Skip to Main Content
Skip Nav Destination
ASTM Manuals
Petroleum Refining and Natural Gas Processing
By
M. R. Riazi
M. R. Riazi
Editor
1
Professor
of Chemical Engineering at
Kuwait University
, and
consultant
and invited
speaker
to more than 50 oil companies and research institutions in Canada, the U.S., Europe, India, China, Malaysia, Australia, the Middle East and North Africa, including invited
speaker
to the
World Economic Forum
,
author/co-author
of more than 100 publications, including three books mainly in the areas of petroleum and chemical technology, founding and
Editor-in-Chief
of
IJOGC
and an
associate editor
of some other international journals, member of
AIChE
and the
Research Society of North America
Search for other works by this author on:
Semih Eser
Semih Eser
Editor
2
Professor
of Energy and Geo-Environmental Engineering at
Penn State University
, and teaches courses on petroleum refining and energy engineering at
John and Willie Department of Energy and Mineral Engineering
and directs the Carbon Materials Program at the
EMS Energy Institute
at
Penn
State
Search for other works by this author on:
Suresh S. Agrawal
Suresh S. Agrawal
Editor
3
Founder and president
of
Offsite Management Systems LLC
and a Bachelors Degree in Chemical Engineering from
Indian Institute of Technology (I.I.T.)
,
Mumbai,
IN
.
Search for other works by this author on:
José Luis Peña Díez
José Luis Peña Díez
Editor
4
Consultant
at the
Technology Center at Repsol
in
Madrid,
ES
, and
part-time associate professor
in chemical engineering at the
Rey Juan Carlos University
of
Madrid
, and
author
of forty technical articles and presentations at international conferences in the fields of petroleum fluids characterization, process engineering and control, and process simulation
Search for other works by this author on:
ISBN:
978-0-8031-7022-3
No. of Pages:
828
Publisher:
ASTM International
Publication date:
2013

This chapter outlines recent efforts to perform Monte Carlo simulation to obtain an assessment of the effect of existing corrective and preventive maintenance practices incorporating details of available labor, task assignment rules, and parts inventory on the plant economics. In addition, the use of a genetic algorithm in conjunction with the Monte Carlo simulation to obtain the economically optimal preventive maintenance frequency, the parts inventory policy (number and type of spare parts to keep in stock), and the labor allocation is presented. The performance of the algorithm is illustrated using the data of a fluid catalytic cracking plant.

