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5.
1 Plant Maintenance: Static Equipment and typical

maintenance jobs
Overview of Fixed Equipment
Contribute to Definition
Fixed Equipment, sometimes also known as static equipment, is a term generally used
to describe non-moving equipment in the oil and gas and process industries. Some
examples include things like pressure vessels, heat exchangers, piping, storage
tanks, valves, pressure relieving devices, boilers, furnaces/heaters and structures.
On the other hand, fixed equipment does not include things such as pumps,
compressors, turbines, electrical equipment, or instrumentation (I&E), even though they
typically don't move.
The risks from fixed equipment are highest compared to other equipment types because
of the sheer number of equipment pieces and quantity of stored fluid. In a typical refinery
or petrochemical facility, a significant portion of the capital/maintenance cost and
reliability events or failures are associated with fixed equipment. A significant percentage
of industry incidents that have resulted in injuries or asset loss also have been
associated with fixed equipment.
Fixed equipment is often subjected to fairly extreme operating conditions and varying
damage mechanisms. In most cases, the damage is not immediate and damage rates
are not linear. A good example of this is corrosion under insulation (CUI) damage,
which can develop over time, but is not immediately obvious.
Unlike other types of equipment, fixed equipment doesn’t have complex sensors that
can be used to monitor for corrosion and damage in real time. For this reason fixed
equipment must be monitored by inspections at fixed intervals. This is why it’s so
important to have a reliability plan in place for all fixed equipment.
Fixed equipment is an essential part of every plant and facility, so it is important to keep
it in good condition
What is a static equipment?

Fixed Equipment, sometimes also known as static equipment, is a term generally
used to describe non-moving equipment in the oil and gas and process industries
Most commonly used Rotating Equipment used in Oil and Gas industries are
pumps,compressors, blowers, turbines,agitators etc and Static equipment category mainly
used for this field are Pressure vessels, Heat ex-changer, Columns,
Reactors,Filters,coalescers,tanks,Knock-out drums etc
What are Static Equipment?

Basically these are the equipment that do not have a prime mover driven rotating component will be
considered a static equipment, and here's some example with what sort of Offline/On-line preventive
maintenance which are usually carried out on the static equipment. Corrective maintenance will be
discussed at the end of this post, as it is what we wish to avoid.
Piping & Typical PM jobs:

- Thickness monitoring(5y or less, depending on code used API570:Piping or API580:RBI)
- Visual Inspection (1y or less)
- Insulation reconditioning (When necessary)
- Painting (1y or more, depending on visual inspection)
- Pressure testing (Usually 10y or less, if critical or national code requires)
Source: Wikipedia
Pressure Vessel & Typical PM jobs:

- Thickness monitoring(10y or less depending on code used API510:PV or API580:RBI)
- External Visual Inspection (1y or less)
- Internal Visual Inspection (half est. remaining life of the vessel, if remaining life is less than 4y
internal inspection shall be every 2y)
- Types of inspection may vary if the vessel operates in potentially damaging susceptible services
Source: Wikipedia
Above ground tanks & Typical PM jobs:

- Thickness monitoring(10y or less depending on code used API653:AGT or API580:RBI)
- Internal Visual Inspection (12y or less, unless with internal lining or leak detection installed)
Source: Wikipedia
Heat exchangers & Typical PM jobs:

- NDT Inspection, WFMPI, eddy current, ultrasonic leak test (when leaks are suspected, or when
service is critical, in corrosive media)
Source: Wikipedia
Distillation/Absorption columns & Typical PM Jobs

- Tray/Packing replacement (Usually 2y or more, depending on manufacturer design or efficiency)
Source: Wikipedia
Reactors & Typical PM Jobs

- Catalyst replacement (Usually 2y or more, depending on manufacturer design or efficiency)
Source: Wikipedia
Separators vessels & Typical PM Jobs

- See Pressure vessel above.
Source: Wikipedia
Steam traps & Typical PM Jobs

- Downstream steam check (1y or less, Live steam (faulty), lazy steam(working))
- Ultrasonic testing (1y or less, functionality check)
Source: Spirax Sarco
Manual Valves/Pressure relief valves & Typical PM Jobs

- These are usually done offline during shutdowns, unless the valves can be positively isolated for
removal.
- Refacing of valve seat/trim
- Repacking of seal
- Replacement of corroded/ parts
- Overhaul of soft kit/spring/actuator/etc
- Overpressure test (MV), Set pressure test (PRV)
Source: Wikipedia
Note: About positive isolation - Positive isolation is done for safety reasons, usually either by closing
two valves both up/downstream OR closing one valve with a blind installed both up/downsteam, to
prevent any passing process media from escaping when maintenance works are carried out.
Valves are usually neglected by operators, they operate these valves using pipe wrench of various
sizes. The huge torque applied with this leverage tool usually will speed up damage of the seats and
as a result we experience passing of process media. Therefore, positive isolation is good practice to
protect maintenance workers.
Filters/Strainers
- Differential pressure monitoring (Frequently)
- Backflushing or cartridge replacement(See manufacturer's recommended interval and action)
Source: Spirax Sarco
What sort of Plant maintenance should be carried out?

Preventive Maintenance
These type of maintenance are pre-scheduled on the plant's CMMS (Computerized Maintenance
Management Systems). The benefits of having a preventive maintenance program is that, there will
always be some work for the contractors to carry out (be it to clock time sheet or earn earn extra
cash??) Okay, the real benefit is that the manufacturer/code/national recommended maintenance
intervals can be practised and followed up, so as to prolong the equipment life.
Types of preventive maintenance for Static equipment

- As discussed above at the top of this post.
- This type of maintenance are carried out offline or on-line, depending on the type of plant operations
adopted or code requirements which may or may not permit carrying it out on-line.
Corrective Maintenance
These type of maintenance are usually carried out because preventive maintenance is not well
practised, due to natural causes, design flaws, operating not according to manufacturer's prescribed
conditions and many more reasons.
Types of corrective maintenance for Static equipment

- Box-in/Leak-sealing of pinhole leakage on pipe/vessel/weldments
- Pipe Spool replacement of piping due to the above
- Vessel/tank repair by cladding, shell course replacement, lap patch, plate lining due to thinning
- Steam trap replacement due to malfunction
- Heat exchange tube plugging due to tube leakage
- Unplugging of catalyst/packing/trays/filters by manual intervention

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5.

1 Plant Maintenance: Static Equipment and typical

What is a static equipment?

What are Static Equipment?

Piping & Typical PM jobs:

Pressure Vessel & Typical PM jobs:

Above ground tanks & Typical PM jobs:

Heat exchangers & Typical PM jobs:

Distillation/Absorption columns & Typical PM Jobs

Reactors & Typical PM Jobs

Separators vessels & Typical PM Jobs

Steam traps & Typical PM Jobs

Source: Spirax Sarco

Manual Valves/Pressure relief valves & Typical PM Jobs

What sort of Plant maintenance should be carried out?

Types of preventive maintenance for Static equipment

Types of corrective maintenance for Static equipment

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