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PERDA discussion with the API Subcommittee on Instruments
and Control Systems
23 April 2012
Your Presenters
Gene MeyerDow Chemical, 28 yearsReliability Engineering for the last 12 years.
Hal Thomas (on the phone)Exida (formerly Air Products)Process SafetyOriginal chair of PERD
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Alignment
AICHECCPS, Center for Chemical Process Safety
PERD, Process Equipment Reliability Database• Participants
» Members and Users
A subscription-based project with CCPS.
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Agenda• Introduction
• Alignment
• Organization
• Goal
• The solution
• Details
• Results
• Discussion
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Reliability Situation Industry-specific reliability data is not available. Quality company data is scarce. Performance-based regulations enacted. CPI and HPI capital intensity forces greater asset
management (i.e. higher process reliability)
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Process Safety SituationPerformance-based regulations enacted.Lack of quality data reduces confidence & jeopardizes industry
credibility with respect to quantitative analysis results Performance-based processes require quality management systems
that are auditable and defensible Quality Assurance requires data to validate performance assumptions
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Current Reliability Modeling Situation7
The VisionReadily available Maintenance and Reliability Data that: Is generated from equipment like yours, Is automatically loaded into a database, Represents industry experience, Is validated for accuracy, Is statistically evaluated by documented methods, Is benchmarked versus your industry Is available for your use in:
Simulation Process validation Process design and troubleshooting Reliability Growth Quantitative Risk Assessment
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The Solution
PERD
Process Equipment Reliability Database A database that works with your computerized maintenance
management system to upload equipment performance data, organize, validate, calculate, benchmark and make available for use with clear statistical guidance.
The database that uses company and industry equipment performance data evaluated against industry standards.
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PERD is:
A member-led project developed by CCPS to provide equipment reliability data with the following mission :
The PERD Mission Operation of an Equipment Reliability Database, Making
Available High Quality, Valid, and Useful Data to the HPI and CPI Enabling Analyses to Support Availability, Reliability, and Equipment Design Improvements, Maintenance Strategies, and Life Cycle Cost Determination
PERD Provides:
Practical approach and Consistent work processes for data collection Sound theoretical foundation based on engineering fundamentals
Efficient software tools for data submission S/W dedicated for use by participating companies
Quality assurance for data analysis Identification and analysis of outliers Defensible and auditable results
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PERD History During development of CCPS Chemical Process Quantitative Risk
Analysis book, committee concluded a separate guideline book was needed to address data
1989 - The result was Guidelines for Process Equipment Reliability Data with Data Tables
Following publication, Hal Thomas and Tom Carmody attended an OREDA meeting and concluded data mining was too expensive, but data harvesting if implemented properly was sustainable, hence the PERD initiative was born.
1998 – Guidelines for Improving Plant Reliability Through Data Collection and Analysis published establishing the basic foundational approach
Today – Work processes established and documented, rolling out 2nd generation PERD software, continuing to develop equipment taxonomies & analyze equipment data
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Fundamental ConceptsDevelop & document equipment boundary diagramPerform rigorous “Functional Analysis” to determine and
document all of the fundamental failure modes that represent complete or degraded failures as well as documenting incipient conditions for an equipment type Reference paper by Rausand and Oin in their critique of
OREDA database
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Fundamental Concepts ContinuedEngineer information systems to
Support data acquisition using a experimental design mentality, facilitating immediate data analysis
Input only facts, i.e. do not require interpretation on part of mechanic or technician• Make use of standard pick lists to extent possible
Create event input forms that allow inference of failure modes by asking the question, ‘What data is it that would allow us to conclude a particular failure mode has occurred.
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Fundamental Concepts ContinuedLeverage existing information systems that are going to
exist anyway, improving data quality with no increase in cost Design equipment design spec data fields to be PERD
compatible Design process demand, inspection and test record data fields
to be PERD compatible
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163Feb00_Insur
ance
Fundamental Concepts - The Data Farm
Periodic batchtransfer of
data
Electronicallyextract
validated data
Events occuron a
continuousbasis
Quality info for use in reliabilityanalysis, maintenance strategies,
risk analysis, etc.
