Reliability equipment

Chemical Process Quantitative Risk Analysis Process Equipment Reliability Data, with Data Tables Technical Management of Chemical Process Safety (Plant)... 

CCPS G-7. Process Equipment Reliability Database. American Institute of Chemical Engineers, Center for Chemical Process Safety, New York. 

Equipment Reliability The probability that, when operating under stated environment conditions, process equipment will perform its intended function adequately for a specified exposure period. 

The Guidelines for Process Equipment Reliability Data with Data Tables covers a variety of components used in the chemical process industry, including electrical equipment, analyzers, instrumentation and controls, detectors, heat exchangers, piping systems, rotating equipment (pump, compressor, and fan), valves, and fire protection systems. 

The IEEE Guide to the Gollection and Presentation of Electrical, Electronic, Sensing Gom-ponent, and Mechanical Equipment Reliability Data for Nuclear Power Generating Stations (IEEE Std. 500-1984) compiles data from over a dozen other references and includes information for most types of components. 

The prime function of the foundations, relative to equipment reliability, is to hold the compressor train in alignment during all operating phases for... 

Operating problems. High-temperature operations create high maintenance requirements and can reduce equipment reliability. 

Pilot plant experiments vary over a wide range, aeeounting for industrial eonstraints (e.g., duration of operation, eontrol parameters, equipment reliability, and impurities in the raw materials). Seale-up problems are investigated during pilot plant experiments. A pilot plant is an experimental rig, whieh displays the part of the operation that eorresponds to an industrial plant. It allows for simultaneous analysis of the physieal and ehemieal meehanisms. A pilot plant is indispensable for measuring the extent of the possible interaetions between these two types of meehanisms. It ean be small to minimize extraneous eosts sueh as the total operation eost as well as other eonstraints. 

From a broader perspective, the Abnormal Situation Management Consortium is working to apply human factors theory and expert system technology to improve personnel and equipment performance during abnormal conditions. In addition to reduced risk, economic improvements in equipment reliability and capacity are expected (Rothenberg and Nimmo, 1996). 

CCPS, 1989b, Process Equipment Reliability Data (Table 4.1-1) is a compilation of chemical and nuclear data. It assesses failure rates for 75 types of chemical process equipment. A taxonomic classification is established and data such as the mean, median, upper and lower (95% and 5%) values, source of information, failure by time and failure by demands are presented. 

Even, limited PSAs use and contain much information. This information may come as memos and process reports and flow sheets, equipment layout, system descriptions, toxic inventory, hazardous chemical reactions, test, maintenance and operating descriptions. From this, data and analyses are prepared regarding release quantities, doses, equipment reliability, probability of exposure, and the risk to workers, public, and environment. An executive summary analysis is detailed, and recommendations made for risk reduction. Thus the information will be text, calculations of envelope fracture stresses, temperatures, fire propagation, air dispersion, doses, and failure probabilities - primarily in tabular form. 

CPS, 1989b, Guidelines for Process Equipment Reliability Data... 

Chapter 5—CCPS 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. 

Figure 1.1. Process equipment reliability data data sources, data flow, and data use.

The above discussion leads to the conclusion that time-related and demand-related failures for a piece of equipment cannot be equated through a general mathematical relationship. These issues are better dealt with in a data base taxonomy (classification scheme) for equipment reliability data by defining a unique application through equipment description, service description, and failure description. 

Another influence on equipment reliability is the environment/application of the equipment. A component working on a rocket into space is quite likely to have a different... 

This chapter has discussed some of the factors that may affect equipment reliability and necessitate data adjustment. At this time, little documented assistance is available to help develop these data adjustments. It may be necessary to get help from experts in some situations. Lastly, failure rates are often reported to several decimal places, a precision frequently unwarranted by the data. It is suggested that only the failure rate s first significant number and associated exponential power be used. 

Many data cells in the CCPS Taxonomy use equipment boundaries found in available generic data sets in which equipment and service is similar to that in the CPI. The boundaries established for other data cells were generally combinations of normal equipment modules—such as pump, seals, coupling, motor and base plate, or refrigeration units—and functionally interdependent basic and auxiliary components, such as motor controllers. Boundaries may change as greater amounts of equipment reliability data become available. 

Guide to the Collection and Representation of Electronic, Sensing Component, and Mechanical Equipment Reliability Data for Nuclear Generating Stations. IEEE Standard 500-1984, Institute of Electrical and Electronics Engineers, New York, 1984. 

Titles of potential resourees were obtained by eonducting a literature search and an industry survey. Simultaneous literature searches were condueted by CCPS and SAIC. CCPS eoneentrated on obtaining CPI data resources while SAIC used a literature search conducted for the nuclear power reliability eommunity. These literature searches used in-house eompany, engineering, and public libraries and recommendations from members of the user eommunity. At the same time, a questionnaire was sent to professionals who eonduct CPQRAs. The survey requested information on the data resourees used by the companies and whether they had plant-speeific data that could be used by CCPS. Members of the CCPS Equipment Reliability Data Subcommittee were also asked to eompile lists of data resources with which they were familiar and which they had used for reliability or risk analyses. As a result, an extensive but not necessarily eomplete list of data resource titles was assembled. Any resources uncovered after the publisher s eutoff date and not reviewed have been included in Appendix D. 

Data base A repository for equipment reliability information categorized to facilitate data retrieval or tabular lists of multiple data vectors, with little text except that needed to explain the data presentation format. 

To help the reader select the appropriate data resource, an index precedes Sections 4.3 through 4.8. The index provides the source number within the section and the following set of data elements for each source title, industry, number and type of records, and data boundary. Appendix C contains additional information about the data elements presented in each data resource. It can also be used to help identify the resources which may provide data for a CPQRA. A discussion of the Appendix C Matrix and an explanation of data elements indexed is presented. After examining Appendix C and the pattern of data elements contained in the data resources, it is evident that equipment reliability data have been published in a variety of formats, often without any apparent effort to conform to a recognized standard for data specification. The CCPS Taxonomy and the raw data collection requirements in Chapter 6 present the basis for reliability data specification in future literature. 

TITLE Data Base Development and Equipment Reliability for Phase 1 of the... 

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