deck Plate

Cracks

Leaking fluids

Angle

Missing fasteners

Way forward
Joint Inspection /
Survey to be
carried out before
shutdown
Add in the
Shutdown scope

Control & Instrumentation:

Example

ZAKUM Asset Business Unit

Component
Instrument
control panels
Loop, Instrument,
Hand switch,
Relay
Telemetry master
control module
UV control panel

Type of Failure

Causes of
Failure

Wire cut / Damage Aging

Fail to function

Improper support

High output

Joint leakage

Overheating

Filter choke

Structural

Fuse failed

deficiency

Way forward
Joint Inspection
/ Survey to be
carried out
before
shutdown.
Add in the
Shutdown
scope

DCS Cabinet

Electricals: Example

ZAKUM Asset Business Unit

Component

Type of Failure

Causes of
Failure

Electrical Cables

Damage

Aging

Battery charger

Earthing

Improper support

Control panel

Short circuit

Loose connection

Breaker

Battery Discharge Protection fault

Junction/Terminal Low output

box

Faulty contacts

Fuse / Switch

Overheating

Distribution

Circuit breaker

board

Fail to function

Way forward
Joint Inspection
/ Survey to be
carried out
before
shutdown.
Add in the
Shutdown
scope

Faulty circuit

Static Equipment:
Example

ZAKUM Asset Business Unit

Component Type of Failure

Shell
Nozzle
Tube

Thickness
Reduction
Crack
Leak

Causes of Failure

Way forward

Joint Inspection /
Survey to be
Material Specification
carried out before
shutdown.
Covered under
Aging

Insulation

Add in the
Shutdown scope

Rotating Equipment:
Example

ZAKUM Asset Business Unit

Component

Type of Failure Causes of Failure

Way forward

Mechanical Seal Low output

Joint Inspection /
Survey to be
Lack of Lubrication carried out before
Abnormal
shutdown.
operation
Add in the
condition
Shutdown scope
Fluid handle

Casing

Flush system leak

Bearing

Cease

Bush

Crack

Shaft

Leak

Coupling

Fail to function
DCS

High Vibration

ZAKUM Asset Business Unit

Thank You

ZAKUM Asset Business Unit

Maximo Support- e.g.

Piping

Causes of
Failure

Failure Class

Failure Problems

Pipe,testheader
Pipe,wirelineriser
Piping,alloys
Piping,steel
Piping,polymer,rei
nforced
Pipe,productionhe
ader
Pipe,line
Pipe,riser
Pipe,subsea
Pipe,stillingtube
Corrosion,(pipe)line

Abnormalinstrument Contamination,
reading
waxing
Breakdown
Externalleakagepro
cessmedium
Overheating
Failuremodenotcov
eredabove
Plugged-choked
Structuraldeficiency
Unknown
Highvibration
Materialrequest
Automation(DCS)

Remedies
Cancelledjob
Degraded-itema
djusted
Degraded-itemc
hangedout
Degraded-furthe
rworkrequired
Degraded-itemr
estored-repairer
Failed-itemadju
sted
Filterreplaced
Failed-furtherw
orkrequired
Failed-itemresto
red-repair
Taskcompleted-
nofaultsfound

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