PERD Database
An Integrated Approach
Process Specs
Process Specs
Process Specs
CCPS PERDIndustry Offline Reliability
Analysis Database
Population Data
Operating Group Information System(s)
Facility PERD
Corporate PERD
Maintenance Activities
Process EventsPlant Operation
Commissioning
Installation
Purchase Order
Design Specs
In-ToolsSmart P&ID
Maintenance Module (i.e. SAP, Maximo, etc.)
The HarvestCCPS IndustryDatabase
Company 1Database
Event Data Maintenance Inspections Proof Testing Incidents Etc.
Inventory Data ID Number Tag Number
Plant nData
Plant 2Data
Company nDatabase
Company 2Database
Plant 1Data
Inventory Data
Event Data
Inventory Data
Event Data
Initiative FocusSound theoretical foundationPractical application to plant and equipment, including
software toolsFundamentally sound engineering information available to
companies to “Engineer” their information management systems
Industry database built upon the platform aboveCapitalize on opportunities
Company databases adapt to the platform above
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Fundamental Taxonomy RelationshipsInventory Record
Device Data Fields
Equip ID- Equip Descriptors
Application Data Fields
Tag Number
OperatingMode
OperatingConditions
Equipment Function(s)
Failure Mode(s)
FailureCause(s)
FailureMechanism(s)
Events
Relationship Legend
Many to Many
Many to One
One to One
One to Many
The same is true for Reliability & simulation
Built Upon a Sound Technical Foundation
PERD Has Adopted a Data Tier Structure That: Eliminates Data Intimidation Allows more rapid expansion of partial Equipment taxonomies
and associated software developmentBasic Tier Concept
Tier 1 – Whatever minimal data might exist – Gets people started; generates a useful event record. Pass/fail
Tier 2 – Begins to provide event specifics; population filtering and failure classification
Tier 3 – Top of the “PERD ladder of success”; failure modes
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Equipment Groups & Systems23
Equipment Groups
Electrical
Fixed Equipment Instrumentation
Pressure Relieving Devices
Rotating Machinery
Valves
Equipment Systems
Circuit Breaker Contactors Motor Relays Transformer
Cylinder Heat Exchanger Piping Circuit Pressure Vessel Atm Storage Vessels
Analyzer Annunciator Fire & Gas
Detection Loop Sensing Element Switch Transmitter Signal Conditioning
Unit Control Logic Unit
Reclosable pressure Relief Devices
Non-reclosable Pressure Relief Devices
Hydraulic Accumulator
Liquid Seal Open Vent
Agitator Compressor Pump Turbine
Check Valve Hand Valve Self-Actuated Solenoid Valve Remote Actuated
Expandable
Inventory Data Tier Concept Tier 1
Location Address (e.g. Plant, tag, etc.) Equipment Group (e.g. Instrumentation) Equipment System (e.g. Transmitter)
PL_Equip_Grp*Equip Group
*Equip System
Comments
PL_Equip_Sys
*Tag Number
*Equip ID
EquipmentType & SubtypeExample
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Equipment Group Equipment System Equipment Type Equipment Subtype
Pressure Relieving Devices
Reclosable pressure relief devices
Pressure Relief Valve (Spring Loaded)
PL_REL_SubType Conventional Balanced Bellows Balanced Bellows With
Auxiliary Balanced Piston Pilot Operated Relief Valve
Conservation Vent Self-Closing Manhole Cover
Non-reclosable pressure relief devices
Rupture Disk Explosion Vent Blow-off Man-way Rupture Pin Buckling Pin Weak Gauge Hatch Fusible plug Weak shell to roof seam
Hydraulic accumulator Liquid seal Open vent
Inventory Data Tier Concept Tier 2
All tier 1 data plus following data user chooses to enter
Equipment Type (e.g. Differential Pressure)
Equipment Subtype (e.g. Level) Manufacturer Model Number Output Signal or Set Point (As
applicable to equipment)
Manufacturer PL_Mfr_Equip
PL_Equip_TypeTransmitter Type
Transmitter Subtype PL_Equip_SubType
Model Number
Output Signal PL_Equip_Sig_Out
Set Point PL_Equip_Set_Point
Whichever field is applicable
Inventory Data Tier Concept
Tier 3 All tier 1 data Equipment type Equipment subtype Plus additional tier 2 and / or 3 data user chooses to enter
Possible to achieve level of a complete equipment specification
Event Data Tier Concept All Events require
• Linkage to tracked equipment• Event date (and time if applicable)
Tier 1• Data showing a failure has occurred
Tier 2• Data sufficient to infer whether failure was “Dangerous” or
“Safe” Tier 3
• Data sufficient to infer true failure modes
User decides what event data to track!! Event data tracked determines what level of inference is achievable.
