CCPS PERD Process Equipment Reliability Database (PERD) perd@aiche

1. CCPS PERD Process Equipment Reliability Database (PERD) perd@aiche.org

2. CCPS PERD • Organization • Project of the Center for Chemical Process Safety (CCPS) • Directorate of the American Institute of Chemical Engineers (AIChE) • 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

3. PERD ERP Subcommittee • Focus on greatly improving the PERD central repository • New repository (SAP database) • Minimum requirements for high-quality trusted data • Help companies with new tools and standard methods to improve their equipment reliability data processes • Guidance for how to collect high-quality failure data with corporate software (SAP is primary focus) • Standard content and methods, e.g. taxonomy definitions • Failure data quality management

4. PERD ERP Overview • Bottom-line driven approach for optimizing equipment reliability • Maximize production throughput • Minimize health, safety, and environmental hazards • Enables data-driven decision-making with high-quality equipment reliability data • Helps companies identify where to focus equipment reliability efforts

5. PERD ERP Bottom-Line Approach • IDENTIFY • Equipment failure events with the greatest consequences • Equipment causing those events (bad-actor equipment) • ANALYZE • High-consequence failure events • Failure patterns of bad-actor equipment causing them • Obtain details necessary to take corrective action • RESOLVE • Bad actor equipment reliability issues • Implement and prioritize corrective measures

6. IDENTIFY High-Consequence Failure EventsThe Bottom Line

7. ANALYZE Failure details:Equipment-Level Analysis

8. ANALYZE Failure details:Component-Level Analysis

9. ANALYZE Failure details:Component-Level Analysis

10. RESOLVE Bad-Actor Equipment Issues • Implement corrective measures for bad actor equipment, e.g.: • Preventive maintenance • Inspections • Procedures • Facilities changes • Prioritize corrective measures based on: • Actual consequences • Future consequence potential

11. PERD ERP Application in Enterprise Software • Architecture • Native to enterprise software • Built-into work management processes • SAP certified solution • Main components • Technical hierarchy • Malfunction reporting • Consequence accounting • PM condition reporting • Data aggregation • Data quality management If you can’t analyze 1000+ things at once, you not doing it right!

12. Design Principals • SIMPLIFY • Integrate equipment reliability and work execution processes • Instill data quality at inception • Structure data for optimal accessibility • STANDARDIZE • Use methods consistent with industry and international standard processes • Represent facilities in a logical and standard manner • One system of record for all technical tags • One unique ID for each equipment object throughout all systems and records and in the field • Use standard failure data collection, merging, and assessment processes • Same look and feel for all malfunction reporting • AUTOMATE • Use system-driven data quality-assurance processes

13. Thank you The CCPS PERD Project perd@aiche.org