The Becht Equipment Reliability Planning (ERP) Work Process was designed to comply with the risk based inspection program as described in API RP-580 - Risk Based Inspection. It also complies with the ASME PCC-3 Inspection Planning Document. In addition, terminology and data are to a large extent consistent with API RP-571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, and API RP-581, Base Resource Document-Risk Based Inspection.
Risk-Based Equipment Reliability Planning programs are an important component of total life cycle analysis for facilities. In addition, appropriate use of risk-based decision making during the design and construction phases of a project, as well as for short term maintenance decisions (e.g. repair of a pump on an emergency basis or rely on the running spare for a few days) is also very important for integrity management. These decisions are facilitated by appropriate benefit/cost analyses that are used in all phases.
The resulting inspection and maintenance plan for each item can be tabulated and sorted both by decreasing benefit to cost ratio, and S/H/E risk levels. This allows task prioritization and enables the client to get the highest return on inspection and maintenance costs. A graphical summary of an ERP assessment sorted by decreasing benefit to cost ratio is shown below.
Critical to effective risk management is the accurate representation of failure scenarios. Becht has a team of experienced subject matter experts in all classes of industrial plant equipment who assist as needed in development of failure mechanisms, probability of failure and failure modes. Becht experts have developed a series of damage mechanism documents, which include guidance on probability of failure, to aid scenario development. A sample document is shown in the figure below.
During the on-site cross functional meetings, a team of experienced plant and Becht personnel are assembled to participate in the working sessions to develop the inspection and maintenance plans. The experts/plant personnel are typically in the areas of inspection, maintenance, materials/corrosion, and process/operations. The size of the team and need for full time/part time participation depends on the complexity of the unit and number of equipment items being addressed. Becht's Strategy Tool for Improving Equipment Reliability (STIER©) software facilitates our ERP work process; the software calculates economic risks and uses a risk matrix to determine the safety, health and environmental (S/H/E) risks. A sample S/H/E risk matrix is shown here
If an unmitigated risk is unacceptable either from an economic or S/H/E perspective, a mitigation plan is developed to reduce/manage the risk. This plan can include inspection, maintenance, or equipment upgrades or combinations thereof. The unmitigated risk probabilities and consequences are reassessed in light of the plan and a residual risk determined. The process is continued until a plan with appropriate cost/benefit return is developed that also has acceptable S/H/E residual risk. The result of the process is an inspection and maintenance plan for each equipment item that has been optimized to address the specific damage mechanisms and failure modes that have been identified for that particular item.
At the close of the ERP session, documentation is provided for each equipment item with:
- A schedule of specific monitoring/surveillance tasks by operations and maintenance personnel
- An on-stream preventative maintenance schedule
- An on-stream inspection schedule
- A turnaround inspection and maintenance work list.
- Estimate of the residual economic and S/H/E risks.
- Estimated cost of the recommended inspection and maintenance plan.
- The equipment, risk and task data, which resides in an Access database. Additionally, this data can be translated to a form suitable for uploading into work order management enterprise systems such as PCMS or SAP.
- Graphical summary of an ERP assessment sorted by decreasing benefit to cost ratio.
Becht’s ERP technology has benefited a number of clients across the globe in their new (capital projects) and existing facilities. The technology helps not only with ERP generation but also with the complex implementation of such initiatives. The combination of ERP Platform (STIER), knowledge base (BIDES), and Art work process (Inspection Based Probability Assessment) makes the Becht’s ERP process stand out in the industry. The Risk Based Inspection Planning is another industry name for the ERPs.
Becht has developed more than 50,000 risk-based inspection plans (ERPs) for refining and production facilities worldwide. These strategies were developed for Clients with commercially available software (Maximo, Meridium, STIER [Becht’s software], EAM, and SAP etc.). Our deliverables are supported by a Knowledge Base and the strategy tasks are integrated with existing Reliability and CMMS plans.