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4Data Bases, Sources, and Studies

This chapter provides summaries of selected data resources available to the CPQRApractitioner. These resources are summarized in a consistent format that allows them to beeasily reviewed and compared. Those resources which are available to CCPS and containequipment failure rate data of sufficient qu ality are used for the data tables in Section 5.5.Section 4.1 describes how data resources were chosen for inclusion in this book.Section 4.2 describes the format used to present the information on the data resources, andSections 4.3 through 4.8 present these data resources. Each resource section is precededby an index of the resources presented in the section.

4.1 Data Resource SelectionTh e selection of data resources was a three-step process:

1. Titles of potential resources were obtained by conducting a literature search andan industry survey. S imultaneous literature searches were conducted by CCPS and SA IC.CCPS concentrated on obtaining CPI data resources while SAIC used a literature searchconducted for the nuclear power reliability comm unity. These literature searches used in-house company, engineering, and public libraries and recommendations from members ofthe user community. At the same time, a questionnaire was sent to professionals whoconduct CPQRAs. The survey requested information on the data resources used by thecompanies and whether they had plant-specific data that could be used by CCPS. Mem-bers of the CCPS Equipment Reliability Data Subcommittee were also asked to compilelists of data resources with which they were familiar and which they had used forreliability or risk analyses. As a result, an extensive but not necessarily complete list ofdata resource titles was assembled. Any resources uncovered after the publisher's cutoffdate and not reviewed have been included in Appendix D.The effort to collect CPI and general reliability data resources is considered byCCPS to be an ongoing project. Users of this book are encouraged to assist in this processby recommending additional resources to CCPS that can be used for subsequent editionsof this book.

2. Subcommittee members selected those resources for further study which hadtitles suggesting that the resource might contain equipment failure rate data. Copies ofthese resources were then obtained and read.

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3. Summaries of the data resources considered useful were prepared. "Useful data"was defined as inform ation that was publicly available, scientifically collected, had statis-tical merit, and could be used for CPQRAs. A list of rejected resources was retained toidentify references for supplemental reading and to avoid review duplication when theanticipated second edition of this book is developed. In total, 72 resources w ere accepted,and over 200 references were rejected.The selected data resources were sorted into the six categories, each presented in asection of this chapter. Resources are num bered consecutively w ithin each category. Thesections and categories are:Section 4.3 Process Equipment Data BasesSection 4.4 Process Equipment Data SourcesSection 4.5 Chemical Process Quantitative Risk Analyses (CPQRA)Section 4.6 Nonprocess Equipment Data BasesSection 4.7 Nonprocess Equipment Data SourcesSection 4.8 Nuclear Probabilistic Risk Assessments (PRA)The terms used in these categories are defined below:

Process: Refers to the CPI.Nonprocess: Refers to industries tha t do not comprise a part of the CPI as their primaryfunction, but which use comparable or equivalent complex equipment systems toperform their function, such as nuclear power plants, fossil fuel plants, and offshore oilrigs.Data base: A repository for equipm ent reliability inform ation categorized to facilitate dataretrieval; or tab ular lists of mu ltiple data vectors, with little text except that needed toexplain the data presentation format.Data source: Descriptive text in a given subject area w hose primary purpose is to discussa reliability or risk topic bu t which also contains some useful reliability data.Risk study (CPQRA or PRA): Specific study performed on a particular facility to deter-mine the areas of weak ness and strength in equipment and plant performance reliability;may include consequence analysis and usually implies some judgment of the risk.

The contents of these data resource summaries have been verified by calling thecontacts and confirming ordering addresses. Information is current as of August 1988.

4.2 Data Resource PresentationThis section describes the format used to characterize the information in the data resourcespresented in Sections 4.3 through 4.8. The following data elements are used to presentinformation in the resources summaries:Title: The name of the data resource as shown on the data source, as described in literatureexplaining data base services, or as conventionally cited when referencing a CPQRA orPRA.Sponsor/author: The organization or individual(s) responsible for performing or fundingthe collection and analysis of the information in the resource.

