Process Equipment Failure Frequencies

Det Norske Veritas Prepared by: J R Spouge / E Funnemark Issued at RiskNet

TECHNICAL NOTE PROCESS EQUIPMENT FAILURE FREQUENCIES

Section 1 Page 1 Date: 20.12 06 Ref: T14 - Rev: 3

TECHNICAL NOTE T14

PROCESS EQUIPMENT FAILURE FREQUENCIES

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Det Norske Veritas Prepared by: J R Spouge / E Funnemark Issued at RiskNet

TECHNICAL NOTE PROCESS EQUIPMENT FAILURE FREQUENCIES

Section 1 Page 2 Date: 20.12 06 Ref: T14 - Rev: 3

1. INTRODUCTION 1.1 Objectives This Technical Note provides failure frequency data for use in QRAs of process facilities, consisting of generic leak frequencies for each process equipment type, together with frequencies of other failure modes for valves and pumps. For each equipment type, it provides a review of the various available sources of such data, record the details of the analysis of the most useful data, and indicates how the generic values may be modified for specific individual applications.

1.2 Scope The document covers the following types of equipment and the various sections may be accessed by using the hyperlinks in the table below. Due to the availability of new HSE data and methodology for the main process items, Sections 2-5, 7, 11-13, 15 and 16 have therefore become obsolete should only be used as background information. The current leak frequencies for these items are given in the datasheets in Section 1.5. Note further that Sections 18-21 are not intended to be comprehensive sources of data or guidance on transport QRA. Their purpose is to allow consistent coverage of transport vehicles in process plant QRAs. Please note that the index in Section 1.6 indicates the location of frequencies for other equipment items.

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Section No.

2 3

TECHNICAL NOTE PROCESS EQUIPMENT FAILURE FREQUENCIES

Equipment Type

8

Process pipes Pipe connections (including flanges, gaskets and mechanical connectors) Flanges Valves Manual valves Actuated valves Combined pipework (small-bore fittings, instruments, and pipe sections, i.e. combinations of pipes, flanges, valves and small-bore fittings) Instruments Cross-country pipelines Pressure vessels (including storage vessels, process vessels, columns, reactors) Process vessels Atmospheric storage tanks

9

Refrigerated storage tanks

10

Underground storage tanks

11

Pumps Centrifugal pumps Reciprocating pumps Compressors Centrifugal compressors Reciprocating compressors Heat exchangers (including coolers, heaters and condensers) Shell side heat exchangers Tube side heat exchangers Plate heat exchangers Air-cooled heat exchangers Fired heaters (including furnaces, boilers and reformers) Filters

4

5

6 7

12

13

14 15

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Link Leak Frequency Datasheet (Section 1.7) D1

Section 1 Page 3 Date: 20.12 06 Ref: T14 - Rev: 3

Link (Sections 2-21)

Process pipes Pipe connections

D2 Valves D3 D4 Combined pipework

D5 Cross-country pipelines

D6

Pressure vessels Atmospheric storage tanks Refrigerated storage tanks Underground storage tanks Pumps

D7 D8 D9 D10

Compressors Heat exchangers

D11 D12 D13 D14 Fired heaters D15

Filters

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TECHNICAL NOTE PROCESS EQUIPMENT FAILURE FREQUENCIES

Pig traps Transfer equipment (loading/unloading hoses and articulated arms) Road vehicles Dangerous goods vehicles (including road tankers and cylinder vehicles) Railway wagons (including rail tankers and goods wagons) Marine vessels (including oil tankers and gas carriers)

18 19

20 21

D16

Section 1 Page 4 Date: 20.12 06 Ref: T14 - Rev: 3

Pig traps Transfer equipment

Road vehicles Dangerous goods vehicles Railway wagons Marine vessels

1.3 Confidentiality In general, project reports should not quote any more than the summary from each section of this Technical Note and the equipment datasheets. Material from the main body of each section may be used, but noting that it has been gathered over many years and represents an important resource to DNV.

1.4 Analysis of HSE Data The leak frequencies for the main process equipment items are based on an analysis of the HSE hydrocarbon release database (HCRD) for 1992-2003, according to a methodology described in DNV Report 2004-0869. This represents the leak size distribution by an analytical frequency function, which ensures non-zero leak frequencies for all holes sizes between 1mm and the diameter of the inlet pipe. The analysis distinguishes three different scenarios, intended to promote compatibility between the leak frequencies and the approach to outflow modelling used in the QRA: •

Full leaks are consistent with flow through the defined hole, beginning at the normal operating pressure, and continuing until controlled by emergency shut-down and blowdown (if present and operable) or inventory exhaustion. This scenario is invariably modelled in any QRA.

•

Limited leaks are cases where the pressure is not zero but the quantity released is much less than from a full leak. This may be because the leak is isolated locally by human intervention (e.g. closing an inadvertently opened valve), or by a restriction in the flow from the system inventory (e.g. leaks of fluid accumulated between pump shaft seals). This scenario may be modelled, depending on the detail of the QRA, but the consequences should reflect the limited release quantities.

