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Software Systems


Enterprise Reliability Management System (ERMS)


An Integrated Software System to Implement Risk Based Inspection


OGM/Capstone's Reliability Based Mechanical Integrity program is a fully integrated Risk Based Inspection software package for pressure vessels, piping, storage tanks, heat exchangers (including bundles), fired heaters and relief devices. This program is the industry's first integrated software package that manages the full cycle of RBI, including automatically generated dynamic inspection plans and automatic updating of risk after an inspection is completed.


OGM/Capstone's extensive experience in helping clients implement efficient and cost effective Risk Based Inspection Programs has been used to design this software package. The program has been designed to keep the plant program up-to-date, and is easy to implement and use. It is based on an efficient and practical work flow that will promote continuous improvement of the inspection program.


Data Structure


The database is designed with an easy to use data structure. It has a familiar browser that allows the user to navigate to any part of the program with only one or two mouse clicks. The browser also allows the user to always know exactly where s/he is in the program.


Pre-designed data sheets are included for each type of equipment and major components, such as the shell, channel, and bundle of a shell and tube heat exchanger. Data from the datasheet is automatically used by the Criticality Calculator in the risk analysis. Summary data from the risk analysis is also displayed on the data sheets.


Links to External Files


The software supports links to external files, permitting easy access to documents, photographs (including scanned documents), and drawings. The linked files can include written procedures, corrosion control documents, inspection sketches, isometric drawings, scanned U-1 forms, or inspection photographs. The files can be linked at the equipment item level or with an inspection report.


Criticality Calculator


The software includes a calculator that performs the risk analysis for each type of equipment or component being evaluated. The calculator evaluates both the likelihood and consequence of failure. Based on identified failure modes, the calculator also assigns inspection priority categories, which are used by the Inspection Planning Module to recommend inspection methods, intervals and extent of inspection.


Technical Reviews to Support Risk Study


The software provides forms to capture the information required to perform the technical studies for the RBI analysis.


The corrosion study identifies the materials of construction and the process conditions that can cause deterioration of the equipment. The damage mechanisms are identified along with the critical process variables.


The form to review the prior inspection history provides a single location to summarize the previous inspections performed on the equipment. This allows inspection confidence to be assigned based on the expected damage mechanisms and the actual inspections performed.


Inspection Planning and Documentation


Modules are included for inspection planning and reporting the results of all types of inspections.


The Inspection Planner looks at the type of equipment and the failure mechanisms and applies the inspection strategies to generate a recommended inspection plan. The inspector can review and accept or modify the recommended plan to create an approved inspection plan. Once due dates are assigned for the inspections, the software will track due dates and provide notification.


Forms are provided to document all types of condition monitoring inspections, including internal and external visuals, thickness measurements, and specialized inspections such as AE, Eddy Current, PT, WFMPT, and others.


The results of the inspections are used to update the risk analysis, which in turn is used to create an updated inspection plan.