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Number: An identifying number based on the resource category and its sequential place-ment within the category; in the range of 4.3-x to 4.8-x.Industry: The industry from wh ich the data originated, such as chemical process, power,nuclear, and offshore oil.Time frame: The years (and months, where available) of calendar period covered by theinformation in the resource.Type: The nature of the resource: data base, report, or paper.Frequency of update: The regularity of incorporation of new information into the re-source or the rate of issuance of new editions of the resource.Number an d type of record: The number of data points or tables of data presented in theresource or the number of events the data set reflects; where available, the form inwhich the data are presented, such as failure rates or availability data, confidenceintervals or error factors; the "raw" data source used, such as surveys, plant records,tests, or judgm ent.Data boundary: The equipment types for wh ich data are presented in the resource (such aspipelines, valves or instruments); plant type (coal gasification facility, nuclear or am -

monia plant, fo r example).Data access: The contact for technical information, the document ordering address andphone num ber, the report num ber to use when ordering, the cost where available, andthe data or report accessibility, if relevant.Description: A summary of the content of the resource, some history of its developmentand the developers, and further information on the other fields in the presentationformat.A sample page is included from many of the data bases.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 thefollowing set of data elements for each source: title, indu stry, num ber and type of records,and data boundary. Appendix C contains additional information about the data elementspresented in each data resource. It can also be used to help identify the resources whichmay provide data for a CPQRA. A discussion of the Appendix C Matrix and an explana-tion of data elements indexed is presented. After exam ining Appendix C and the pattern ofdata elements contained in the data resources, it is evident that equipment reliability datahave been published in a variety of formats, often without any apparent effort to conformto a recognized standard for data specification. The CCPS Taxonomy and the raw datacollection requirements in Chapter 6 present the basis for reliability data specification infuture literature.

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I 4.3 INDEX OF PROCESS EQUIPMENT DATA BASESO . & T YPE O F R E C O R D SN DU STR YITLENO.

P u m p se r r o r s

2 1 sc r y o g ep r o t e cM e c hc o m p oV a r i e ss o m e

T h e Dm a j o rt h r o u gT h e ds o m ee q u i p mv a l v e s

A b o u t 1 , 0 0 0 m i s c e l l a n e o u s f a i l u r e r a t e s , e v e n tr a t e s , a n d p r o b a b ilitie s . T h e r e i s s o m e t re a t m e n to f h u m a n e r r o r p r o b a b i lityM e a n T i m e B e t w e e n F a i l u r e s ( M T B F s ) b a se d o n1 ,1 16 f a i l u r e sU n k n o w n n u m b e r o f r e c o r d s c o d e d b yc o m p o n e n t , f a i l u r e m o d e , a n d d a t a s o u r c eF a ilu r e a n d r e s t o r e d a t a f o r s p e c ific a n d g e n e r icapplication

1000-1- f a i l u re r a t e e n t r ie s f r o m v a r i o u s p u b l i s h e ds o u r c e sF a ilu r e r a t e d a t a f r o m p u b lic d o m a in s o u r c e s a n dd e r i v e d f r o m f ie ld f a i l u r e - s t u d i e s . O v e r 1,500f a i l u r e r a t e s .

C h e m i c a l P r o c e s s

C h e m i c a l P r o c e s sV a r i e dC h e m i c a l P r o c e s s ,P o w e r , P e t r o c h e m i c a l ,T e l e c o m m u n i c a t i o n s ,N u d e a r F u e l C y c l eC h e m i c a l P r o c e s s ,P e t r o l e u m , NuclearC h e m i c a l P r o c e s s ,P e t r o l e u m , N a t u r a lG a s a n d N u c l e a r

Imperial C h e m i c a l I n d u s t r i e s Re l ia b i l i t yD a t a B o o k

D e v e l o p m e n t o f a n I m p r o v e d L iq u i fie dN a t u ra l G a s P l a n t Failure R a t e D a t a B a s eC O M P I : D a t a B a n k fo r C o m p o n e n t F a i l u r eD a t aF l u o r D a n i e l Inc. D a t a B a s e

C o m p u t e r i z e d L i b r a r y o f E q u i p m e n tF a i l u r e s ( C L E F )H A R I S - H a z a r d s a n d Reliability I n fo r m a t io nS y s t e m - R e lia b i lity D a ta B a s e

4 . 3 - 1

4 . 3 - 24 . 3 - 34 . 3 - 4

4 . 3 - 5

4 . 3 - 6

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PROCESSEQUIPMENT DATA BASESHIM?,!Imperial Chemical Industries Reliability Data Book

SPONSOR/AUTHOR: 1Imperial Chemical Industries |

INDUSTRY:Chemical Process

TYPE:Data Base and Report

I NO.: 4.3-1TIME FRAME:Varies

FREQUENCY OF UPDATE:Infrequent

NUMBER AND TYPE OF RECORDS: About 1,000 miscellaneous failure rates,event rates, and probabilities. There is some treatment of human errorprobabilityDATA BOUNDARY: Pumps, valves, pipes, bursting discs, human errors, and othermiscellaneous items

