The document provides an overview of the Process Equipment Reliability Database (PERD) Project. It discusses PERD's mission to operate an equipment reliability database and help companies improve their reliability and maintenance data collection processes. It also describes how PERD participants can benefit from PERD's methods for addressing common deficiencies in enterprise resource planning and computerized maintenance management systems. The document outlines PERD's bottom-line approach to optimizing equipment reliability through identifying, analyzing, and resolving high-consequence failure events and issues with "bad actor" equipment.

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

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Tony Ciliberti PE
PERD ERP Subcommittee Chair
• Thirty years experience as a reliability engineer in
petrochemical, oil and gas, and utilities
– Bachelor of Science, Chemical Engineering, Texas A&M
University, 1987
• Four years with SAP Americas’ National Practice
as a Principal Consultant and Solution Architect
• Industry standards involvement
– Center for Chemical Process Safety (CCPS) Process
Equipment Reliability Database (PERD) Project, PERD
ERP Subcommittee Chair
– ISO TC 67/WG4 PG1 (US expert): ISO 14224 -
Collection and exchange of reliability and
maintenance data for equipment
– ISO TC 67/WG4 PG2 (US expert): ISO 20815 –
Production assurance and reliability management
Principal Engineer
Reliability Dynamics LLC

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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
– Help companies improve their internal reliability and maintenance
data collection processes

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PERD ERP Subcommittee
1. Alignment with international standard ISO 14224
– PERD promulgates standard methods for application of ISO 14224
methods in enterprise software
– PERD actively participates in ISO 14224 development with an ANSI-
appointed US Expert Member in ISO TC67/WG4/PG1
2. 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
– Standard content and methods, e.g. taxonomy definitions
– Failure data quality management
3. Improving data quality in the PERD central repository
– New repository (commercial ERP software)
– Minimum requirements for high-quality trusted data

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How PERD Participants Benefit
• PERD methods address prevalent ERP/CMMS deficiencies
– Technical hierarchy construction
– Standard processes for reliability and maintenance data
– Equipment reliability data quality
– Ability to manage assets against the bottom line
• PERD methods give improved efficiency
– Collect the right data
– Analyze data en masse
– Eliminate data mining
– Use data-driven decision-making
– Focus on true priorities

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PERD Overview
• Bottom-line driven approach for optimizing equipment
reliability
– Maximize production throughput
– Minimize health, safety, and environmental hazards
• Enables corporate line-of-sight between equipment failure
events and the bottom line
• Enables data-driven decision-making with high-quality
equipment reliability data
• Helps companies identify where to focus equipment reliability
efforts

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PERD Methods by Reliability Dynamics
The Industry Standard Solution for Plant Maintenance (ISPM®)
• Standard application of ISO 14224
methods
– Software vendor certified
– Built-in solution
• Proven methodology
– 30 years – OREDA/ISO 14224
– 13 years – ISPM
• Evolutionary product
– Refined through application in
industry
(13 years)
– Solicit and incorporate customer
feedback

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Involvement in ISO TC 67/WG 4
May 2018

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PERD (ISPM) 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

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IDENTIFY High-Consequence Failure Events
The Bottom Line

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ANALYZE Failure details:
Equipment-Level Analysis

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ANALYZE Failure details:
Component-Level Analysis

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ANALYZE Failure details:
Component-Level Analysis

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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

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PERD (ISPM) Application in Enterprise
Software

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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

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Equipment Reliability Data Quality
Management
• Quality assurance
– Technical hierarchy
• Structure defines equipment
boundaries and
interrelationships
• Programmatic consistency
checks
– Malfunction reporting
• Minimum dataset for each
event
• Failure data validations
• Quality control
– Event record reviews
– Feedback to field

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PERD Details

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Technical Hierarchy Main Elements
Asset register
Equipment boundary
envelope

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Technical Hierarchy Construction
Compressor Technical Drawings

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Technical Hierarchy Construction
Compressor Taxonomy Definition

