Meticulous inspection planning and predictive maintenance are the essential ingredients for ensuring fitness-for-service of process equipment. The analysis of data collected during inspections is applied to evaluate the effect of component aging, which directly affects plant reliability. Component aging and maintenance optimization are two critical issues, which are needed to integrate engineering analysis and economic evaluation for judicious decision-making. A well planned maintenance activity helps in keeping the plant reliability at a high level and also helps in keeping the maintenance expenses low. This paper presented here specifically deals with the case studies of a 1969 vintage fertiliser plant running on reciprocating compressors.
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