CAPITAL PROJECT AND GREENFIELD RELIABILITY CENTERED DESIGN

Design for Reliability. Optimize Lifecycle Costs. Maximize Availability from Startup.

When building a new unit or facility, reliability is often not a major focus. However, improper design can lead to significant increased lifecycle cost over the operational life of an asset. For that reason, it's important to ensure you're designing with reliability in mind during the design phase, as it's the most cost-effective way of making a facility reliable to maximize production and return on investment.

Common Challenges We Help Solve

Inadequate design/maintenance considerations present reliability issues and associated downtime prior to the first turnaround

Improper metallurgy selection during design results in elevated corrosion rates and higher loss of containment risk

Tank buffering not properly accounted for in design, which leads to downtime

Maintenance costs higher than anticipated after startup because maintainability was not considered in design phase

How We Solve These Challenges

Designing with reliability in mind is the only way to truly minimize lifecycle cost of your assets. We can support your facility by leveraging the following solutions:

RAM Modeling

RAM Modeling, utilizing a Monte Carlo statistical approach, simulates future performance situations for a given process design. The output is used to quantify the economics or other design options, including equipment redundancy, spare parts, equipment sizing, maintenance practices and policies, quality of components, and other variables. By using this analysis during Front End Engineering Design (FEED), the following can be identified:

    • Critical unavailability contributors
    • Validation of design throughput and performance criteria

Reliability Centered Design

Reliability Centered Design (RCD) analysis builds asset management principles into greenfield facilities before construction begins, which reduces the maintenance, repair, and staff requirements of your facility without sacrificing your operational goals. The RCD process includes a complete review of the design from the perspective of key operations and maintenance staff, management, and process experts prior to finalizing the design. Design deficiencies that affect system reliability and availability are identified, and risk-justified redesign recommendations are provided to the project team for review and possible incorporation into the project design. The RCD process also identifies equipment configuration best practice opportunities and critical/capital spare parts. RCD then forms the foundation of a reliability-based asset management program for your facility through expansion into full Reliability Centered Maintenance for the final design.

Mechanical Integrity and Metallurgical Analysis

Reviewing the design for Mechanical Integrity will ensure the right metallurgy and design elements are being introduced to minimize loss of containment risk and optimize lifecycle cost prior to startup. This step is crucial to identifying weak design elements that are not traditionally designed for by most Engineering, Procurement, and Construction (EPC) firms.

These services are managed under a single project management team that works in tandem with the EPC firm to ensure alignment between customer and end user. This results in a seamless integrated offering that enables owner-operators to build the entire Reliability, Maintenance, and Mechanical Integrity programs prior to startup.

Contact Us to Learn More About Designing for Reliability