In today's refining and petrochemical industries, sustained long term reliability is key to profitability and competitiveness. Becht has for many years been on the leading edge, based on our experience, in the development of Equipment Reliability Plans (ERP). Becht Engineering has the expertise and tools to successfully help clients with plant-wide, unit-wide, or equipment specific reliability issues. These tools include cutting-edge economic analysis programs which facilitate the development of risk-based, cost-effective, long-term maintenance strategies.
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 rotating equipment who assist as needed in development of failure mechanisms, probability of failure and failure modes.
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.