Short-term site-wide maintenance scheduling

Abstract

Preventive maintenance is essential for every chemical production site to prevent failure and accidents, however, it upsets material and utility flows inside the site and also causes production loss. In order to minimize the loss, maintenance of each plant unit has to be carefully scheduled together with considerations on site-wide material and utility balances. This will involve both production and utility systems, and indeed is a very complicated problem. A scheduling strategy is then employed to handle the problem efficiently. It divides the scheduling into two steps, long-term and short-term. Long-term maintenance scheduling determines the combination of plant shutdown in a period of 2–5 years. Base upon the long-term schedule, a short-term maintenance scheduling optimizes the exact timing of plant shutdown, overhaul, inspection and startup within a maintenance period of 4–10 weeks. Short-term maintenance scheduling involves pre-set utility and material demand profiles during a plant shutdown, overhaul and startup making it a very challenging task. In this paper, a multi-period mixed integer linear programming (MILP) model, a site-model, is proposed as an aid to optimize short-term site-wide maintenance schedule. A special formulation is also developed to deal with the pre-set utility and material demand profiles in the site-model.