Each overhaul of the petrochemical industry means a major investment. In order for parking to proceed smoothly, careful planning and assessment of potential risks are required. In April 2009, the ÄŒeská Rafinérská refinery carried out challenging plant overhauls for the entire plant. The same is true of Milos Hlavacek, head of instrumentation and electrical at ÄŒeská Rafinérská. In April 2009, Milos Hlavacek was responsible for this overhaul. "In the past, ÄŒeská Rafinérská had equipment servicing every four years, which is the first time the overhaul cycle has been extended to five years, and after nine years of operation, the equipment is estimated to have some problems," explained Milos Hlavacek. "However, the method used by ÄŒeská Rafinérská was different from the past: the range of control valves has been reduced and the number of on / off valves classified according to SIL's safety rating has increased," he continued. "Metso's field survey and the Neles ND9000 The diagnostic system provided the basis for the planning of the valve overhaul cycle, and Metso's importance analysis of equipment provided us with great help in spare parts and overhaul schedules. "Key to efficient maintenance of RCM and Metso's iValveSurvey â„¢ All instrumentation It is based on SIL safety level and IEC 61511 standard. The range of on-off valves is based on SIL level, daily experience and Metso's iValveSurvey results. iValveSurvey implemented in 2004, provided the basis for the valve overhaul plan. Milos Hlavacek said: "This is the first reliability-centered maintenance (RCM) that the on-off valve performs overhaul according to the RCM maintenance program. Both the air tightness and the function are tested during the overhaul test. ANSI VI standard. "" As the range of control valves shrinks, it is important to determine which valves should be serviced. Hlavacek explains: "This can be accomplished by a thorough analysis of the Neles ND9000 diagnostic system to determine the range of control valves, diagnostic data to determine the valve and possible problems with it, plan maintenance activities and prepare the required Spare Parts. "Valve Maintenance Milos Hlavacek, an experienced supplier, is pleased with current valve maintenance partner Elmep, one of Metso's authorized service providers. Hlavacek said: "They have all the necessary skills for good workmanship and repair work." According to Milos Hlavacek, all overhaul work in ÄŒeská Rafinérská ended in 35 working days. Metso's partnership with Elmep began 10 years ago when Elmep was selected as Metso's authorized service provider for the installation of the FFC (Refining and Catalytic Cracking Equipment) project. Elmep staff are regularly trained at Metso plants and stay in touch daily with the Metso office in Prague. All overhaul work in ÄŒeská Rafinérská is completed in 35 working days. In the old Refinery 25, 297 control valves were diagnosed, 75% of which came from other suppliers using the Neles ND800. Based on the results of the diagnostic analysis, 15 non-Metso-supplied valves were removed from the pipeline and 76 valves were verified on the pipeline. At Refinery 24 (FCC unit), 235 valves were diagnosed, 98% of which were from Metso. Only six Metso valves require service and 41 valves are calibrated on the pipeline. The Importance of ESD Valves ÄŒeská Rafinérská pays special attention to ESD (emergency shut-off) valves throughout the overhaul. A total of 187 ESD valves (body pressure test, seat leak test and function test) were tested in the workshop. Of 57 Metso's ESD valves, 15 were serviced, including seven "most critical" valves. For these "most critical" valves, all of their internal parts are still replaced, even though the valve is still in good condition. Two-thirds of ESD valves from other suppliers failed the test. This also proves that the parking maintenance test is very important, but in the same way, the partial stroke test with diagnostic function can also help to find out the problems of the valve in advance. "Fewer, less risky; we also use Metso's service!" Having proper spare parts and skilled personnel available on-site during the overhaul was important to ensure the entire parking program. Metso's equipment importance analysis helps identify the correct spare part type and planned valve maintenance activities. In the device importance analysis, all tags are reviewed to determine their importance based on their impact on quality, safety and process. Milos Hlavacek said: "The Metso equipment importance analysis helped us to plan spare parts optimization and valve overhaul, and we also performed extensive overhaul of important valves based on equipment importance analysis using Metso's 'Valve Spare Parts Library' Service to completely overhaul the other valves. "Hlavacek confirms:" This is our first use of the Valve Spare Parts Library service and we found that we are better able to cope with the potential problems in the factory. "These services offer many benefits, For example: Minimize the number of service spare parts; Make our warehouse management more efficient and reduce the error rate due to the clear identification of spare parts by Metso; Eliminate the need to order spare parts and reduce spare parts costs during maintenance . Finally, Milos Hlavacek said with great satisfaction: "Metso's' Valve Spare Parts' service helps us to efficiently carry out equipment repairs while reducing working capital and risk, and we also use these services for ÄŒeská Rafinérská! '" For more information, Please contact: automation.china@metso.com ÄŒeská Rafinérská is the largest oil refinery company in the Czech Republic and the largest producer of petroleum products in the country. The company operates two refineries located in LitvÃnov and Kralupy nad Vltavou with a total capacity of 175,000 bbl / d (27,800 m³ / d). The company's largest shareholder is the Czech Republic United Petrochemical Group, the British shell company Shell and Eni.