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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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


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


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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16 17


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


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


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

TECHNICAL NOTE

Section 1 Page 6 Date: 20.12 06


Issued at RiskNet

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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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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Process Equipment Leak Frequencies Equipment Type:

D1 Steel Pipes

Prep. by:

J.R. Spouge

Rev.:

2

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 C, m a, n Frup D d

= = = = = =

frequency of leaks (per metre year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per metre year) pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 3.7E-05 8.0E-06 9.0E-06

a 1000 1000 0

n -1.5 -1.3 0.0

m -0.74 -1.42 -0.50

Frup 3.0E-06 0.0E+00 1.0E-06

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

FREQUENCY OF HOLE >= 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 <1mm) 316 149 36 501

EXPOSURE (metre years) 1,539,554 2,577,294 722,242 4,839,090

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Process Equipment Leak Frequencies Equipment Type: Frequency Tables:

D1 Steel Pipes

Prep. by:

J.R. Spouge

Rev.:

2

Date:

10.02.05

Source:

HCRD 10/92 – 03/03

Selected steel pipe sizes.

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

(a) Total leak frequencies (per metre year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 7.9E-05 3.2E-05 2.5E-05 2.3E-05 3.7E-05 1.5E-05 1.2E-05 1.1E-05 2.9E-05 7.2E-06 5.6E-06 5.2E-06 0.0E+00 6.2E-06 1.4E-06 1.3E-06 0.0E+00 0.0E+00 4.1E-06 4.0E-06 1.4E-04 6.0E-05 4.7E-05 4.4E-05

24" DIA (600 mm) 2.2E-05 1.0E-05 5.0E-06 1.2E-06 4.0E-06 4.3E-05


(b) Full leak frequencies (per metre year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 4.5E-05 1.6E-05 1.0E-05 8.6E-06 9.9E-06 3.4E-06 2.2E-06 1.9E-06 2.2E-06 6.8E-07 4.4E-07 3.7E-07 0.0E+00 7.7E-08 3.9E-08 3.3E-08 0.0E+00 0.0E+00 1.0E-08 8.8E-09 5.7E-05 2.0E-05 1.3E-05 1.1E-05

24" DIA (600 mm) 7.9E-06 1.7E-06 3.4E-07 3.0E-08 8.1E-09 1.0E-05

(c) Zero pressure leak frequencies (per metre year) HOLE DIA 2" DIA 6" DIA 12" DIA 18" DIA RANGE (mm) (50 mm) (150 mm) (300 mm) (450 mm) 1-3 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 10-50 3.8E-06 1.6E-06 1.6E-06 1.6E-06 50-150 0.0E+00 2.3E-06 5.4E-07 5.4E-07 >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


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D2 Flanges

Prep. by:

J.R. Spouge

Rev.:

2

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 of leaks (per flanged joint year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per flanged joint year) flange diameter (mm), i.e. diameter of connected pipe hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 7.5E-05 3.0E-05 5.0E-06

a 1.9E-04 5.3E-05 3.8E-05

n 1.5 1.8 1.8

m -0.84 -1.22 -0.33

Frup 5.0E-06 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per flange year)

Frequency Plot:

Example 150mm diameter flange

1.0E-04

1.0E-05


1.0E-06

1.0E-07 1

10

100

1000

HOLE DIAMETER (mm)

Input Data: FLANGE DIAMETER (in) ≤3 3-11 >11 TOTAL

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


HSE EXPOSURE (flange face years) 3,118,164 1,957,942 295,659 5,371,765

DNV EXPOSURE (flanged joint years) 1,559,082 978,971 147,830 2,685,883

• HSE exposure counting “flange faces” has been halved to give DNV exposure of “flanged joints”, each consisting of 2 flange faces.

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D2 Flanges

Prep. by:

J.R. Spouge

Rev.:

2

Date:

24.02.05

Source:

HCRD 10/92 – 03/03

Selected flange sizes.


