Process Equipment Failure Frequencies

Det Norske Veritas TECHNICAL NOTE Section 1

Prepared by: J R Spouge / E Funnemark

PROCESS EQUIPMENT Date: 20.12 06

Issued at RiskNet FAILURE FREQUENCIES Ref: T14 - Rev: 3

© DNV RiskNet Document

TECHNICAL NOTE T14

PROCESS EQUIPMENT FAILURE FREQUENCIES






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.






Section No.

Equipment Type Link Leak Frequency

Datasheet (Section 1.7)

Link (Sections 2-21)

2 Process pipes D1 Process pipes 3 Pipe connections (including flanges,

gaskets and mechanical connectors) Pipe connections

Flanges D2 4 Valves Valves

Manual valves D3 Actuated valves D4

5 Combined pipework (small-bore fittings, instruments, and pipe sections, i.e. combinations of pipes, flanges, valves and small-bore fittings)

Combined pipework

Instruments D5 6 Cross-country pipelines Cross-country pipelines 7 Pressure vessels (including storage

vessels, process vessels, columns, reactors)

Process vessels D6 Pressure vessels 8 Atmospheric storage tanks Atmospheric storage

tanks 9 Refrigerated storage tanks Refrigerated storage

tanks 10 Underground storage tanks Underground storage

tanks 11 Pumps Pumps

Centrifugal pumps D7 Reciprocating pumps D8

12 Compressors Compressors Centrifugal compressors D9 - Reciprocating compressors D10 -

13 Heat exchangers (including coolers, heaters and condensers)

Heat exchangers

Shell side heat exchangers D11 Tube side heat exchangers D12 Plate heat exchangers D13 Air-cooled heat exchangers D14

14 Fired heaters (including furnaces, boilers and reformers)

Fired heaters

15 Filters D15 Filters






16 Pig traps D16 Pig traps 17 Transfer equipment

(loading/unloading hoses and articulated arms)

Transfer equipment

18 Road vehicles Road vehicles 19 Dangerous goods vehicles

(including road tankers and cylinder vehicles)

Dangerous goods vehicles

20 Railway wagons (including rail tankers and goods wagons)

Railway wagons

21 Marine vessels (including oil tankers and gas carriers)

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






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 SECTION NO DATASHEET Absorbers 7 D6 Air receivers 7 Atmospheric storage tanks 8 Bellows 3 Boilers 7, 14 Bullets 7 Cars 18 Caverns 10.7 Clamp connections 3 D2 Columns 7 D6 Combined pipework 5 Compressors 12 D9-10 Condensers 13 Coolers 13 Cross-country pipelines 6 Cylinders 7 Cylinder vehicles 19 Distillation columns 7 D6 Drums 7 ESD valves 4 D4 Filters 15 D15 Fin-fan coolers 13 D14 Fired heaters 14 Fittings (small-bore) 5.5 D5 Flanges 3 D2 Gaskets 3 Gas receivers 7 Goods vehicles 18 Grayloc connectors 3 D2 Heaters 13 Heat exchangers 13 D11-D14 Hydrocyclones 7 Instruments 5.5 D5 ISO tanks 20.4 Joints (in pipes) 3 Knock-out drums 7 D6 Marine tankers 21.3 Petrol filling station tanks 10.5 Pig traps (launchers/receivers) 16 D16 Pipe connections 3 D2 Pipelines 6 Pipes 2 D1






SUBJECT SECTION NO DATASHEET Pipe sections 5.6 Pipe stills 14 Pressure vessels 7, 10.6 D6 Process reactors 7 D6 Process vessels 7 D6 Pumps 11 D7-D8 Rail tankers 20.2 Railways 20 Reactors 7 D6 Reboilers 13 Receivers 7 Reformers 14 Refrigerated storage tanks 9 Relief valves 4 Road vehicles 18 Road tankers 19 Salt dome caverns 10.8 Scrubbers D6 Separators 7 D6 Ships 21 Small-bore fittings 5.5 D5 Spheres 7 Tanks 7, 8, 9, 10 Tankers (ships) 21.3 Transfer equipment 17 Underground storage tanks 10 Valves 4 D3-D4 Vaporisers 13, 14 Vessels 7 D6 Waste heat boilers 13 Welds (in pipes) 2.9.16

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:

catruppipenpipe

m FFaDCDddF +++= )1()( 2

However, the equation used in the above referred Statoil project is slightly different (which is also the basis for the following datasheets:

rupmn

pipe FdaDCdF ++= )1()(

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






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.