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Functional Location / Equipment
Relationship
• Functional equipment location Tag P101 is an intangible object that defines process requirements for a
particular pumping service, e.g. pressure, temperature, flow, fluid type (Tag P101 in the example below)
• Equipment items (serial numbers 1234 and 2345) define specific materialized objects that execute process
requirements
• Field equipment change-outs are captured in SAP via corresponding equipment dismantle/installation
transactions (on 5/8/2001 S/N 1234 was dismantled and S/N 2345 installed)
ISO 15926-2 (Data Model) Industrial automation systems and integration—Integration of life-cycle data for process plants including oil and gas
production facilities, Figures E.9 and E.10.
The duty represented by TAG P101, and Pump 1234 are coincident for the period of the installation, i.e. the state S1 of
Pump 1234 that is installed as TAG P101 is in fact also a state of TAG P101. TAG P101 consists of those states of the pumps
that are installed in this location.
FEL/FCL Equipment

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Technical Structure
• ERP is system of record for all
technical tags
• One unique ID for each tag
throughout all systems, records,
and in the field
• Equipment interrelationships
defined in system

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Construction of Technical Hierarchy
K-102 Equipment Boundary Envelope

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Construction of Technical Hierarchy
K-102 Specifications and Properties

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Malfunction Reporting
Impart Data Quality on Inception
Step Details Responsibility
Work Initiation Problem Report (equipment-level
failure notations)
Facility personnel
Approvals and
processing
Work approval, planning and
scheduling, create statistical records
Operations
Superintendent
Execution, repair
notes, and close-out
Repair Report (item-level failure
notations)
Maintenance Lead
Technician
Failure data quality
control
QA/QC, consequence assessment , and
methods feedback
Reliability Engineer

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Malfunction Problem Report (Work Initiation)
Equipment-Level Failure Notations

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Approvals and Processing
Data Aggregation

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Malfunction Repair Report (Work Close-out)
Component-Level Failure Notations

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Malfunction Repair Report (Work Close-out)
Event Consequence Assessment

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Preventive Maintenance and
Inspections
• Program
– Administered at grouping/admin
or technical tag level
– Results reported at technical tag
level
• PM Condition Report
– One condition report per
technical tag inspected
– Inspection verdict and condition
details
– Generated from object list of PM
inspection order
• Follow-on malfunction report
– Generated for any equipment
malfunction verdict
– Linked to PM Condition Report as
subordinate object

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RM Data Quality Control Processes
• Review malfunction and condition reports to ensure completeness
and a clear and concise description of what happened
• Identify “non-malfunction” malfunction reports and set user status
to exclude them from the failure data dataset
• Review other ERP data to identify missing failure events, e.g. review
materials booked against blanket orders of cost centers, review
preventive maintenance and inspection results to ensure follow-on
malfunction reporting was done, etc.
• Identify and document follow-on requirements, e.g. preventive
maintenance additions, facilities change requirements, SJP
requirements
• Circle-back with personnel when issues are found with completion
of malfunction reports

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Getting started with PERD
1. RM data quality check-up (complementary)1
Submit an initial dataset using the PERD Data Extract Procedure. PERD will:
– Provide feedback on the data quality of your initial submittal and your failure reporting
practices
– Recommend steps to bring your data into compliance with PERD minimum data standards
2. Evaluate PERD for your company2
– Onsite workshop covering PERD methods
– PERD prototype
• Provide P&ID and tag list for one of your equipment installations
• PERD will create a fully-functional prototype in our demo system and give
you access to that system
3. Implement PERD recommendations2
– PERD experts can assist you with implementation of our recommendations
Notes
1 Complementary, if submitted using our data extract procedure.
2 Consulting rates apply.

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Full PERD Participation
1. Join PERD
2. Contribute data to the PERD central repository (optional)
3. Notes
– The degree of data that can be accessed is defined in the participation
class table attached to the bylaws
– Access to PERD data and technical content requires payment of annual
dues of $5,000

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Thank you
Please contact Dave Belonger for further questions on this
presentation or for additional PERD Project information
perd@aiche.org
PERD Contacts
Name Position Contact
David Belonger,
DJB Associates, LLC
CCPS Staff Consultant dbelonger@verizon.net
Hal Thomas,
exida
PERD Technical Consultant
(founding member)
thomashw@exida.com
Tony Ciliberti,
Reliability Dynamics
PERD ERP Subcommittee
Chair
tony.ciliberti@rd-eam.com