(a) Total leak frequencies (per flanged joint year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 4.8E-05 6.1E-05 9.0E-05 1.3E-04 2.0E-05 2.6E-05 3.8E-05 5.3E-05 1.7E-05 1.1E-05 1.6E-05 2.3E-05 0.0E+00 8.8E-06 3.4E-06 4.8E-06 0.0E+00 0.0E+00 7.2E-06 8.1E-06 8.5E-05 1.1E-04 1.5E-04 2.2E-04

24" DIA (600 mm) 1.7E-04 7.2E-05 3.0E-05 6.4E-06 9.2E-06 2.9E-04


(b) Full leak frequencies (per flanged joint year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 2.3E-05 3.2E-05 5.6E-05 9.2E-05 6.4E-06 8.7E-06 1.5E-05 2.5E-05 1.9E-06 2.2E-06 3.9E-06 6.5E-06 0.0E+00 3.6E-07 4.7E-07 7.8E-07 0.0E+00 0.0E+00 1.7E-07 2.8E-07 3.2E-05 4.3E-05 7.6E-05 1.2E-04

24" DIA (600 mm) 1.4E-04 3.8E-05 9.8E-06 1.2E-06 4.2E-07 1.9E-04

(c) Zero pressure leak frequencies (per flanged joint year) HOLE DIA 2" DIA 6" DIA 12" DIA 18" DIA 24" DIA RANGE (mm) (50 mm) (150 mm) (300 mm) (450 mm) (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 10-50 2.4E-06 1.3E-06 2.0E-06 3.1E-06 4.6E-06 50-150 0.0E+00 1.8E-06 8.8E-07 1.4E-06 2.0E-06 >150 0.0E+00 0.0E+00 2.0E-06 3.1E-06 4.6E-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 2" DIA 6" DIA 12" DIA 18" DIA RANGE (mm) (50 mm) (150 mm) (300 mm) (450 mm) 1-3 2.3E-05 2.7E-05 3.1E-05 3.0E-05 3-10 1.3E-05 1.5E-05 2.0E-05 2.4E-05 10-50 1.2E-05 7.3E-06 1.0E-05 1.3E-05 50-150 0.0E+00 6.6E-06 2.0E-06 2.6E-06 >150 0.0E+00 0.0E+00 5.0E-06 4.7E-06 TOTAL 4.8E-05 5.6E-05 6.8E-05 7.5E-05

24" DIA (600 mm) 2.4E-05 2.8E-05 1.6E-05 3.2E-06 4.2E-06 7.6E-05

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D3 Manual Valves

Prep. by:

J.R. Spouge

Rev.:

1

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 of leaks (per valve year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per valve year) valve diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 7.0E-05 6.0E-06 1.0E-08

a 3.4E-05 3.8E-03 6.8

n 2.0 1.5 1.0

m -0.76 -1.17 -0.15

Frup 1.0E-05 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per valve year)

Frequency Plot:

Example 150mm diameter valve

1.0E-03

1.0E-04 Total leaks Limited leaks Zero pressure leaks Full leaks

1.0E-05

1.0E-06

1.0E-07 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:

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

LEAKS (#) 96 48 20 164


EXPOSURE (valve years) 1,060,745 369,359 36,284 1,466,388

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D3 Manual Valves

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Selected valve sizes.