Please use the << Back link at the bottom of this page to return to the Equipment list, NOT the Browser’s Back button.


Process Equipment Leak Frequencies

Prep. by: J.R. Spouge

Rev.: 2

Equipment Type: D1 Steel Pipes Date: 10.02.05

Source: HCRD 10/92 – 03/03

Definition: Offshore: Includes pipes located on topsides (between well and riser) and subsea (between well and pipeline). Onshore: Includes pipes within process units, but not inter-unit pipes or cross-country pipelines. The scope includes welds but excludes all valves, flanges, and instruments.

Frequency Function:

F(d) = C(1 + aDn) dm + Frup

F = frequency of leaks (per metre year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per metre year) D = pipe diameter (mm) d = hole diameter (mm)

SCENARIO C a n m Frup

Total leaks 3.7E-05 1000 -1.5 -0.74 3.0E-06 Full leaks 8.0E-06 1000 -1.3 -1.42 0.0E+00 Zero pressure 9.0E-06 0 0.0 -0.50 1.0E-06

Range of validity: D = 20 to 1000mm; d = 1mm to D

Frequency Plot: Example 150mm diameter pipe

1.0E-07

1.0E-06

1.0E-05

1.0E-04

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er m

etre

yea

r)

Total leaksLimited leaksZero pressure leaksFull leaks

Input Data: HCRD (October 1992 to March 2003)

PIPE DIAMETER (in)

LEAKS (#)

LEAKS (exc N/A and <1mm)

EXPOSURE (metre years)

≤3 335 316 1,539,554 3-11 169 149 2,577,294 >11 42 36 722,242

TOTAL 546 501 4,839,090

<< Back





Rev.: 2

Equipment Type: D1 Steel Pipes Date: 10.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Selected steel pipe sizes.

(a) Total leak frequencies (per metre year)

HOLE DIA RANGE (mm)

2" DIA (50 mm)

6" DIA (150 mm)

12" DIA (300 mm)

18" DIA (450 mm)

24" DIA (600 mm)

1-3 7.9E-05 3.2E-05 2.5E-05 2.3E-05 2.2E-05 3-10 3.7E-05 1.5E-05 1.2E-05 1.1E-05 1.0E-05

10-50 2.9E-05 7.2E-06 5.6E-06 5.2E-06 5.0E-06 50-150 0.0E+00 6.2E-06 1.4E-06 1.3E-06 1.2E-06 >150 0.0E+00 0.0E+00 4.1E-06 4.0E-06 4.0E-06

TOTAL 1.4E-04 6.0E-05 4.7E-05 4.4E-05 4.3E-05

(b) Full leak frequencies (per metre year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 4.5E-05 1.6E-05 1.0E-05 8.6E-06 7.9E-06 3-10 9.9E-06 3.4E-06 2.2E-06 1.9E-06 1.7E-06


TOTAL 5.7E-05 2.0E-05 1.3E-05 1.1E-05 1.0E-05

(c) Zero pressure leak frequencies (per metre year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 3.8E-06 3.8E-06 3.8E-06 3.8E-06 3.8E-06 3-10 2.4E-06 2.4E-06 2.4E-06 2.4E-06 2.4E-06


TOTAL 1.0E-05 1.0E-05 1.0E-05 1.0E-05 1.0E-05

(d) Limited leak frequencies (per metre year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 3.0E-05 1.2E-05 1.1E-05 1.0E-05 1.0E-05 3-10 2.5E-05 9.2E-06 7.0E-06 6.5E-06 6.3E-06


TOTAL 7.7E-05 3.0E-05 2.4E-05 2.3E-05 2.3E-05

<< Back





Rev.: 2

Equipment Type: D2 Flanges Date: 24.02.05

Source: HCRD 10/92 – 03/03

Definition: The following frequencies refer to a flanged joint, comprising two flange faces, a gasket (where fitted), and two welds to the pipe. Flange types include ring type joint, spiral wound, clamp (Grayloc) and hammer union (Chicksan).

