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Risk and Reliability Methods PDF
Risk and Reliability Methods PDF
Bhopal
Seveso
Piper A
Root Cause:
Rich-oil de-ethanizer re-boiler Brittle fracture
E::
ASSE
CCA
Root cause:
Thermal fatigue and
material embrittlement
caused by poor weld quality
E::
ASSE
CCA
Design Error
Large property losses in the HC-chemical ind., a 4%
30 year review, 14th edition, M&M Protection
Consultants, 1992
Identified root causes for accidents
Fewtrell & Hirst and DNV have identified a number of root
causes related to safety and safety critical equipment and
process control systems:
whilst Minimising
manning costs
materials costs
maintenance work load
transportation and support
downtime affecting revenue/operating costs
and Maintaining
contractual nominations
HSE requirements
Risk Based Maintenance Management
By assessing past performance, identifying the risk
among individual equipment and identifying opportunity
areas for improvement, plants are moving towards a risk
based management philosophy incorporating the latest
thinking in:
Reliability Centered Maintenance (RCM) and Root Cause
Failure Analysis (RCFA)
Risk Based Inspection (RBI)
Safety Integrity Analysis (SIL)
Task bundling and resource load-leveling
Work Order Automation
RIMAP Consortium - project sponsors
Project Manager:
ExxonMobil Chemical Ltd. (Exxon)
Det Norske Veritas AS (DNV)
Bureau Veritas (BV) Energie Baden-Wrttemberg AG (EnBW)
for European
VTT Industrial Systems (VTT)
industry
Commission (JRC)
TV Industrie Service, TV
SD Electricity Supply Board (ESB)
Group
TNO Industrial Technology
Vado Ltd.
(TNO)
YARA Sluiskil B.V. (Norsk
The Dow Chemical Company N.V. (DOW)
Hydro)
Mitsui Babcock Energy Ltd.
Solvay S.A.
(MBEL)
RIMAP - Large industry participation
Chemical Steel
DOW Corus
Hydro Agri
Solvay Chemical
EnBW
Petrochemical ESB
ExxonMobil Siemens,
RIMAP - Large industry participation
Consultants
Bureau Veritas
Technical Research
Centre of Finland
(VTT)
TNO
RIMAP; Risk based Inspection and MAintenance Procedures
for European industry
Hazid Scenario description (Bow-tie). All failure Leak failures only. Standard
modes. Leak size per damage type. leak sizes.
CoF All chemicals. (DNV uses the DIPPR database Limited chemicals.
& Phast). Screening models available. Consequence sum (S, E, C)
Risk decision Risk matrix tailored to actual company/-plant. Generic risk matrix.
SIL-requirement for safety systems
c Screening
Qualitative analysis
d Detailed Analysis
Quantitative analysis
Risk Based Maintenance (RBM) Strategy Development
INSP, CMMS, DOC
Input data for screening Input data
DNV, for detailed
Equipment Screening Operator assessment
database Experience
Inspection,
Maintenance High Y Risk Based
history, Risk Level Containment
Risk RBI Maintenance
Failure Strategies
records N
(RBM)
-
Low Risk Y
Protective SIL Output:
Function y Inspection plans
y Equipment function testing
y Preventative maintenance
Minimum N
y Operator surveillance rounds
maintenance y First line maintenance tasks
evaluation/ y Condition monitoring
y On-line maintenance
Corrective y Off-line maintenance
Maintenance y Turn around tasks
RCM
ASSET
REGISTER
RCM
RCM/ SIL RBI
OVERLAP
ANALYSIS ANALYSIS
Operation, Inspection
Operation, and Maintenance
Inspection Plans
and Maintenance Plans
Plant
Unit
System
Sub-system
Function Equipment
Tag
Failure mode #1 Failure mode #2 Failure mode #3
Consequence
Probability of
of X Risk
Failure
Failure
Standard Consequence
RBI- Containment Analysis techniques
SIL- Safety System, E/E/PES Fault trees
RCM Rotating, electrical,.. Leak and Dispersion modeling
/ Probabilities of ignition
DNV PHAST Software
Financial consequence models
Environmental impact models
RBM - Risk Based Inspection (RBI)
Containment
Define limit state functions for
Corrosion local /general
Limit load solutions
Stress corrosion cracking
Fatigue and corrosion fatigue
Creep and creep fatigue Fracture mechanics
Non-linear FAD methods,
HTHA
Calculation of Risk in RBI as per API
PROBABILITY
OF FAILURE CONSEQUENCE RISK
x =
PoF CoF
Generic Failure
Management Likelihood Factor Injury ($)
Factor x Frequency
GFF
X DF
Env. clean up ($)
Downtime ($)
ESD 1 ESD 2
Requirements to availability or cost/benefit?
Cost-benefit
In some cases it is economically beneficial to test more
frequently than the requirements says.
In some cases the consequence is reduced to an economic
consequence only.
RBM-Reliability Centered Maintenance (RCM)
Risk Analysis
Drawings
CMMS
Document
Mgnt. Site
SitePersonnel
Personnel
Asset Data Bank
Information
Information
SOP
/ISO
Data
Data
Measured
Measured Export
Export
Data Orbit RBI
Orbit RBI
SAFETY LocalReporting
Reporting
Orbit RCM
Orbit RCM Local
System
Technical Graphics
Turnaround
Mgnt. Data/history
Primalux Enterprise Asset Management System
as a value-added to the financial ERP
Advanced
External AutoCad ORBIT Process PDA
Data
HMI EDMS
Systems Integration RBI Logger
System
ORBIT
RCM
Data Exchange Asset Conditioning Drawing/
/ Data Loading Inspection
Register Monitoring Document
Utilities
ERP
Benefits from RBI/RCM implementation at refinery