Process Plant Bad Actor Program

By Walter Lambertin

Any process plant that wishes to have a cost-effective maintenance program and maximize unit run lengths must have an effective equipment Bad Actor Program. Such a program will systematically minimize repetitive or costly repairs, extend run lengths, and focus maintenance expenditures on those items that impact on plant reliability. This will contribute to increasing profits through longer unit run lengths and reduced maintenance expenditures in the long run.

The first step in starting a general equipment Bad Actor Program is to define what a “Bad Actor” is. Each plant must develop a definition that suits their particular situation. We offer the following proposed definitions as guidance.

Static Equipment – Piping, Drums, Pressure Vessels, Heat Exchangers

Fired Equipment – Furnaces & Boilers

Other Equipment – Machinery, Instrumentation, Analyzers & Electrical

Prioritization of Bad Actors

Having a Bad Actor Program in place is not the only thing needed to have a cost-effective, process plant reliability and maintenance program. But without one, plant management cannot hope to achieve “world class” results.