Frequency Function:

F(d) = C(1 + aDn) dm + Frup

F = frequency of leaks (per flanged joint year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per flanged joint year) D = flange diameter (mm), i.e. diameter of connected pipe d = hole diameter (mm)


Total leaks 7.5E-05 1.9E-04 1.5 -0.84 5.0E-06 Full leaks 3.0E-05 5.3E-05 1.8 -1.22 0.0E+00 Zero pressure 5.0E-06 3.8E-05 1.8 -0.33 0.0E+00


Frequency Plot: Example 150mm diameter flange

1.0E-07

1.0E-06

1.0E-05

1.0E-04

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er fl

ange

yea

r)



FLANGE DIAMETER

(in) LEAKS

(#) LEAKS

(exc N/A and <1mm) HSE EXPOSURE (flange face years)

DNV EXPOSURE (flanged joint years)

≤3 128 125 3,118,164 1,559,082 3-11 112 111 1,957,942 978,971 >11 32 29 295,659 147,830

TOTAL 272 265 5,371,765 2,685,883 • HSE exposure counting “flange faces” has been halved to give DNV exposure of “flanged joints”, each

consisting of 2 flange faces.

<< Back





Rev.: 2

Equipment Type: D2 Flanges Date: 24.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Selected flange sizes.

(a) Total leak frequencies (per flanged joint year)

HOLE DIA RANGE (mm)

2" DIA (50 mm)

6" DIA (150 mm)

12" DIA (300 mm)

18" DIA (450 mm)

24" DIA (600 mm)

1-3 4.8E-05 6.1E-05 9.0E-05 1.3E-04 1.7E-04 3-10 2.0E-05 2.6E-05 3.8E-05 5.3E-05 7.2E-05


TOTAL 8.5E-05 1.1E-04 1.5E-04 2.2E-04 2.9E-04

(b) Full leak frequencies (per flanged joint year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 2.3E-05 3.2E-05 5.6E-05 9.2E-05 1.4E-04 3-10 6.4E-06 8.7E-06 1.5E-05 2.5E-05 3.8E-05


TOTAL 3.2E-05 4.3E-05 7.6E-05 1.2E-04 1.9E-04

(c) Zero pressure leak frequencies (per flanged joint year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 1.6E-06 2.0E-06 3.2E-06 5.0E-06 7.3E-06 3-10 1.2E-06 1.5E-06 2.4E-06 3.7E-06 5.5E-06


TOTAL 5.2E-06 6.6E-06 1.0E-05 1.6E-05 2.4E-05

(d) Limited leak frequencies (per flanged joint year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 2.3E-05 2.7E-05 3.1E-05 3.0E-05 2.4E-05 3-10 1.3E-05 1.5E-05 2.0E-05 2.4E-05 2.8E-05


TOTAL 4.8E-05 5.6E-05 6.8E-05 7.5E-05 7.6E-05

<< Back





Rev.: 1

Equipment Type: D3 Manual Valves Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Includes all types of manual valves (block, bleed, check and choke). Valve types gate, ball, plug, globe, needle and butterfly. The scope includes the valve body, stem and packer, but excludes flanges, controls and instrumentation.

Frequency Function: F(d) = C(1 + aDn) dm + Frup

F = frequency of leaks (per valve year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per valve year) D = valve diameter (mm) d = hole diameter (mm)


Total leaks 7.0E-05 3.4E-05 2.0 -0.76 1.0E-05 Full leaks 6.0E-06 3.8E-03 1.5 -1.17 0.0E+00 Zero pressure 1.0E-08 6.8 1.0 -0.15 0.0E+00


Frequency Plot: Example 150mm diameter valve

1.0E-07

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er v

alve

yea

r)



VALVE DIAMETER

(in) LEAKS

(#) LEAKS

(exc N/A and <1mm) EXPOSURE (valve years)

≤3 96 88 1,060,745 3-11 48 45 369,359 >11 20 19 36,284

TOTAL 164 152 1,466,388

<< Back





Rev.: 1

Equipment Type: D3 Manual Valves Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Selected valve sizes.