DATA ACCESS:Contact: Process Safety Section

ICI Engineering Department, P.O. ox 7, Northwich Cheshire CW8 4DJPhone: England 0606-704995, 0606-704712 (secretary)Report accessibility: Available as part of 2-week risk assessment andreliability engineering training course for the process industries. Detailsfrom the above address or Health and Environmental Affairs, ICI America Inc.,Wilmington, DE 19897. Phone: (302) 575-4501DESCRIPTION:The book contains, in alphabetical order, failure rates, event rates andprobabilities, and descriptive information which has been collected since1970in the course of doing risk and reliability assessments. Twenty appendicescontain results of surveys on bursting discs, pipes, valves, relief valves, pumpfailures and information on human error, international fire losses, andblast effects.

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PROCESSEQUIPMENT DATABASESTlILR:Development of an Improved Liquified Natural Gas Plant Failure Rate Data BaseSPONSOR/AUTHOR: ]Gas Research InstituteINDUSTRY:Chemical ProcessTYPE:Data Base and Report

I NO.: 4.3-2TIME FRAME:March 1980 to June 1981

FREQUENCY OF UPDATE:Intended every five years

NUMBER AND TYPE OF RECORDS: Mean Time Between Failures (MTBFs) based on1,116 failures

DATA BOUNDARY: 21 system/component categories such as cryogenic valvesheat exchangers, and fire protection

DATA ACCESS:Contact: Steve WiersmaGas Research Institute8600 West Bryn Mawr Ave.,Chicago, IL 60631Phone: (312) 399-8100

Report order address: NTIS, Springfield, VA 22161Phone: (703) 487-4650NTIS Report No: PB 82-153503DESCRIPTION:Failure rate questionnaires were sent to 35 companies which operate LNG baseloading or satellite facilities. T hese operators had previously expressedan interest in participating in the study. Twenty-five companies returnedquestionnaires which covered failures at 27 separate LNG facilities.Approximately 1,626,000 hours of plant operating time were represented by thereturned questionnaires.The results of the study are presented for these equipment groups:gas pretreatment systems, heat exchangers, vaporizers, cryogenic storagetanks, compressor systems, cryogenic pumps, cryogenic valves, cryogenicpiping, piping insulation, equipment insulation, process control systems,human errors, spills and leaks, truck loading and unloading facilities, fireprotection systems, hazard detection system.Major and minor type failures are treated. Minor failures are defined asthose which cause (or would have caused) an unscheduled shutdown of equipmentfor a period of less than 24 hours. A major failure is defined as any failurewhich results in an unscheduled shutdown for a period 4 > f greater than 24hours. Safety-related failures were defined as failures which resultedeither in a fire, injury, loss of life, or a large leak of liquid or gas.To qualify as a safety-related failure, the liquid or gas release had to belarge enough to have the potential to injure or have injured plant personnel,or have been severe enough to propagate beyond the immediate area.

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Data Resource 4.3-2Development of an Improved Liquified Natural Gas PlantFailure Rate Data BaseExample Data Sheet

TABLE 1SUMMARY OF MAJOR FAILURES

ft-hours operator-hours in service hours "normalizedSDs see discussionFrom Gas Research Institute GRI-80/0093

Plant Area

Gas PretreatmentHeat ExchangersVaporizersCryogenic Storage TanksCryogenic Storage SystemsCompressor SystemsCryogenic PumpsCryogenic ValvesCryogenic PipingPiping InsulationEquipment InsulationProcess Control SystemsHuman ErrorsSpills and LeaksTruck Loading and UnloadingFire Protection Systemsfire water systems

dry chemical systemsgas systemsfoam systemsHazard Detection Systemsgas detectorslow temp. det.flame det.high temp. det.

OperatingHours675,000

2,837,000188,0001,809,0001,809,0002,256,000366,0006,278,000f1,16*4,000,000SDSD1,505,0004,779,000*,626,000,156,00O 11,450,00O11,450,00O11.423.00O11364,00O1188,00016,703,00016,703,0002,631,00010,570,0008,418,000

MajorFailures

251 62624

1 1 686U2SDSD9

1 91 1O24n1 422O76"44212O

MTBF(hours)

27,000177,0007,200904,500452,00019,0004,0001,569,00O 1582,000,000SD

S t f167,000252,000^148,000

> 1 , 156, 0O1160,00O11104,00O 11712,00O 11182,00O11>88,000220,000380,000 (SD)1,315,000881,000>8, 418, 000

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PROCESS EQUIPMENTDATABASESTITLE:COMF1: Data Bank for Component Failure DataSPONSOR/AUTHOR: 1TNOINDUSTRY:VariedTYPE:Data Base and Report

