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Introduction

This chapter introduces the need for process equipment failure rate data, defines the scope and organization of this book and the data it contains, and explains how to the use the book.

1.1 Background The Chemical Process Industry (CPI) uses various quantitative and qualitative techniques to assess the reliability and risk of process equipment, process systems, and chemical manufacturing operations. These techniques identify the interactions of equipment, systems, and persons that have potentially undesirable consequences. In the case of reliability analyses, the undesirable consequences (e.g., plant shutdown, excessive downtime, or production of off-specification product) are those incidents which reduce system profitability through loss of production and increased maintenance costs. In the case of risk analyses, the primary concerns are human injuries, environmental impacts, and system damage caused by occurrence of fires, explosions, toxic material releases, and related hazards. Quantification of risk in terms of the severity of the consequences and the likelihood of occurrence provides the manager of the system with an important decisionmaking tool. By using the results of a quantitative risk analysis, we are better able to answer such questions as, "Which of several candidate systems poses the least risk?" "Are risk reduction modifications necessary?" and "What modifications would be most effective in reducing risk?" In performing such a risk analysis, the risk analyst first uses hazard identification techniques such as those presented in Guidelines for Hazard Evaluation Procedures (henceforth, HEP Guidelines) such as Failure Modes and Effects Analysis (FMEA) or Hazard and Operability Studies (HAZOP) to identify the incidents or combinations of incidents that must occur to create a given consequence. The analyst may also use techniques such as fault tree analysis or event tree analysis to further define the particular process or equipment failures that will result in the incidents of concern. Using procedures contained in Guidelines for Chemical Process Quantitative Risk Analysis (henceforth, CPQRA Guidelines), the severity of the consequences is then evaluated by considering the environment in which the incident occurs and, if necessary, applying techniques such as dispersion, blast, or heat radiation modeling. To evaluate the likelihood of occurrence of the incident, the analyst must know how frequently the contributory failure incidents are likely to occur. Consequently, failure rate data for the equipment involved in the incidents is essential to the risk analysis.

1.2 Guidelines Purpose, Scope, and Organization 7.2.7 Purpose The primary purpose of this book is to provide the engineer and risk analyst with failure rate data needed to perform a CPQRA. Consequently, the book contains easily accessible data in the CCPS Generic Failure Rate Data Base, information on several available generic data resources, and procedures to develop failure rate data using information from the plant and process being studied. Another purpose is to present an approach that coordinates the collection of raw plant data, their conversion into plant-specific failure data, and their storage using a CPI-oriented taxonomy. This approach will allow future data generated by chemical process facilities to be added to the CCPS Generic Failure Rate Data Base. The book provides specifications for the transfer of data. It is hoped this approach and standardization will stimulate the chemical processing industry to generate and transfer failure rate data to CCPS for industry use. It is also expected that this book and the CCPS Taxonomy will be revised and updated when sufficient new data become available. Finally, this Guidelines is written to help engineers and analysts develop an understanding of the derivation, usefulness, and limitation of failure rate data so they can form better judgments about the use of data. 7.2.2 Scope The data presented in this book are characterized as equipment failures per 106 operating hours for time-related failure rates and failures per 103 demands for demand-related failure rates. These rates are given for some common CPI equipment. Equipment used solely to transport chemicals is not covered in this book. The cause of equipment failures, the means to improve reliability and the "most" reliable equipment are not addressed. Other types of failure rate data, such as predicted values or estimated values using expert opinion or the Delphi technique, are addressed in the CPQRA Guidelines. Sources of common cause/mode failure data are not addressed. Human error rates, though necessary for CPQRAs, and human performance in CPI facilities will be addressed in a forthcoming Guidelines. Figure 1.1 illustrates the scope of this book in relation to the CPQRA Guidelines. In preparing this book, the CCPS Subcommittee tried to review all published sources of available generic equipment reliability and failure rate data, including reliability studies, published research works, reliability data banks, or government reports that contained information gathered from chemical process, nuclear, offshore oil, and fossil fuel industries around the world. An industry survey was conducted to solicit unpublished data. 7.2.3 Organization The sections of this book and their contents are: Chapter 1Introduction: Discusses the need for process equipment failure rate data, describes the purpose, scope and organization of this book, and explains how to the use it. Chapter 2Origin, Use, and Limitations of Failure Rate Data: Explains the meaning of generic and plant-specific data, the difference between time-related and demand-