1.
Tan
,
J.S.
, and
Kramer
,
M.A.
, “
A General Framework For Preventive Maintenance Optimization in Chemical Process Operations
,”
Comput. Chem. Eng.
, Vol.
21
,
1997
, pp. 1451–1469.
2.
Dhillon
,
B.S.
,
Engineering Maintenance
,
CRC Press
,
Boca Raton, FL
,
2002
.
3.
Murthy
,
D.N.P
,
Atrens
,
A.
, and
Eccleston
,
J.A.
, “
Strategic Maintenance Management
,”
J. Qual. Mainten. Eng.
, Vol.
8
,
2002
, pp. 287–305.
4.
Christofides
,
P.D.
,
Davis
,
J.F.
,
El-Farra
,
N.H.
,
Clark
,
D.
,
Harris
,
K.D.
, and
Gipson
,
J.N.
, “
Smart Plant Operations: Vision, Progress and Challenges
,”
AIChE J.
, Vol.
53
,
2007
, pp. 654–668.
5.
Humphrey
,
J.L.
,
Seibert
,
A.F.
,
Lewis
,
J.C.
, and
Farone
,
J.P.
, “
Smart Manufacturing Plants: Advances and Priorities
,” presented at the
AIChE Annual Meeting
, November 18,
2008
,
Philadelphia, PA
.
6.
Mobley
,
R.K.
, and
Higgins
L.R.
,
Maintenance Engineering Handbook
,
McGraw-Hill
,
New York
,
2002
.
7.
Gopalakrishnan
,
M.
,
Ahire
,
S.L.
, and
Miller
,
D.M.
, “
Maximizing the Effectiveness of a Preventive Maintenance System: An Adaptive Modeling Approach
,”
Manage. Sci.
, Vol.
43
,
1997
, pp. 827–840.
8.
Smith
,
A.M.
, and
Hinchcliffe
,
G.R.
,
RCM Gateway to World Class Maintenance
,
Elsevier
:
New York
,
2004
.
9.
Ahire
,
S.
,
Greenwood
G.
,
Gupta
,
A.
, and
Terwilliger
,
M.
, “
Workforce-Constrained Preventive Maintenance Scheduling Using Evolution Strategies
,”
Decision Sci.
, Vol.
31
,
2000
, pp. 833–858.
10.
Yao
,
X.
,
Fernández-Gaucherand
,
E.
,
Fu
,
M.C.
, and
Marcus
,
S.I.
, “
Optimal Preventive Maintenance Scheduling in Semiconductor Manufacturing
,”
IEEE Trans. Semicond. Manuf.
, Vol.
17
,
2004
, pp. 345–356.
11.
Nguyen
,
D.Q.
,
Brammer
,
C.
, and
Bagajewicz
,
M.
, “
New Tool for the Evaluation of the Scheduling of Preventive Maintenance for Chemical Process Plants
,”
Ind. Eng. Chem. Res.
, Vol.
47
,
2008
, pp. 1910–1924.
12.
Bagajewicz
,
M.
,
Smart Process Plants
,
McGraw Hill
,
New York
,
2009
.
13.
Wang
,
H.
, and
Pham
,
H.
, “
Optimal Age-Dependent Preventive Maintenance Policies with Imperfect Maintenance
,”
Int. J. Reliability Quality Safety Eng.
, Vol.
3
,
1996
, pp. 119–135.
14.
Wang
,
H.
, “
A Survey of Maintenance Policies of Deteriorating Systems
,”
Eur. J. Oper. Res.
, Vol.
139
,
2002
, pp. 469–489.
15.
Nguyen
,
T.
,
Quang
,
D.
, and
Bagajewicz
,
M.
, “
Optimization of Preventive Maintenance in Chemical Process Plants
,”
Ind. Eng. Chem. Res.
, Vol.
49
,
2010
, pp. 4329–4339.
16.
Center for Chemical Process Safety,
Guidelines for Process Equipment Reliability Data with Data Tables
,
AIChE
,
New York
,
1989
.
17.
Tischuk
,
J.L.
,
The Application of Risk Based Approaches to Inspection Planning
,
Tischuk Enterprises (UK), Ltd.
,
Aberdeen, United Kingdom
,
2002
.
18.
Ricker
,
N.L.
, and
Lee
,
J.H.
, “
Nonlinear Modeling and State Estimation for the Tennessee Eastman Challenge Process
,”
Comput. Chem. Eng.
, Vol.
19
,
1995
, pp. 983–1005.
19.
Wang
,
H.
, and
Pham
,
H.
,
Reliability and Optimal Maintenance
, Springer Series in Reliability Engineering,
Springer-Verlag
,
London, United Kingdom
,
2006
.
20.
Garg
,
A.
, and
Deshmukh
,
S.G.
, “
Maintenance Management: Literature Review and Directions
,”
J. Qual. Mainten. Eng.
, Vol.
12
,
2006
, pp. 205–238.
21.
Savic
,
D.A.
,
Walters
,
G.A.
, and
Knezevic
,
J.
, “
Optimal Opportunistic Maintenance Policy Using Genetic Algorithms, 1: Formulation
,”
J. Qual. Mainten. Eng.
, Vol.
1
,
1995
, pp. 34–49.
22.
Sarker
,
R.
, and
Haque
,
A.
, “
Optimization of Maintenance and Spare Provisioning Policy Using Simulation
,”
Appl. Mathem. Model.
, Vol.
24
,
2000
, pp. 751–760.
23.
Marseguerra
,
M.
, and
Zio
,
E.
, “
Optimizing Maintenance and Repair Policies via a Combination of Genetic Algorithms and Monte Carlo Simulation
,”
Reliability Eng. Syst. Safety
, Vol.
68
,
2000
, pp. 69–83.
24.
Marseguerra
,
M.
,
Zio
,
E.
, and
Podofillini
,
L.
, “
Condition-Based Maintenance Optimization by Means of Genetic Algorithms and Monte Carlo Simulation
,”
Reliability Eng. Syst. Safety
, Vol.
77
,
2002
, pp. 151–165.
25.
Marseguerra
,
M.
,
Zio
,
E.
, and
Podofillini
,
L.
, “
Multiobjective Spare Part Allocation by Means of Genetic Algorithms and Monte Carlo Simulation
,”
Reliability Eng. Syst. Safety
, Vol.
87
,
2005
, pp. 325–335.
26.
Podgorelec
,
V.
,
Kokol
,
P.
, and
Kunej
,
A.
,
Nuclear Power Plant Preventive Maintenance Planning Using Genetic Algorithms
, Lecture Notes in Computer Science Book Series,
Springer-Verlag
,
Berlin
, Vol.
1821
,
2002
, pp. 611–616.
27.
Saranga
,
H.
, “
Opportunistic Maintenance Using Genetic Algorithms
,”
J. Qual. Mainten. Eng.
, Vol.
10
,
2004
, pp. 66–74.
28.
Shum
,
Y.S.
, and
Gong
,
D.C.
, “
The Application of Genetic Algorithm in the Development of Preventive Maintenance Analytic Model
,”
Int. J. Adv. Manufact. Technol.
, Vol.
32
,
2006
, pp. 169–183.
29.
Ilgin
,
M.A.
, and
Tunali
S.
, “
Joint Optimization of Spare Parts Inventory and Maintenance Policies Using Genetic Algorithms
,”
Int. J. Adv. Manufact. Technol.
, Vol.
34
,
2007
, pp. 594–604.
30.
Haupt
,
R.L.
, and
Haupt
,
S.E.
,
Practical Genetic Algorithms
, 2nd ed.,
Wiley-Interscience
,
Hoboken, NJ
,
2004
.
31.
Okogbaa
,
O.G.
, and
Peng
X.
, “
A Methodology for Preventive Maintenance Analysis under Transient Response
,” In:
Proceedings of the Annual Reliability and Maintainability Symposium
, January 22-25,
1996
, pp. 335–340.
32.
Kennedy
,
W.J.
,
Patterson
,
J.W.
, and
Fredendall
,
L.D.
, “
An Overview of Recent Literature on Spare Parts Inventories
,”
Int. J. Product. Econ.
, Vol.
76
,
2002
, pp. 201–215.
33.
Mannan
,
S.
, Ed.,
Lees' Loss Prevention in the Process Industries
, 3rd ed.,
Elsevier Butterworth-Heinemann
,
Oxford, United Kingdom
,
2005
.
This content is only available via PDF.
You do not currently have access to this chapter.
Close Modal

or Create an Account

Close Modal
Close Modal