(a) Total leak frequencies (per valve year)

HOLE DIA RANGE (mm)

2" DIA (50 mm)

6" DIA (150 mm)

12" DIA (300 mm)

18" DIA (450 mm)

24" DIA (600 mm)

1-3 4.3E-05 7.0E-05 1.6E-04 3.1E-04 5.2E-04 3-10 2.0E-05 3.2E-05 7.4E-05 1.4E-04 2.4E-04


TOTAL 8.6E-05 1.3E-04 2.9E-04 5.6E-04 9.4E-04

(b) Full leak frequencies (per valve year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 1.0E-05 3.5E-05 9.0E-05 1.6E-04 2.5E-04 3-10 2.9E-06 1.0E-05 2.6E-05 4.7E-05 7.1E-05


TOTAL 1.4E-05 4.8E-05 1.2E-04 2.2E-04 3.4E-04

(c) Zero pressure leak frequencies (per valve year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 5.2E-07 1.6E-06 3.1E-06 4.7E-06 6.2E-06 3-10 4.8E-07 1.4E-06 2.9E-06 4.3E-06 5.7E-06


TOTAL 3.4E-06 1.0E-05 2.0E-05 3.1E-05 4.1E-05

(d) Limited leak frequencies (per valve year) HOLE DIA

RANGE (mm) 2" DIA

(50 mm) 6" DIA

(150 mm) 12" DIA

(300 mm) 18" DIA

(450 mm) 24" DIA

(600 mm) 1-3 3.2E-05 3.4E-05 6.8E-05 1.5E-04 2.7E-04 3-10 1.6E-05 2.1E-05 4.5E-05 9.3E-05 1.6E-04


TOTAL 6.8E-05 7.5E-05 1.5E-04 3.1E-04 5.5E-04

<< Back





Rev.: 2

Equipment Type: D4 Actuated Valves Date: 3.05.05

Source: HCRD 10/92 – 03/03

Definition: Includes all types of actuated valves (block, blowdown, choke, control, ESDV and relief), but not actuated pipeline valves (pipeline ESDV and SSIV). Valve types include gate, ball, plug, globe and needle. The scope includes the valve body, stem and packer, but excludes flanges, controls and instrumentation.


F = frequency of leaks (per valve year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per valve year) D = valve diameter (mm) d = hole diameter (mm)


Total leaks 6.9E-04 0 0 -0.82 0.0E+00 Full leaks 2.6E-04 0 0 -1.26 0.0E+00 Zero pressure 4.4E-05 0 0 -0.37 0.0E+00


Frequency Plot: Example 150mm diameter valve

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er v

alve

yea

r)



LEAKS LEAKS

(exc N/A and <1mm) EXPOSURE (valve years)

204 187 272206

<< Back





Rev.: 2

Equipment Type: D4 Actuated Valves Date: 3.05.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per valve year) for valves >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 4.1E-04 1.9E-04 1.5E-05 2.0E-04 3-10 1.8E-04 5.1E-05 1.1E-05 1.1E-04

10-50 7.7E-05 1.2E-05 8.4E-06 5.6E-05 50-150 1.7E-05 1.4E-06 3.5E-06 1.2E-05 >150 1.1E-05 4.7E-07 6.9E-06 4.0E-06

TOTAL 6.9E-04 2.6E-04 4.4E-05 3.9E-04

<< Back





Rev.: 1

Equipment Type: D5 Instruments Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Includes small-bore connections for flow, pressure and temperature sensing. The scope includes the instrument itself plus up to 2 valves, 4 flanges, 1 fitting and associated small-bore piping, usually 25mm diameter or less.

Frequency Function: F(d) = C dm + Frup

F = frequency of leaks (per instrument connection year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per instrument connection year) D = instrument connection diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup

Total leaks 6.1E-04 -0.80 0.0E+00 Full leaks 2.3E-04 -0.88 0.0E+00 Zero pressure 2.5E-05 -0.44 0.0E+00


Frequency Plot: Example 25mm diameter instrument

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

inst

rum

ent y

ear)



LEAKS LEAKS

(exc N/A and <1mm) EXPOSURE

(instrument years) 409 370 607414

<< Back





Rev.: 1

Equipment Type: D5 Instruments Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per instrument year) for instruments 10-50mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 3.6E-04 1.4E-04 9.6E-06 2.0E-04 3-10 1.6E-04 5.7E-05 6.3E-06 9.3E-05

