Introduction This paper is about implementing CMMS in MHPC when I was working there as maintenance planning and Inspection Head. MHPC is located in north of Iran, Assaluyeh district, Pars Special Economic Energy Zone. It is a High density polyethylene (HDPE) producer. MHPC has the yearly production of 350,000 tons HDPE. I worked in MHPC […]
Look at this tube sheet. Those sealed tubes weren’t fouled; they were plugged. Each one was leaking, so it was taken out of service. The exchanger? Still running. No alarms. No downtime. Heat exchangers are intentionally overdesigned. Engineers build in a fouling margin, so losing a handful of tubes rarely hurts performance immediately. The unit
Plugging a leaking tube isn’t a fix — it’s a deadline. Read More »
We Maintain What We Can See. We Ignore What We Can’t. That’s the Real Risk. Look at the photo as a system, not just individual assets: ✔️ The storage vessel: inspected, monitored, NFPA-labeled ✔️ The pressure/temperature gauge: read on rounds ✔️ The fire water ring main: painted red, always there, rarely challenged 💡 Jardine &
The vessel gets maintained. The system protecting it doesn’t. Read More »
👉That yellow valve is a Pressure Safety valve, your last line of defense if system pressure exceeds safe limits. If its disc were corroded shut right now, no one would know. ✔ RCM II (Moubray, Ch. 5) uses a PSV as its precise example of a non-fail-safe protective device: “If the pressure relief valve was
That PSV looks fine. It might already be failed. Here’s the problem. Read More »
Companies spend millions on preventive maintenance (PM), assuming it increases equipment reliability. ⚠️ It doesn’t. PM only preserves inherent reliability—it cannot improve it. 🧮 Example: Machine is designed with (Mean Time Between Failures) MTBF = 1,000 hours. You perform PM every 500 hours. If the PM is done well, the MTBF remains 1,000 hours—not 1,500
Preventive Maintenance (PM) Cannot Improve Inherent Reliability Read More »
When a regulator failure on our MD/HD plant created an unplanned 10-day window, my team didn’t scramble — we activated a pre-staged opportunity maintenance plan, finalized scope in a single kick-off meeting, and executed 4,545 man-hours of work across 397 work orders without a single safety incident, on schedule, and within budget. That outcome wasn’t
Abstract The objective of this research is to calculate the optimal time for performing preventive maintenance on the HP Packings2 of the secondary compressor in the Low-Density Polyethylene (LDPE) unit of Aryasasol Polymer Company, using Weibull analysis. In this study, the life data of HP Packings from 6 cylinders in the second stage of this compressor
How a Risk-Based Inspection Study Extended Our Overhaul Interval by 40% Read More »
Abstract The objective of this research is to calculate the optimal time for performing preventive maintenance on the HP Packings2 of the secondary compressor in the Low-Density Polyethylene (LDPE) unit of Aryasasol Polymer Company, using Weibull analysis. In this study, the life data of HP Packings from 6 cylinders in the second stage of this compressor
Weibull Analysis for HP Packing of Secondary Compressor in LDPE Plant Read More »
