Operation Risk Management of Planning and Piping Design in a Large Petrochemical Plant Project

Purpose – The purpose of this paper is to present practical and research lessons learned from analysis and the identification of failures which can occur. Failure mode and effects piping analysis (FMEPA) has been shown to be an effective way of improving piping design reliability. FMEPA is also employed for making sample control plans. Design/methodology/approach – To reduce project losses by using failure mode and effects piping analysis as a tool for analysis of the piping design department. The samples were selected from five projects. It was found that nine major points yielded a risk priority number (RPN) higher than 125. Findings – Results of RPN calculation concerning four topics revealed that the RPN value was reduced from 211 to 75, demonstrating a 64.4 percent improvement. Research limitations/implications – The study is limited to a planning and piping case study which considers RPN. Testing of the performance network regression model can be employed in companies, in which quality control has been implemented of solutions for failure prevention of piping design. Practical implications – This paper serves practitioners as a guideline and tool to understand and implement the FMEPA methodology. At this level, management sets the limits for determining measures. Management also decides whether a risk is acceptable or not. Management needs to clarify which risk priority number (RPN) represents the critical level above which requires risk reduction. Social implications – Conflicts and social unrest can cause costly delays to new projects and operations. Conflicts can also result in damage to a company’s reputation. This depends on the company’s responses to the conflict and the consequences or perceived consequences of its behavior and actions. Originality/value – This paper furnishes lessons learned for practitioners in various industrial sectors in preference to other methods of risk assessment and control activities.