•

Zero pressure leaks are pressure inside the leaking equipment is virtually zero (0.01 barg or less). This may be because the equipment has a normal operating pressure of zero (e.g. open drains), or because the equipment has been depressurised for

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TECHNICAL NOTE

Section 1 Page 5 Date: 20.12 06

PROCESS EQUIPMENT FAILURE FREQUENCIES

Ref: T14 - Rev: 3

maintenance. This scenario is typically excluded from QRA, and is included mainly for consistency with the original HSE data. The total leak frequencies are the sum of the frequencies of these three scenarios.

1.5 Index SUBJECT Absorbers Air receivers Atmospheric storage tanks Bellows Boilers Bullets Cars Caverns Clamp connections Columns Combined pipework Compressors Condensers Coolers Cross-country pipelines Cylinders Cylinder vehicles Distillation columns Drums ESD valves Filters Fin-fan coolers Fired heaters Fittings (small-bore) Flanges Gaskets Gas receivers Goods vehicles Grayloc connectors Heaters Heat exchangers Hydrocyclones Instruments ISO tanks Joints (in pipes) Knock-out drums Marine tankers Petrol filling station tanks Pig traps (launchers/receivers) Pipe connections Pipelines Pipes

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SECTION NO 7 7 8 3 7, 14 7 18 10.7 3 7 5 12 13 13 6 7 19 7 7 4 15 13 14 5.5 3 3 7 18 3 13 13 7 5.5 20.4 3 7 21.3 10.5 16 3 6 2

DATASHEET D6

D2 D6 D9-10

D6 D4 D15 D14 D5 D2

D2 D11-D14 D5

D6

D16 D2 D1

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SUBJECT Pipe sections Pipe stills Pressure vessels Process reactors Process vessels Pumps Rail tankers Railways Reactors Reboilers Receivers Reformers Refrigerated storage tanks Relief valves Road vehicles Road tankers Salt dome caverns Scrubbers Separators Ships Small-bore fittings Spheres Tanks Tankers (ships) Transfer equipment Underground storage tanks Valves Vaporisers Vessels Waste heat boilers Welds (in pipes)

SECTION NO 5.6 14 7, 10.6 7 7 11 20.2 20 7 13 7 14 9 4 18 19 10.8 7 21 5.5 7 7, 8, 9, 10 21.3 17 10 4 13, 14 7 13 2.9.16

Ref: T14 - Rev: 3 DATASHEET

D6 D6 D6 D7-D8

D6

D6 D6 D5

D3-D4 D6

1.6 LEAK software In the current LEAK software (as per September 2006) the frequency F(d) of a hole greater than size d is given by: 2 n F (d ) = d mCD pipe (1 + aD pipe ) + Frup + Fcat

However, the equation used in the above referred Statoil project is slightly different (which is also the basis for the following datasheets: n F (d ) = C (1 + aDpipe )d m + Frup

In March 2006 work was carried out in order to establish a new set of coefficients based on HCRD data up to March 2005. This was for use in LEAK and so we were establishing

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TECHNICAL NOTE PROCESS EQUIPMENT FAILURE FREQUENCIES

Section 1 Page 7 Date: 20.12 06 Ref: T14 - Rev: 3

coefficients compatible with the first of the equations given above. Furthermore, a spreadsheet tool was also developed for this purpose which can be used to derive coefficients for both equations. Hence, it should be easy to obtain coefficient for use with other equation Note that if there is no dependence on equipment size and Fcat is set to zero then both equations reduce to: F(d) = Cdm +Frup In practice this is applied to all equipment types other than pipes, flanges and valves. Consequently, for the majority of equipment types the same coefficients apply to both equation types.

1.7 Datasheets For the process items based on HCRD, the following datasheets summarise the leak frequencies for selected equipment sizes and hole size ranges. The leak frequency functions are also presented, from which the leak frequencies can be obtained for other equipment and hole sizes. The datasheets also indicate the size of the datasets on which the frequency functions are based. The index in Section 1.6 below indicates the location of frequencies for other equipment items.

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Please use the = SIZE (per metre year)

Frequency Plot:

Example 150mm diameter pipe

1.0E-04

1.0E-05

Total leaks Limited leaks Zero pressure leaks Full leaks

1.0E-06

1.0E-07 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:

HCRD (October 1992 to March 2003) PIPE DIAMETER (in) ≤3 3-11 >11 TOTAL

LEAKS (#) 335 169 42 546

LEAKS (exc N/A and 150 0.0E+00 0.0E+00 1.7E-06 1.7E-06 TOTAL 1.0E-05 1.0E-05 1.0E-05 1.0E-05

24" DIA (600 mm) 3.8E-06 2.4E-06 1.6E-06 5.4E-07 1.7E-06 1.0E-05

(d) Limited leak frequencies (per metre year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 3.0E-05 1.2E-05 1.1E-05 1.0E-05 2.5E-05 9.2E-06 7.0E-06 6.5E-06 2.3E-05 5.0E-06 3.6E-06 3.2E-06 0.0E+00 3.8E-06 7.8E-07 6.9E-07 0.0E+00 0.0E+00 2.3E-06 2.3E-06 7.7E-05 3.0E-05 2.4E-05 2.3E-05

24" DIA (600 mm) 1.0E-05 6.3E-06 3.1E-06 6.5E-07 2.2E-06 2.3E-05

HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

11 TOTAL

HCRD (October 1992 to March 2003) LEAKS (#) 128 112 32 272

LEAKS (exc N/A and