(a) Total leak frequencies (per valve year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 4.3E-05 7.0E-05 1.6E-04 3.1E-04 2.0E-05 3.2E-05 7.4E-05 1.4E-04 2.3E-05 1.5E-05 3.5E-05 6.8E-05 0.0E+00 1.6E-05 8.2E-06 1.6E-05 0.0E+00 0.0E+00 1.6E-05 2.2E-05 8.6E-05 1.3E-04 2.9E-04 5.6E-04

24" DIA (600 mm) 5.2E-04 2.4E-04 1.1E-04 2.7E-05 3.1E-05 9.4E-04


(b) Full leak frequencies (per valve year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 1.0E-05 3.5E-05 9.0E-05 1.6E-04 2.9E-06 1.0E-05 2.6E-05 4.7E-05 9.5E-07 2.7E-06 7.1E-06 1.3E-05 0.0E+00 4.9E-07 9.3E-07 1.7E-06 0.0E+00 0.0E+00 3.5E-07 6.4E-07 1.4E-05 4.8E-05 1.2E-04 2.2E-04

24" DIA (600 mm) 2.5E-04 7.1E-05 2.0E-05 2.5E-06 9.7E-07 3.4E-04


(c) Zero pressure leak frequencies (per valve year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 5.2E-07 1.6E-06 3.1E-06 4.7E-06 4.8E-07 1.4E-06 2.9E-06 4.3E-06 2.4E-06 1.6E-06 3.1E-06 4.6E-06 0.0E+00 5.7E-06 1.7E-06 2.6E-06 0.0E+00 0.0E+00 9.6E-06 1.4E-05 3.4E-06 1.0E-05 2.0E-05 3.1E-05

24" DIA (600 mm) 6.2E-06 5.7E-06 6.2E-06 3.4E-06 1.9E-05 4.1E-05


(d) Limited leak frequencies (per valve year) 2" DIA 6" DIA 12" DIA 18" DIA (50 mm) (150 mm) (300 mm) (450 mm) 3.2E-05 3.4E-05 6.8E-05 1.5E-04 1.6E-05 2.1E-05 4.5E-05 9.3E-05 2.0E-05 1.1E-05 2.5E-05 5.0E-05 0.0E+00 1.0E-05 5.6E-06 1.2E-05 0.0E+00 0.0E+00 6.3E-06 7.2E-06 6.8E-05 7.5E-05 1.5E-04 3.1E-04

24" DIA (600 mm) 2.7E-04 1.6E-04 8.8E-05 2.1E-05 1.0E-05 5.5E-04

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D4 Actuated Valves

Prep. by:

J.R. Spouge

Rev.:

2

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.


= = = = = =

frequency of leaks (per valve year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per valve year) valve diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 6.9E-04 2.6E-04 4.4E-05

a 0 0 0

n 0 0 0

m -0.82 -1.26 -0.37

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per valve year)

Frequency Plot:

Example 150mm diameter valve

1.0E-03

1.0E-04


1.0E-05

1.0E-06 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:

HCRD (October 1992 to March 2003) LEAKS 204

LEAKS (exc N/A and <1mm) 187

EXPOSURE (valve years) 272206

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D4 Actuated Valves

Prep. by:

J.R. Spouge

Rev.:

2

Date:

3.05.05

Source:

HCRD 10/92 – 03/03

Frequency (per valve year) for valves >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

4.1E-04 1.8E-04 7.7E-05 1.7E-05 1.1E-05 6.9E-04

1.9E-04 5.1E-05 1.2E-05 1.4E-06 4.7E-07 2.6E-04

ZERO PRESSURE LEAKS 1.5E-05 1.1E-05 8.4E-06 3.5E-06 6.9E-06 4.4E-05

LIMITED LEAKS 2.0E-04 1.1E-04 5.6E-05 1.2E-05 4.0E-06 3.9E-04

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D5 Instruments

Prep. by:

J.R. Spouge

Rev.:

1

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 C, m Frup D d

= = = = =

frequency of leaks (per instrument connection year) exceeding size d constants representing hole size distribution additional rupture frequency (per instrument connection year) instrument connection diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 6.1E-04 2.3E-04 2.5E-05

m -0.80 -0.88 -0.44

Frup 0.0E+00 0.0E+00 0.0E+00


Frequency Plot:

Example 25mm diameter instrument

FREQUENCY OF HOLE >= SIZE (per instrument year)