I NO.: 4.3-3TIME FRAME:1978 to Present

FREQUENCY OF UPDATE:Continuous

NUMBER AND TYPE OF RECORDS: Unknown number of records coded by component,failure mode, and data sourceDATA BOUNDARY: Mechanical, electrical, and electronic component failuredata

DATA ACCESS:Contact: TNO,Dept . of Industrial Safety, Ir. J. Van der HorstP.O. Box 342, 7300 AH Apeldoorn, The NetherlandsPhone: (O) 55 77 33 44Telex: 36395 TNOAP NLCost: Fixed price of 150 DFL,plus charge per hour for datasearch /analysisReport accessibility: Letter requests specifying data searches neededDESCRIPTION:The Department of Industrial Safety has been collecting and recording componentfailure data since 1978. For this purpose use is made of the following sourcesof information: accessible (international) data-banks, literature and datafrom TNO research pro jects . The Department of Industrial Safety has failuredata-bases relating to: mechanical components, electronic components, andelectric components.As failure data relating to mechanical components differ widely from sourceto source, TNO has set up a documentation system in which all relevantinformation is stored in one, uniform automated code called COMPI, which usesa component description code for the following information: system ofconstruction, operation and function. The automated data-base supplies thefollowing standard output : component code; failure behaviour, cause of failure;failure rate, i.e. the quotient of the number of failures and the number ofservice hours/cycles; and source of information. On request further particularscan be supplied like: (a) failure rate: number of failures, number ofservice hours, calculated distribution. (b) the conditions and situationsin which the component has been used (e.g. the medium: LNG, ammonia, and petrol) .The failure data relating to electronic and electric components are availablein the form of handbooks. Failure rates are derived with the aid of calculationmodels based on statistical relations for which the incorporation of a (large)number of parameters is required. The following minimum of informationis needed: type of component, manufacturer and environmental factors.

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PROCESS EQUIPMENT DATA BASE S1 I 1 I T L K !

Fluor Daniel Inc. Data BaseS P O N S O R / A U T H O R :

VariousINDUSTRY: Chemical Process, Power,Petrochemical, Telecommunications,Nuclear Fuel CycleTYPE:

Data Base

NO.:4 . 3 - 4

TIME FRAME:I Q T C 4 . r> ^4-1975tOPresenFREQUENCY O F U

With new data aPDATE:vailability

N U M B E R A N D T Y P E O F R E C O R D S :generic application. Failure and restore data for specific and

D A T A B OU N D A R Y: Varies extensiwhich is specialized or unique. vely for particular industry sector some of

D A T A ACCESS:Contact: R A M Engineering( B 4 H )Fluor Daniel Inc. 333Phone: (714)975-5854Report ordering address: Same asReport cost: Varies with consultReport accessibility: Through

3 Michelson Drive,aboveing time require ddata consulting ag

Irvine, CA 92730

to provide relevant data.reement.

DESCRIPTION:

Fluor Daniel Inc. has developeof industry applications. This duse requirements necessary to pMaintenance and operational factouses .

d data that it applata is updated anerform risk and ars are assessed and

ies to a wide spectrumd tailored for specificvailability assessments.incorporated fo r specific

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PROCESS EQUIPMENT DATA BASESTITLE:C o m p u t e r i z e d Library o f E q u i pm e n t Failures ( C L E F )S P O N S O R /A U T H O R :

Technica, and Various other sourcesI N D U S T R Y : chemical ProcessPetroleum, N u c l e a rTYPE:D a t a B a s e

I NO.: 4.3-5TIME FRAME:1980 to PresentFREQUENCY OF UPDATE:

ContinuousNUMBER A N D TYPE O F RECORDS: 1000+ Failure rate entries f rom variouspublished sourcesDATA BOUNDARY: T h e D a t a b a s e contains failure rate data for most m a j o requipment items that are f o u n d throughout the process Industries.DATA ACCESS:

Contact: M a t t h e w J. Z e r a f a , Database M an ag e rTechnica Inc.P h o n e : (614)8 4 8 - 4 0 0 0Report ordering address: 355 Campus View Blvd.,Columbus , Ohio 43235Report cost: A fee gives clients access to initial CLEF data setR e p o r t accessibility: Available in c om pu te r fo rm to clientsDESCRIPTION:

T e c h n i c a has compiled computerized failure rate data f r o m the public domainthat can developed into a database. Each database can be customized by addingclient plant-specific data and updated easily in its electronic f o r m . CLEFis also s o f t w a r e compatible with the IRRAS fault tree package put out by E G & G .Failure rate l ibraries can be generated and imported f rom CLEF to the IRRASp r o g r a m .