Relief Valve Proof Test Example29
Getting Started
Upon Joining as a Full Participant PERD provides the software & initial help to companies
loading the software onto their company server PERD provides initial help and guidance allowing you to
contribute whatever data you have, enabling companies to quickly get involved and begin accruing benefits
Company data contribution means access to aggregated anonymous industry data and a path to continuous improvement
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Helping Hand Work Process – Getting Started31
Existing CMMS or other Info Mgmt
System
Company downloads
data
PERD Imports Data & Manages
Dataset
PERD Aggregates Data
(Multiple Data Subscribers)
Data Analysis
PERD Anonymizes Data
Ad Hoc Data Acquisition & Analysis
Company submits data to
CCPS PERD
PERD translates data &
populates PERD compatible files
Helping Hand Work Process
PERD Performs Data Map
PERD Guidance
Immediate Benefits Access to fundamental technical information that documents
specific data user needs to: Filter inventory data for populations of interest Infer failure modes of interest
Access to work process knowledge needed to achieve company goals
Facilitates moving to data farming (low cost) work process rather than data mining (high cost) activity
Enables maximization of benefits from enterprise systems (eg SAP, Maximo, Matrikon, Meridian, etc.) Provides pre-engineered solutions that can be implemented
cost effectively Best available info transfer between engineering and
programmers
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On-Going Work Process33
Existing CMMS or other Info Mgmt
System
Company downloads data in
compatible format
PERD import data into industry
database
PERD Aggregates data from
(Multiple Data Subscribers)
Data analysisData analysis
PERD makes data anonymous
On Going Data Acquisition & Analysis
Company submit data to CCPS PERD
per quality plan
Quality Process
Company Documents Quality
Plan
Long Term BenefitsData Harvesting per Defined Quality Plans Provide:
Operating company database capable of achieving proven in use data for safety and reliability analysis
Data Contribution to PERD Facilitates Operation of industry database Industry benchmarking Statistical analysis by true experts due to best data
available to support their research Data available for improved reliability and risk analysis On going continuous improvement via reliability
growth
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Why Join PERD?PERD enables user companies to leverage existing IT and MI systems to collect and submit data resulting in:
Improved Reliability Industry benchmarking Identification of “low hanging fruit” for immediate impact Minimization of unforeseen losses Increased Effectiveness for
Information Systems Technology Reliability & Quantitative Risk Assessments Regulatory Compliance
For a small financial investment and minimal data.
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You would join…
Full Participantso Air Productso Chevrono DNVo Dow Chemicalo DuPonto FM Global
Subscribers & Volunteerso Exidao Rosemounto Savannah River Siteo Sis-Techo TMC
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Getting Started.
Join as a Full ParticipantBenefits of Full Participant Status:
PERD provides the software & initial help to companies loading the software onto their company server
PERD provides initial help and guidance allowing you to contribute whatever data you have, enabling companies to quickly get involved and begin accruing benefits
Company data contribution means access to aggregated anonymous industry data and a path to continuous improvement
Networking with industry experts involved with the PERD project.
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In Summary
PERD provides you a roadmap to improved performance whereby you can Improve Information Systems Effectiveness Create Value Minimize unforeseen losses Improve Regulatory Compliance Effectiveness
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Enroll Now!!
For More Information Contact Dave Belonger – CCPS PERD Staff Consultant 609-654-4914 dbelonger@verizon.net
Gene Meyer – Chairperson Dow Chemical (989) 638-4064 grmeyer@dow.com
Hal Thomas – Technical Consultant exida 610-481-9681 thomashw@exida.com
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