10-50 9.7E-05 3.0E-05 9.1E-06 5.7E-05 50-150 0.0E+00 0.0E+00 0.0E+00 0.0E+00 >150 0.0E+00 0.0E+00 0.0E+00 0.0E+00

TOTAL 6.1E-04 2.3E-04 2.5E-05 3.6E-04

<< Back





Rev.: 1

Equipment Type: D6 Process Vessels Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Offshore: Includes all types of pressure vessel (horizontal/vertical absorber, knock-out drum, reboiler, scrubber, separator and stabiliser), but not the HCRD category “other”, which are mainly hydrocyclones. Onshore: Includes process vessels and columns, but not storage vessels. The scope includes the vessel itself and any nozzles or inspection openings, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per vessel year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per vessel year) D = diameter (mm) of the largest pipe connection d = hole diameter (mm)

SCENARIO C m Frup

Total leaks 1.8E-03 -0.43 1.0E-04 Full leaks 5.0E-04 -0.38 0.0E+00 Zero pressure 4.3E-04 -0.18 0.0E+00


• Catastrophic ruptures should be modelled separately

Frequency Plot: Example vessel with maximum 150mm diameter connection

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

ves

sel y

ear)



LEAKS

(#) LEAKS

(exc N/A and <1mm) EXPOSURE (vessel years)

35 26 14069

<< Back





Rev.: 1

Equipment Type: D6 Process Vessels Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per vessel year) for connections >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 6.8E-04 1.7E-04 7.7E-05 4.3E-04 3-10 4.5E-04 1.2E-04 6.9E-05 2.6E-04

10-50 3.3E-04 9.5E-05 7.1E-05 1.7E-04 50-150 1.3E-04 3.9E-05 3.8E-05 4.9E-05 >150 3.1E-04 7.4E-05 1.7E-04 6.0E-05

TOTAL 1.9E-03 5.0E-04 4.3E-04 9.7E-04

<< Back





Rev.: 2

Equipment Type: D7 Centrifugal Pumps Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition: Centrifugal pumps including single-seal and double-seal types. The scope includes the pump itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per pump year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per pump year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



Frequency Plot: Example pump with 150mm diameter inlet

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

pum

p ye

ar)



LEAKS

(#) LEAKS

(exc N/A and <1mm) EXPOSURE (pump years)

88 78 11942

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Rev.: 2

Equipment Type: D7 Centrifugal Pumps Date: 14.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per pump year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 4.2E-03 1.3E-03 2.2E-04 2.7E-03 3-10 1.6E-03 3.9E-04 1.5E-04 1.0E-03

10-50 5.7E-04 1.2E-04 1.1E-04 3.4E-04 50-150 1.0E-04 1.7E-05 4.1E-05 4.4E-05 >150 5.6E-05 7.3E-06 4.8E-05 0.0E+00

TOTAL 6.5E-03 1.8E-03 5.7E-04 4.1E-03

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Rev.: 1

Equipment Type: D8 Reciprocating Pumps Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Reciprocating pumps including single-seal and double-seal types. The scope includes the pump itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per pump year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per pump year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



Frequency Plot: Example pump with 150mm diameter inlet

1.0E-06

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

pum

p ye

ar)



LEAKS

(#) LEAKS

(exc N/A and <1mm) EXPOSURE (pump years)

16 15 2167

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Rev.: 1

Equipment Type: D8 Reciprocating Pumps Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per pump year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 3.1E-03 1.6E-03 1.1E-04 1.4E-03 3-10 1.8E-03 9.7E-04 9.1E-05 7.7E-04

10-50 1.2E-03 6.5E-04 8.6E-05 4.2E-04 50-150 3.7E-04 2.2E-04 4.2E-05 1.1E-04 >150 4.6E-04 3.0E-04 1.3E-04 2.8E-05

TOTAL 6.9E-03 3.7E-03 4.6E-04 2.7E-03

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Rev.: 2

Equipment Type: D9 Centrifugal Compressors Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition: The scope includes the compressor itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per compressor year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per compressor year) D = inlet pipe diameter (mm) d = hole diameter (mm)


Total leaks 9.0E-03 0 0 -0.79 0.0E+00 Full leaks 2.0E-03 0 0 -1.76 0.0E+00 Zero pressure 8.2E-04 0 0 -0.28 0.0E+00


Frequency Plot: Example compressor with 150mm diameter inlet

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1.0E-01

1 10 100 1000 10000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er c

ompr

esso

r yea

r)



LEAKS LEAKS


(compressor years) 27 22 2442

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Rev.: 2

Equipment Type: D9 Centrifugal Compressors Date: 14.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per compressor year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 5.2E-03 1.7E-03 2.2E-04 3.3E-03 3-10 2.3E-03 2.5E-04 1.7E-04 1.9E-03