1.0E-02 Total leaks 1.0E-03

Limited leaks Zero pressure leaks Full leaks

1.0E-04

1.0E-05

1.0E-06 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (instrument years) 607414

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D5 Instruments

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Frequency (per instrument year) for instruments 10-50mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

3.6E-04 1.6E-04 9.7E-05 0.0E+00 0.0E+00 6.1E-04

1.4E-04 5.7E-05 3.0E-05 0.0E+00 0.0E+00 2.3E-04

ZERO PRESSURE LEAKS 9.6E-06 6.3E-06 9.1E-06 0.0E+00 0.0E+00 2.5E-05

LIMITED LEAKS 2.0E-04 9.3E-05 5.7E-05 0.0E+00 0.0E+00 3.6E-04

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D6 Process Vessels

Prep. by:

J.R. Spouge

Rev.:

1

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.


= = = = =

frequency of leaks (per vessel year) exceeding size d constants representing hole size distribution additional rupture frequency (per vessel year) diameter (mm) of the largest pipe connection hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 1.8E-03 5.0E-04 4.3E-04

m -0.43 -0.38 -0.18

Frup 1.0E-04 0.0E+00 0.0E+00

Range of validity: D = 40 to 400mm; d = 1mm to D • Catastrophic ruptures should be modelled separately

FREQUENCY OF HOLE >= SIZE (per vessel year)

Frequency Plot:

Example vessel with maximum 150mm diameter connection

1.0E-02 Total leaks Limited leaks

1.0E-03

Zero pressure leaks Full leaks 1.0E-04

1.0E-05

1.0E-06 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:

HCRD (October 1992 to March 2003) LEAKS (#) 35


EXPOSURE (vessel years) 14069

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D6 Process Vessels

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Frequency (per vessel year) for connections >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

6.8E-04 4.5E-04 3.3E-04 1.3E-04 3.1E-04 1.9E-03

1.7E-04 1.2E-04 9.5E-05 3.9E-05 7.4E-05 5.0E-04



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D7 Centrifugal Pumps

Prep. by:

J.R. Spouge

Rev.:

2

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.

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

= = = = =

frequency of leaks (per pump year) exceeding size d constants representing hole size distribution additional rupture frequency (per pump year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 6.5E-03 1.8E-03 5.9E-04

m -0.95 -1.10 -0.43

Frup 0.0E+00 0.0E+00 0.0E+00


Frequency Plot:

Example pump with 150mm diameter inlet

FREQUENCY OF HOLE >= SIZE (per pump year)

1.0E-02 Total leaks Limited leaks

1.0E-03

Zero pressure leaks Full leaks 1.0E-04

1.0E-05

1.0E-06 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (pump years) 11942

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D7 Centrifugal Pumps

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03

Frequency (per pump year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

4.2E-03 1.6E-03 5.7E-04 1.0E-04 5.6E-05 6.5E-03

1.3E-03 3.9E-04 1.2E-04 1.7E-05 7.3E-06 1.8E-03


LIMITED LEAKS 2.7E-03 1.0E-03 3.4E-04 4.4E-05 0.0E+00 4.1E-03

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D8 Reciprocating Pumps

Prep. by:

J.R. Spouge

Rev.:

1

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.


= = = = =

frequency of leaks (per pump year) exceeding size d constants representing hole size distribution additional rupture frequency (per pump year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 6.9E-03 3.7E-03 4.6E-04

m -0.54 -0.50 -0.25

Frup 0.0E+00 0.0E+00 0.0E+00


Frequency Plot:

Example pump with 150mm diameter inlet

FREQUENCY OF HOLE >= SIZE (per pump year)

1.0E-02

Total leaks Limited leaks

1.0E-03

Zero pressure leaks Full leaks

1.0E-04

1.0E-05

1.0E-06 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (pump years) 2167

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D8 Reciprocating Pumps

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Frequency (per pump year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

3.1E-03 1.8E-03 1.2E-03 3.7E-04 4.6E-04 6.9E-03

1.6E-03 9.7E-04 6.5E-04 2.2E-04 3.0E-04 3.7E-03



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D9 Centrifugal Compressors

Prep. by:

J.R. Spouge

Rev.:

2

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.


