Why modern refinery maintenance is becoming a competitive differentiator in oil and gas

Core Insights - The oil and gas refining industry is entering a new era characterized by global demand fluctuations, regulatory pressures, decarbonization goals, and the need for operational intelligence to optimize complex refining assets [1] Group 1: Global Refining Capacity - Global refining capacity was approximately 103.5 million barrels per day (mbbl/d) in 2023, with expected growth primarily in the Middle East and Asia-Pacific regions, particularly China and India [2] - Refinery capacity is projected to increase by 2.6mbbl/d to 4.9mbbl/d by 2028, coinciding with advancements in digital technologies [2] Group 2: Challenges in Refining - Refineries are facing challenges such as aging infrastructure, labor shortages, rising operational costs, and increased vulnerability to unplanned shutdowns [3] - The oil and gas refinery maintenance industry is heavily reliant on aging infrastructure, which complicates the extraction, transportation, and processing of hydrocarbons [3] Group 3: Maintenance Strategies - To remain competitive, operators must minimize downtime, ensure asset longevity, and comply with stricter global emission standards, necessitating intelligent maintenance solutions [4] - Traditional maintenance models based on periodic inspections and manual monitoring are becoming inadequate for modern refineries [5] Group 4: Aging Assets and Risks - Many refineries are operating beyond their original design lifetimes, increasing the risk of equipment degradation and unexpected failures [6] - In the US, there are 132 operable refineries with a total crude-distillation capacity of around 18.4mbbl/d, where even minor outages can disrupt supply chains [6] - Upgrading to condition-based maintenance regimes is essential to mitigate risks and protect throughput, as unplanned shutdowns can have significant financial impacts [7]