RELIABILITY PROGRAM

Program: Inspection, Lubrication and Tensioning of Steel Cables on Flare Stacks

Responsible: Inspection Department     Role: Area Inspector

Purpose:  Maintain the mechanical integrity of flare stack steel cables by monitoring the percentage of strength loss and predicting retirement dates, performing periodic lubrication to prevent accelerated corrosion, and re-tensioning the cables.

Scope: This program covers the inspection, lubrication, tensioning, and other repairs of the guy cables on guyed flare stacks at the refinery.

Frequency:  The inspection interval for all elements within scope will be approximately half the useful life of the steel cable, with a maximum interval not to exceed 60 months.

Work Process – Notification / Work Order: The Area Inspector issues SAP MI Notifications for the inspection, lubrication, and tensioning of the steel cables; one notification per designated equipment item. The Area Planner generates the Work Order, plans the activities, and informs the Area Inspector of pending work.

Task Execution: The Area Inspector reviews the Contractor's Work Plans upon arrival at the Work Site. The Area Maintenance Supervisor assists and supervises the contractor during inspection, lubrication, and tensioning activities. The Area Inspector or their designee oversees work in progress to verify completeness.

Records / Reports: Repair or replacement recommendations are submitted to the Area Inspector and Area Maintenance Engineer for approval. Inspection results are reported to the inspection and engineering team for evaluation and historical record, with the final report distributed to the Area Asset Manager.

Acceptance Criteria: Steel cables will require replacement when they exceed 25% strength loss. Inspection results are documented in the CMMS, with supporting materials filed in the Reliability Equipment Files. Design change details must be filed in the designated equipment records file. A SAP MI Notification will be issued to initiate replacement work and/or schedule the next inspection. The desired due date for the next inspection will be the lesser of 5 years or half of the remaining useful life, based on available history. The CMMS will be used to track the next Test Due Date.