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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