October 7, 2024 Chemical Industry: Preventive Maintenance & Reliability

Preventive maintenance is a cornerstone of operational excellence in the chemical industry.

By Randy Heisler, Vice President of Metals, Mining, Power Generation, and Chemicals at Life Cycle Engineering

The chemical manufacturing industry is both high-stakes and complex. With more than 13,500 facilities in operation, precision and efficiency are crucial. Given the complexity of machinery, strict regulations, and significant safety concerns, effective maintenance strategies are not just beneficial—they’re critical. A solid preventive maintenance plan can help chemical plants keep their operations running smoothly, safeguard their workforce, and adhere to regulatory standards.

The Benefits

Preventive maintenance is a cornerstone of operational excellence in the chemical industry. Regularly inspecting and servicing equipment before issues arise enables plants to avoid costly breakdowns, maintain safety and regulatory standards, and ensure a smooth production process. With the right strategy in place, chemical leaders can see long-term operational success.

Reduced Downtime

Unplanned downtime due to equipment failure significantly impacts production capacity and output, and can also cause significant environmental impacts. Addressing these failures quickly and effectively is critical, but it also underscores the need for proactive maintenance strategies to minimize the frequency and severity of such occurrences and maximize day-to-day efficiency. By setting up a system to regularly identify and address potential failures before they escalate, chemical plants can operate at optimal performance levels.

Enhanced Safety

The chemical industry inherently involves risks due to the handling of potentially toxic and flammable substances. In fact, the Toxic Substances Control Act (TSCA) currently lists ove 86,000 chemicals in its inventory. A robust maintenance strategy protects employees from dangerous chemicals and minimizes the risk of environmental hazards and regulatory fines.

Extended Asset Lifespan

Chemical plants have complex machinery and processes with varying operating conditions. The harsh chemical environments also accelerate equipment degradation, leading to issues such as corrosion and wear. Troubleshooting and fixing issues in this environment can be challenging, requiring specialized knowledge and advanced diagnostic tools to ensure that failures are prevented.

Regular inspections and preventive maintenance are essential to mitigate these effects and maintain equipment integrity. Proper maintenance extends the lifespan of equipment, reducing the need for premature replacements. By following manufacturer recommendations along with identifying failure modes, and conducting regular inspections, facilities can ensure that their assets perform efficiently for longer periods, optimizing capital investment and reducing long-term maintenance costs.

Cost Savings

Proactive maintenance is a more cost-effective strategy compared to reactive repairs. By preventing equipment breakdowns through preventive and predictive tasks and scheduled maintenance, facilities can avoid the high costs of emergency repairs and replacements. This approach cuts costs and simplifies budgeting and financial planning by minimizing unexpected expenses.

Strategies to Address Common Challenges

Addressing these common challenges in the chemical industry involves a multifaceted approach that considers preventive and predictive maintenance strategies and staff education.

Organizations can reach their full potential when they put these actions into practice.

1. Maintenance Strategies

• Preventive and Predictive Maintenance: Develop comprehensive preventive and predictive maintenance schedules based on criticality and equipment failure modes. Regularly planned and scheduled maintenance helps prevent unexpected breakdowns and prolongs equipment life.
• Risk Based Asset Maintenance: Conduct asset criticality analysis to identify the most critical components and develop maintenance strategies focused on risk to the operation. This approach ensures that maintenance efforts are concentrated where they will have the greatest impact.
• Root Cause Analysis (RCA): Investigate equipment failures to uncover underlying causes and implement corrective actions. RCA helps address the root issues rather than treat symptoms, reducing the likelihood of future failures.

2. Training and Skills Development

• Technician Training: Provide comprehensive training for maintenance technicians on equipment operation, troubleshooting, and best practices.
  Well-trained technicians are better equipped to handle complex maintenance tasks efficiently and safely.
• Continuous Learning: Encourage ongoing education and training for managers, supervisors, planners, reliability engineers and technicians on best practices and to also keep them updated on new technologies and maintenance methodologies. This commitment to continuous learning helps support an organization capable of managing evolving challenges.

3. Safety and Compliance

• Safety Protocols: Prioritize safety in all maintenance activities by adhering to strict safety procedures and regulations. Implementing rigorous safety protocols helps protect personnel and reduces the risk of accidents and hazardous incidents.
• Regulatory Compliance: Ensure that all maintenance practices comply with industry regulations and standards. Staying current with regulatory requirements helps avoid legal issues and ensures that operations are conducted within the bounds of the law.

Prioritize Proactive Maintenance and Reliability Today

As the chemical industry continues to evolve, prioritizing maintenance and reliability will be essential for long-term success. Investing in maintenance and reliability in the chemical business is not merely a best practice—it’s a business imperative. By addressing the key benefits and challenges outlined above and implementing proactive strategies, chemical manufacturers can enhance efficiency, reduce costs, improve safety, and ensure downtime is a worry of the past.

About the Author
Randy Heisler has over 40 years of experience in maintenance and reliability, operations, and business improvement. He is currently the Vice President of Metals, Mining, Power Generation, and Chemicals at Life Cycle Engineering, where he focuses on improving reliability, reducing cost, and increasing capacity

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