10-50 1.1E-03 3.3E-05 1.6E-04 8.6E-04 50-150 2.4E-04 1.7E-06 1.0E-04 1.3E-04 >150 1.7E-04 3.0E-07 1.7E-04 0.0E+00

TOTAL 9.0E-03 2.0E-03 8.2E-04 6.2E-03

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Rev.: 1

Equipment Type: D10 Reciprocating Compressors Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: The scope includes the compressor itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per compressor year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per compressor year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup

Total leaks 6.2E-02 -1.00 0.0E+00 Full leaks 2.7E-02 -2.00 0.0E+00 Zero pressure 0.0E+00 0.00 0.0E+00


Frequency Plot: Example compressor with 150mm diameter inlet

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1.0E-01

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er c

ompr

esso

r yea

r)

Total leaksLimited leaksFull leaks


LEAKS LEAKS


(compressor years) 27 25 402

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Rev.: 1

Equipment Type: D10 Reciprocating Compressors Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per compressor year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 4.1E-02 2.4E-02 0.0E+00 1.7E-02 3-10 1.4E-02 2.7E-03 0.0E+00 1.2E-02

10-50 5.0E-03 2.6E-04 0.0E+00 4.7E-03 50-150 8.3E-04 9.6E-06 0.0E+00 8.2E-04 >150 4.1E-04 1.2E-06 0.0E+00 4.1E-04

TOTAL 6.2E-02 2.7E-02 0.0E+00 3.5E-02

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Rev.: 1

Equipment Type: D11 Shell Side Heat Exchangers Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Shell & tube type heat exchangers with hydrocarbon in the shell side. The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded


F = frequency of leaks (per heat exchanger year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per heat exchanger year) D = shell side inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



Frequency Plot: Example heat exchanger with 150mm diameter inlet

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

hea

t exc

hang

er y

ear)



LEAKS LEAKS


(heat exchanger years)

16 13 2780

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Rev.: 1

Equipment Type: D11 Shell Side Heat Exchangers Date: 16.07.04

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per heat exchanger year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 2.4E-03 6.8E-04 1.0E-04 1.6E-03 3-10 1.2E-03 3.7E-04 7.8E-05 8.0E-04

10-50 6.8E-04 2.2E-04 6.9E-05 4.0E-04 50-150 1.9E-04 6.5E-05 3.1E-05 9.3E-05 >150 1.8E-04 6.9E-05 8.0E-05 3.2E-05

TOTAL 4.7E-03 1.4E-03 3.6E-04 2.9E-03

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Rev.: 2

Equipment Type: D12 Tube Side Heat Exchangers Date: 16.07.04

Source: HCRD 10/92 – 03/03

Definition: Shell & tube type heat exchangers with hydrocarbon in the tube side. The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per heat exchanger year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per heat exchanger year) D = tube side inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup




1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

hea

t exc

hang

er y

ear) Total leaks

Limited leaksZero pressure leaksFull leaks


LEAKS LEAKS



19 15 4965

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Rev.: 2

Equipment Type: D12 Tube Side Heat Exchangers Date: 14.02.05

Source: HCRD 10/92 – 03/03


HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 1.8E-03 5.7E-04 8.5E-05 1.1E-03 3-10 7.7E-04 2.6E-04 5.2E-05 4.6E-04

10-50 3.4E-04 1.2E-04 3.5E-05 1.9E-04 50-150 7.7E-05 2.8E-05 1.2E-05 3.7E-05 >150 5.4E-05 2.1E-05 1.6E-05 1.7E-05

TOTAL 3.0E-03 1.0E-03 2.0E-04 1.8E-03

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Rev.: 1

Equipment Type: D13 Plate Heat Exchangers Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition: The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per heat exchanger year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per heat exchanger year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



• No zero pressure scenarios were identified from HCRD.