= = = = = =

frequency of leaks (per compressor year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per compressor year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 9.0E-03 2.0E-03 8.2E-04

a 0 0 0

n 0 0 0

m -0.79 -1.76 -0.28

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per compressor year)

Frequency Plot:

Example compressor with 150mm diameter inlet

1.0E-01

1.0E-02 Total leaks Limited leaks Zero pressure leaks Full leaks

1.0E-03

1.0E-04

1.0E-05 1

10

100

1000

10000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (compressor years) 2442

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D9 Centrifugal Compressors

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03

Frequency (per compressor year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

5.2E-03 2.3E-03 1.1E-03 2.4E-04 1.7E-04 9.0E-03

1.7E-03 2.5E-04 3.3E-05 1.7E-06 3.0E-07 2.0E-03


LIMITED LEAKS 3.3E-03 1.9E-03 8.6E-04 1.3E-04 0.0E+00 6.2E-03

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D10 Reciprocating Compressors

Prep. by:

J.R. Spouge

Rev.:

1

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.


= = = = = =

frequency of leaks (per compressor year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per compressor year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 6.2E-02 2.7E-02 0.0E+00

m -1.00 -2.00 0.00

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per compressor year)

Frequency Plot:

Example compressor with 150mm diameter inlet

1.0E-01

1.0E-02 Total leaks Limited leaks Full leaks

1.0E-03

1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (compressor years) 402

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D10 Reciprocating Compressors

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Frequency (per compressor year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

4.1E-02 1.4E-02 5.0E-03 8.3E-04 4.1E-04 6.2E-02

2.4E-02 2.7E-03 2.6E-04 9.6E-06 1.2E-06 2.7E-02

ZERO PRESSURE LEAKS 0.0E+00 0.0E+00 0.0E+00 0.0E+00 0.0E+00 0.0E+00


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D11 Shell Side Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

1

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

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

= = = = =

frequency of leaks (per heat exchanger year) exceeding size d constants representing hole size distribution additional rupture frequency (per heat exchanger year) shell side inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 4.7E-03 1.4E-03 3.6E-04

m -0.65 -0.60 -0.30

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per heat exchanger year)

Frequency Plot:

Example heat exchanger with 150mm diameter inlet

1.0E-02

Total leaks Limited leaks Zero pressure leaks

1.0E-03

Full leaks 1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:

HCRD (October 1992 to March 2003) LEAKS

LEAKS (exc N/A and <1mm)

16

13

EXPOSURE (heat exchanger years) 2780

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D11 Shell Side Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03

Frequency (per heat exchanger year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

2.4E-03 1.2E-03 6.8E-04 1.9E-04 1.8E-04 4.7E-03

6.8E-04 3.7E-04 2.2E-04 6.5E-05 6.9E-05 1.4E-03



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D12 Tube Side Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

2

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.


= = = = =

frequency of leaks (per heat exchanger year) exceeding size d constants representing hole size distribution additional rupture frequency (per heat exchanger year) tube side inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 3.0E-03 1.0E-03 2.0E-04

m -0.80 -0.77 -0.50

Frup 0.0E+00 0.0E+00 0.0E+00



Frequency Plot:


1.0E-02 Total leaks Limited leaks 1.0E-03

Zero pressure leaks Full leaks

1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



19

15


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D12 Tube Side Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03


TOTAL LEAKS

FULL LEAKS

1.8E-03 7.7E-04 3.4E-04 7.7E-05 5.4E-05 3.0E-03

5.7E-04 2.6E-04 1.2E-04 2.8E-05 2.1E-05 1.0E-03



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D13 Plate Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

1

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.


