2004 - ORPIC & CBI, PIC EPC-1 Steam Cracker Unit (SCU) with Offsite Works Unit, Oman
Summary
The Steam Cracker Unit was a key component of Oman’s Liwa Plastics Industrial Complex, designed to convert feedstock into high-value petrochemical products. The facility was expected to operate under high temperatures and pressures, making reliability and process safety a priority.
Challanges
Achieving high operational uptime while managing complex thermal and mechanical stresses in cracking furnaces was a major concern. The project also required a structured maintenance strategy to avoid unplanned shutdowns, which could lead to significant production losses.
Solution
Conducted RAM analysis to assess process availability and develop a proactive maintenance schedule.
Developed a risk-based inspection (RBI) framework to monitor and manage equipment degradation.
Applied failure mode and effects analysis (FMEA) to identify critical failure modes and mitigate potential risks.
Implemented condition-based monitoring techniques to track the performance of key assets and reduce failure probabilities.