1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

hea

t exc

hang

er y

ear)

Total leaksLimited leaksFull leaks


LEAKS LEAKS



25 25 2223

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Rev.: 1

Equipment Type: D13 Plate Heat Exchangers Date: 16.07.04

Source: HCRD 10/92 – 03/03


HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 5.3E-03 3.3E-03 0.0E+00 2.0E-03 3-10 2.9E-03 1.6E-03 0.0E+00 1.3E-03

10-50 1.7E-03 7.8E-04 0.0E+00 9.3E-04 50-150 5.1E-04 2.0E-04 0.0E+00 3.1E-04 >150 5.4E-04 1.6E-04 0.0E+00 3.8E-04

TOTAL 1.1E-02 6.0E-03 0.0E+00 5.0E-03

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Rev.: 2

Equipment Type: D14 Air-Cooled Heat Exchangers

Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition: Defined in HCRD as fin-fan coolers, but in principle including all air-cooled type heat exchangers. The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per heat exchanger year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per heat exchanger year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



• No zero pressure scenarios were identified from HCRD.


1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FRE

QU

EN

CY

OF

HO

LE >

= S

IZE

(per

hea

t exc

hang

er y

ear)

Total leaks

Full leaks +limited leaks


LEAKS LEAKS



2 2 839

<< Back





Rev.: 2

Equipment Type: D14 Air-Cooled Heat Exchangers

Date: 14.02.05

Source: HCRD 10/92 – 03/03


HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 1.3E-03 6.6E-04 0.0E+00 6.6E-04 3-10 6.3E-04 3.1E-04 0.0E+00 3.1E-04

10-50 3.1E-04 1.5E-04 0.0E+00 1.5E-04 50-150 7.6E-05 3.8E-05 0.0E+00 3.8E-05 >150 6.2E-05 3.1E-05 0.0E+00 3.1E-05

TOTAL 2.4E-03 1.2E-03 0.0E+00 1.2E-03

<< Back





Rev.: 2

Equipment Type: D15 Filters Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition:


F = frequency of leaks (per filter year) exceeding size d C, m = constants representing hole size distribution Frup = additional rupture frequency (per filter year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



Frequency Plot: Example 150mm diameter filter

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er fi

lter y

ear)



LEAKS LEAKS

(exc N/A and <1mm) EXPOSURE (filter years)

38 37 10072

<< Back





Rev.: 2

Equipment Type: D15 Filters Date: 14.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per filter year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 1.9E-03 6.7E-04 9.9E-05 1.1E-03 3-10 9.8E-04 1.7E-04 8.1E-05 7.3E-04

10-50 5.3E-04 4.2E-05 7.5E-05 4.1E-04 50-150 1.4E-04 4.8E-06 3.6E-05 1.0E-04 >150 1.4E-04 1.6E-06 1.1E-04 2.5E-05

TOTAL 3.7E-03 8.9E-04 4.0E-04 2.4E-03

<< Back





Rev.: 2

Equipment Type: D16 Pig Traps Date: 14.02.05

Source: HCRD 10/92 – 03/03

Definition: Includes pig launchers and pig receivers. The scope includes the pig trap itself, but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.


F = frequency of leaks (per pig trap year) exceeding size d C, m = constants representing hole size distribution a, n = constants representing equipment size dependency Frup = additional rupture frequency (per pig trap year) D = inlet pipe diameter (mm) d = hole diameter (mm)

SCENARIO C m Frup



Frequency Plot: Example 150mm diameter pig trap

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1 10 100 1000

HOLE DIAMETER (mm)

FREQ

UEN

CY

OF

HO

LE >

= SI

ZE(p

er p

ig tr

ap y

ear)



LEAKS LEAKS


(pig trap years) 19 17 3189

<< Back





Rev.: 2

Equipment Type: D16 Pig Traps Date: 14.02.05

Source: HCRD 10/92 – 03/03

Frequency Tables: Frequency (per pig trap year) for inlets >150mm diameter

HOLE DIA

RANGE (mm)

TOTAL LEAKS

FULL LEAKS

ZERO PRESSURE

LEAKS

LIMITED LEAKS

1-3 1.9E-03 1.4E-03 1.6E-04 3.5E-04 3-10 1.3E-03 2.7E-04 1.5E-04 8.8E-04

10-50 1.0E-03 4.9E-05 1.7E-04 7.8E-04 50-150 3.9E-04 3.9E-06 1.0E-04 2.9E-04 >150 7.1E-04 9.3E-07 7.1E-04 7.6E-07

TOTAL 5.3E-03 1.7E-03 1.3E-03 2.3E-03

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Process Equipment Failure Frequencies

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Transcript of Process Equipment Failure Frequencies