FCCU Maintenance Turnaround/Refinery Field Service

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What is a MEA Turnaround Service (MTS)?

An MEA Turnaround service is a complete overhaul of the unit with the following objectives:

Service history of the equipment is examined. Current issues are documented.
Test the current system and prepare a Pre Service Report.
Dismantle the system in the systematic order that allows check of variable systems.
Inspect individual parts and determine if the part is safe to use until next turnaround.
Replace parts based on the following:
1. Recommended rebuild consumables (Seals, etc.)
2. Spares that affect the current issues (if any)
3. Deformed / damaged parts. An analysis is done on products failing before the MTBF (Mean Time Before Failure) of the product.
Perform post build tests and calibrate the unit to specifications.

How often is a MTS required?

As an Industry Standard, most Petrochemical plants maintain a 4 year period for a complete turnaround service. MEA also follows this standard unless some issues were reported between the periods.

Why should MEA service the unit?

All MEA equipments are customized units and designed to work with specific parameters. MEA engineers are well versed with the equipment layout and design parameters. They are capable of understanding the issues and recommend solutions.
Align the maintenance schedules to MEA standards.
The service period allows the client's Maintenance team to interact with MEA Engineers and resolve any concerns.
The work carried by MEA engineers is warranted and reliable.

Brief Outlay of Service for Refinery MTS

The following outlay is designed for most MEA equipments. Additional steps and calibration may be necessary for unforeseen factors.

Rebuild all the Cylinders
1. If units are running we must place the units into hand wheel mode first
2. We will remove cylinders
3. Rebuild them in the shop or on site if needed
4. Return the units to the correct valves and re-install
5. Remove air out of the lines and test. This can be done by moving about 5% in either direction
Replace all the Check Valves
1. Hand wheel mode first
2. Turn pump off to the unit
3. Bleed the system
4. Take them out and use water , if needed, to clean out cavities
5. Replace with new ones
6. Shut all bleeders
7. Start the system back up and test as needed
Replace the needle valves as needed
1. Have the unit in manual (hand wheel) mode if the unit is running
2. Shut all the pumps off
3. Bleed the system of all pressure
4. Replace valves as needed
5. Shut all bleeds
6. Start unit and check for leaks
Check the motors
1. Use an AMP meter to check and ensure that we are not going over full load as is stated on the motors
Check the Pumps and most likely replace
1. Check recovery time for a drained system
2. If not to specified time within 15% then it is a good idea to change
Check the calibration of all the electronics
1. Follow procedures written by M.E.A., If the units are or were exposed to long bouts of high temps then I would suggest that we replace the boards.
Replace the fluid
1. Drain the fluid
2. Test the fluid
3. Clean the reservoir
4. Replace the fluid with new fluid
Rebuild the accumulators
1. If unit is running then the M.E.A. Actuator must be placed in hand wheel mode
2. Bleed the pressure off the unit
3. Remove the accumulators
4. Replace the seals in the accumulators
5. Put back on to the unit
6. Turn unit on and check for leaks
7. Place the unit back into the position it was when started or in the mode that operations wants it to be in

Duration of Service

This rebuild will take about 1.5 to 2 weeks (with between 4 to 6 units) with two engineers and help from the refinery. This should be completed on all HPU's and Actuators

Support from Refinery

Shut down may not be required and the units can be operated in Manual Mode.
A list of MEA spares will be submitted which need to be available for the engineers during the service.
Site support from engineers from different departments
Commercial agreements prior to beginning of service. A proposal will be sent by our representative.

MEA Recommendation

MEA strongly recommends using MEA parts and service. In more than 45 years of service, we have had cases where clients have resorted to third party spares and service for short term gains, if any. However, more often it seems to have caused unplanned shutdowns & catastrophic problems to the client. MEA has had to rework and rebuild the equipment to get the unit online.

MEA has had to the pleasure of working with your Refinery in building these actuators. We have and shall stand with said Refinery in an effort to eliminate down time and improve performance.

If there are any questions contact MEA. Inc as soon as possible to stave off any problems before they happen.