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Barringer Process Reliability (BPR) Tool
Raul Valdez
Safety Topic
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Describe a stop sign – Hint
Did you remember the white border?
Describe a “curves ahead” sign-hint
Did you feel the words “curves ahead” was
included?
Describe a yield sign - Hint
Did you feel the words “yield right of way”
should be on the sign?
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In 1971 yield signs were standardized to
the red sign that exists today
“Normalization of Deviation”
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These are the words of John Carlin, Vice President at the
Ginna Nuclear Plant, referring to a situation in the past
where chronic water leakages from the reactor refueling pit
were tolerated by the plant’s former owners.
BPR- A modified Weibull
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Many companies keep track of very noticeable losses e.g.
Failure of asset to perform function
Loss of main power
Loss due to weather related issues, etc.
Very few companies track and quantify subtle losses.
Often the subtle losses become “accepted” as normal-
”Normalized Deviation”.
The BPR tools can be used to identify and quantify losses
that are not normally realized.
The tool is a combination qualitative and quantitative tool.
Background of BPR
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Developed by Paul Barringer, Barringer and Associates, in
the 90’s.
A few consulting firms e.g. ABB and Allied started
recommending the tool to clients.
The use/acceptance of the tool is growing.
Significant firms have used the tool.
Example of BPR Plot
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Creation of a graph
Annual Production Data – Plotted in “Rain Cloud Chart” Da
ily O
utput
Day of Year
Annual Production Data – Plotted in “Rain Cloud Chart” Da
ily O
utput
Day of Year
All production rates below a “target” production rate identified by most record keeping systems -Normally equipment failures or TAR related
Annual Production Data-Plotted in BPR Plot
Annual Production Data – Plotted in “Rain Cloud Chart” Da
ily O
utput
Day of Year
“Bandwidth” of lower and upper daily production rate when unit was “under control”
Bandwidth Shown on BPR
Bandwidth of our competitors, for this process, is 250
Annual Production Data – Plotted in “Rain Cloud Chart” Da
ily O
utput
Day of Year
What is daily average production that can be counted on in the future? Hint, the average daily production rate is 37 Widgets
Daily Average Production Rate Shown on BPR
Daily production rate shown where production line crosses “Eta” or dotted line
Annual Production Data – Plotted in “Rain Cloud Chart” Da
ily O
utput
Day of Year
What percentage of time was unit operated within this bandwidth?
Bandwidth Shown on BPR
Point at which raw data is not located on production line is percent of time unit operated within bandwidth – Shown as reliability %. Our competitors at 80% on this process
What are our competitors doing, or what is nameplate?
Us
Our Competitors
What are our losses due to “crash and burn issues”?
Losses are area under “raw data” and “production line”. In this case 1,839 Widgets/Year
What are our losses due to the way we operate and manage this unit?
Losses are area under “production line” and “nameplate line”. In this case 720 Widgets/Year
Very few total losses are due to mechanical failures – Items normally identified in EChoke
Data points are mechanical failures or TAR related. In this examples losses are 41 units/year or amount normally captured in Echoke. Most losses do not fall in this area of curve.
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Any Questions