related failures, issues of confidence and tolerance, what is captured as an equipment failure, the failure model used and the role of the taxonomy. Chapter 3CCPS Taxonomy: Explains the CCPS taxonomy. Discusses the rationale and process for its development and the factors considered in its construction. Chapter 4Data Bases, Sources, and Studies: Summarizes and characterizes several generic data resources available to risk analysts and process engineers in the CPI. It includes a discussion of the resource search and selection process and the presentation format for the information on resources. Chapter 5CCPS Generic Failure Rate Data Base: Contains tables of generic process equipment reliability data that are structured by the CCPS Taxonomy. The data are extracted from data resources in Chapter 4. The chapter includes a discussion of the selection, treatment, and presentation of the data in the Tables. Chapter 6Collection and Conversion of Plant-Specific Data: Describes the type of data required and their treatment to develop a plant-specific data set suitable for use or aggregation with other data. Chapter 7Failure Rate Data Transfer: Provides a form to facilitate the transfer of plant-specific data to the CCPS Data Base or to combine it with other generic data. Chapter 8Supplemental References: A collection of references that describe data collection, analysis, and application techniques but, in general, do not contain reliability data. Appendix ACCPS Taxonomy: The full CCPS Taxonomy for process equipment failure rate data. Appendix BEquipment Index: Allows the user to determine the taxonomy location for equipment types familiar to the CPI. Appendix CMatrix of Data Elements in Each Data Resource: Presents the user with a more detailed summary of the data elements available from each data resource in Chapter 4. Appendix DUnreviewed Data Bases, Data Sources, and Studies: Provides a list of data resources that were uncovered too late for review.

1.3 Use of This Guidelines It is recommended as a first step that the user of the book review the entire volume to become familiar with the various aspects of equipment failure rates that are presented. This can provide a better understanding of the derivation, value, and limitations of generic data. Beyond this, the volume is structured to assist the reader in one or more of three basic tasks. These tasks are: locating generic data for use in a CPQRA; finding potential data resources for additional data or more information; and developing a system for collecting and recording in-plant reliability data. To find generic data in this book for use in a CPQRA, the reader should first locate the taxonomy number for the equipment under study by referring to Appendix B, Equipment Index. This index shows the taxonomy number for various types of commonly used equipment. Knowing the taxonomy number, the reader can consult the Index of Filled Data Cells (Table 5.2) to determine if the data exist in Chapter 5. Alternatively, the user

RECORDS FROM ONE PLANT

INDUSTRYGENERIC DATA GENERIC DATA SOURCE SELECTION SELECTED GENERIC DATA SOURCES

FLOW, PIPING, AND INSTRUMENTATION DRAWINGS

OPERATINGAND MAINTENANCE PROCEDURES

PLANT RECORDS

EQUIPMENTLISTS

RAW DATA COLLECTION AND REVIEW

RELEVANT DATA RAW DATA CLASSIFICATION AND SORTING SORTED DATA

OPERATIM LOGS, REPORTS

IRRELEVANT RECORDS

DATA REQUIREMENTS

RECORDS FROM OTHER PLANTS

PERMANENT TRACEABLE RAW DATA & PROCESS FILES

GUIDELINES FOR PROCESS EQUIPMENT RELIABILITY DATA


Figure 1.1. Process equipment reliability data: data sources, dataflow, and data use.

GENERIC RELIABILITY DATA GENERIC DATA EXTRACTION CCPS GENERIC DATABASE PROTOCOL INTEGRATIONAND AGGREGATION OF PLANT-SPECIFIC AND GENERIC DATA CCPS TAXONOMY

CCPSGENERIC DATABASE CCPS DATA SHEETS

IIFICATION AND

DATA CLASSSORTING

COMPUTER ACCESSIBLE DATABASE (Future)

RAW DATA ANALYSIS AND REDUCTION

REDUCED DATA

FAILURE RATE AND PROBABILITY CALCULATIONS

PLANT-SPECIFIC DATA EXPERT OPINION ANALYSIS DATABASE INTEGRATION AND AGGREGATION OF DATA GENERIC DATA

ANALYSIS Component Populations Demand Counts Exposure Times Failure Counts REDUCTION Failure Model and Parameters

PLANTSPECIFIC RELIABILITY DATA Time Related Failure Rates Demand Related Failure Rates Error Bounds

PREDICTED DATA COMPANY, COMMUNITY, REGULATORYAND OTHER SPECIAL REPORTS

GUIDELINES FOR CHEMICAL PROCESS QUANTITATIVE RISK ANALYSIS

CPQRA

may look in the Chapter 5 Data Tables once the taxonomy number has been located. Readers who require additional sources of data should refer to the indexes at the beginning of each resource section in Chapter 4 (Sections 4.3, 4.4, 4.5, 4.6, 4.7, or 4.8). These indexes help the reader identify the most useful resources in terms of the type and extent of data presented. Appendix C is also useful, as it provides additional detail about these data resources. When plant-specific data are required, Chapter 6 discusses how to collect and treat the data so that the resulting failure rates can be used in a CPQRA or be combined with the data in the CCPS Generic Failure Rate Data Base. Chapter 7 provides a form that can be used to transfer these data to CCPS's Generic Failure Rate Data Base.

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