This downstream oil company refines, distributes and markets petroleum products with their largest location in Texas with a capacity to refine over 600,000 barrels of crude oil per day. The maintenance and asset management experts of MaxGrip were asked to support their Reliability Improvement Program with a Failure Mode Effects Criticality Analysis (FMECA)pilot project. The goal was to optimize asset reliability and comply with safety regulations.

Approach: Three-Stage FMECA

The FMECA project was executed in three stages:

  1. Scoping: Involved a thorough review of historical failure data and documentation to define the system and its boundaries.
  2. FMECA Execution: Conducted a workshop with a cross-functional team to assess operational context and validate failure modes.
  3. Implementation of Equipment Care Strategy: Developed effective Preventive Maintenance (PM) strategies based on FMECA insights.

Results: Cost & Safety Gains

  • Established a technical risk profile and Asset Care Strategies for the equipment in scope.
  • Achieved a 33% reduction in Total Cost of Maintenance (TCM) for high-risk assets.
  • Developed a systematic framework that reduces the time to generate PMs by up to 50%.
  • Ensured reliability assurance compliance for the equipment in scope.

More results are outlined in the downloadable case study.

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FMECA Pilot Project Shows Significant Cost Savings For Downstream Oil Company


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