The Center for Chemical Process Safety (CCPS) has been actively involved in pursuing equipment reliability data since the 1980’s. In 1989, the CCPS Guidelines for Equipment Reliability Data was published with the intent to support chemical process quantitative risk assessments.
At the conclusion of this project it was apparent that better data was needed. To obtain such data, it was further determined that the emphasis had to change from risk assessment to reliability and tools to improve maintenance decisions. Following this decision, the committee set about putting together an action plan meant to accomplish the following mission.
The equipment reliability database is intended to provide high quality, valid, and useful data to the HPI and CPI. This type of data allows analyzes of availability, reliability and equipment design improvements, maintenance strategies and life cycle cost determination.
The CCPS Process Equipment Reliability Database (PERD) Project was created to provide a practical approach with consistent work processes for using the data you already generate. The PERD project technology allows collection of quality data using efficient software tools that contains a defined and reproducible taxonomy , providing a fundamentally sound structure to capture data in a format that allows immediate analysis, facilitating the understanding of what the raw data means or represents. The PERD Process facilitates identification of “low hanging fruit”, identification and elimination of non-value added tasks and ensures “apples” to “apples” comparison, allowing users to understand where the application of resources will provide the greatest benefit. Several taxonomies have progressed to a quality that supports sale to the public, and additional taxonomies continue to be developed.
In this project several items are available for Full Participants:
- fundamental technical information showing the user how to generate and use equipment event data,
- technical papers showing relief device analysis results generated from data submitted to PERD, and
- developing software to enable the participant to share data within your company and with the larger CPI and HPI community.
Relief device data is available through the PERD project in a few forms. Firstly, data immediately available to PERD Full Participants was generated from early test activities to demonstrate PERD and how it could be applied in a company and industry. Several companies provided relief valve data sets, comprising multiple thousands of proof test records to PERD for analysis. A number of technical papers were generated from the data describing the analysis, various results and techniques used for their analysis. The data was provided in a format that utilized the PERD technical foundation. The taxonomy developed for spring operated relief valves highlights the technical foundation. While this data does not currently exist in the PERD software database, the papers are available in the PERD participants SharePoint site.
Currently, PERD is close to releasing its software to the participants for full use, establishing an industry database of high quality data designed to facilitate advanced analysis. By the end of 2012 we will be importing data sets into the software as well as enhancing the quality assurance regarding the data.
Secondly, data is available in your system that can be extracted using the fundamentals of PERD’s technical foundation. Using this technical foundation and an understanding of your systems, the power of the project will be unleashed to release events from your existing records. The road to accessing your data starts with developing a fundamental understanding of data structure (taxonomy) and conversion of your data to a format (csv files) that matches fields in the PERD data structure. The starting point is simply to provide your data in an Excel spreadsheet.
Upon joining as a full participant, PERD will provide you access to all the technical information that has been developed. This includes the current version of the software with initial help and guidance to get you started using the PERD technology. Starting with an initial data set in an Excel spreadsheet allows you to contribute whatever data you have, enabling you to quickly get involved and begin accruing benefits.
In the process of learning and applying the PERD concepts you will realize immediate and ongoing benefits, including a fundamental understanding of how to leverage your existing maintenance management systems to improve the quality and quantity of your data that is available for analysis for less cost.