= = = = =

frequency of leaks (per heat exchanger year) exceeding size d constants representing hole size distribution additional rupture frequency (per heat exchanger year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 1.1E-02 6.0E-03 0.0E+00

m -0.60 -0.72 0.00

Frup 0.0E+00 0.0E+00 0.0E+00

Range of validity: D = 40 to 400mm; d = 1mm to D • No zero pressure scenarios were identified from HCRD.


Frequency Plot:


1.0E-02

Total leaks

1.0E-03

Limited leaks Full leaks 1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



25

25


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D13 Plate Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

1

Date:

16.07.04

Source:

HCRD 10/92 – 03/03


TOTAL LEAKS

FULL LEAKS

5.3E-03 2.9E-03 1.7E-03 5.1E-04 5.4E-04 1.1E-02

3.3E-03 1.6E-03 7.8E-04 2.0E-04 1.6E-04 6.0E-03



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D14 Air-Cooled Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

2

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.


= = = = =

frequency of leaks (per heat exchanger year) exceeding size d constants representing hole size distribution additional rupture frequency (per heat exchanger year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

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

m -0.73 -0.73 0.00

Frup 0.0E+00 0.0E+00 0.0E+00

Range of validity: D = 40 to 400mm; d = 1mm to D • No zero pressure scenarios were identified from HCRD.


Frequency Plot:


1.0E-02

1.0E-03 Total leaks Full leaks + limited leaks

1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



2

2


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D14 Air-Cooled Heat Exchangers

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03


TOTAL LEAKS

FULL LEAKS

1.3E-03 6.3E-04 3.1E-04 7.6E-05 6.2E-05 2.4E-03

6.6E-04 3.1E-04 1.5E-04 3.8E-05 3.1E-05 1.2E-03



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D15 Filters

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03

Definition:


= = = = =

frequency of leaks (per filter year) exceeding size d constants representing hole size distribution additional rupture frequency (per filter year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 3.7E-03 8.9E-04 4.0E-04

m -0.66 -1.26 -0.26

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per filter year)

Frequency Plot:

Example 150mm diameter filter

1.0E-02

1.0E-03


1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (filter years) 10072

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D15 Filters

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03

Frequency (per filter year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

1.9E-03 9.8E-04 5.3E-04 1.4E-04 1.4E-04 3.7E-03

6.7E-04 1.7E-04 4.2E-05 4.8E-06 1.6E-06 8.9E-04



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D16 Pig Traps

Prep. by:

J.R. Spouge

Rev.:

2

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.


= = = = = =

frequency of leaks (per pig trap year) exceeding size d constants representing hole size distribution constants representing equipment size dependency additional rupture frequency (per pig trap year) inlet pipe diameter (mm) hole diameter (mm) SCENARIO Total leaks Full leaks Zero pressure

C 5.3E-03 1.7E-03 1.3E-03

m -0.40 -1.50 -0.12

Frup 0.0E+00 0.0E+00 0.0E+00


FREQUENCY OF HOLE >= SIZE (per pig trap year)

Frequency Plot:

Example 150mm diameter pig trap

1.0E-02

1.0E-03


1.0E-04

1.0E-05 1

10

100

1000

HOLE DIAMETER (mm)

Input Data:



EXPOSURE (pig trap years) 3189

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D16 Pig Traps

Prep. by:

J.R. Spouge

Rev.:

2

Date:

14.02.05

Source:

HCRD 10/92 – 03/03

Frequency (per pig trap year) for inlets >150mm diameter HOLE DIA RANGE (mm) 1-3 3-10 10-50 50-150 >150 TOTAL

TOTAL LEAKS

FULL LEAKS

1.9E-03 1.3E-03 1.0E-03 3.9E-04 7.1E-04 5.3E-03

1.4E-03 2.7E-04 4.9E-05 3.9E-06 9.3E-07 1.7E-03



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Process Equipment Failure Frequencies

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