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LOW20.0e-003O. Oe+00017.0e-005

FAILURE MODE

LOWO.Oe+000O.Oe+000O.Oe+000

FAILURE MODE

LOW30.Oe-OOS

FAILURE MODE

LOWO. Oe+000O. Oe+000

FAILURE MODE

LOWO. e+000O.Oe+000

FAILURE RATESMEDIAN35.06-00320.0e-00320.06-004

: FAIL TO CLOSEFAILURE RATES

MEDIAN10.06-00326.06-00517.06-004

UPPER70.06-003O. Oe+000

49.Oe-OOl

UPPERO.Oe+000O. e+000O.Oe^OOO

: F TO TRANSFER (/D)FAILURE RATES

MEDIAN10.06-004

: FAIL TO TRIPFAILURE RATES

MEDIAN50.06-00417.06-005

: SPURIOUSFAILURE RATES

MEDIAN10.06-00486.06-006

UPPER30.06-004

UPPERO. Oe+000O.Oe+000

UPPERO. Oe+000O.Oe+000

AVERAGEREPAIRO. Oe+000O.Oe+000O. Oe+000

AVERAGEREPAIRO. e+000O.Oe+00038.06-005

AVERAGEREPAIRO.Oe+000

AVERAGEREPAIRO. Oe+000O. Oe+000

AVERAGEREPAIR

O.Oe+000O. Oe+000

TESTINTERVALO. e+000O. e+000O. Oe+000

TESTINTERVALO. Oe+000O. Oe^OOOO. e+000

TESTINTERVALO. Oe^OOO

TESTINTERVALO. Oe+000O. e+000

TESTINTERVAL

O. e+000O. e+000

REFERENCESOURCEOREDACONF AIEEE-500

REFERENCESOURCELEESIEEE-500CONF A

REFERENCESOURCEWASH-I 00

REFERENCESOURCECONF AIEEE-500

REFERENCESOURCECONF AIEEE-500

FAILURE MODE : FAIL TO CLEAR

LOWO.Oe+000

FAILURE RATESMEDIAN30.06-004

UPPERO. Oe+000

AVERAGEREPAIRO. Oe+000

TESTINTERVALO. Oe+000

REFERENCESOURCECONF D

Data Resource 4.3-5Computerized Library of Equipment FailuresExample Data SheetCOMPONENT : CIRCUIT BREAKERS

FAILURE MODE : ALL MODES

Reprinted with permission of Technica, Inc.

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PROCESSEQUIPMENTDATABASESTITLE: HARIS - Hazards and Reliability Information System - Reliability DataBase

SPONSOR/AUTHOR:Various SourcesINDUSTRY: chemical Process,Petroleum, Natural Gas and Nuclear

TYPE:Data Base and Report

I NO.: 4.3-6TIME FRAME:1979 to date

FREQUENCY OF UPDATE:Continuous

NUMRER AND TYPE OF RECORDS: Failure rate data from public domain sourcesand derived from field failure studies. Over I r500 failure rates.DATA BOUNDARY: The data base contains failure rate data plus some failuremode information for process equipment - pumps, compressors, gas turbines,valves, vessels, heat exchangers etc.DATA ACCESS:Contact: HARIS Manager (Mr. P. Stead)

RM Consultants Ltd, Suite 7, Hitching CourtAbingdon, Oxon, OXl IDY, ENGLANDPhone: 0235 - 555755Report cost: Based on time and type of data requiredReport accessibility :Public domain source documents available - also abstracts

DESCRIPTION:The R MC HAR IS (Hazards and Reliability Information System) programs provideorganizations with a data bank of reliability, maintain ability, accident, andsource-abstract data. The programs permit the input of information in a standarddata sheet format. Search capability is built into the programs for retrievalof these data sheets against specific search profiles. H AR IS presently containsover 4400 data sheets.

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PROCESS EQUIPMENT DATA SOURCESTITLE:

Pressure Vessel ReliabilityS P O N S O R / A U T H O R :

S. H . BushI N D U S T R Y :

Chemical Process & P o w e rT Y P E :

Report

I NO.: 4.4-1TIME FRAME:Varies

FREQUENCY OF UPDATE:None

NUMBER A N D TYPE O F RECORDS: Disruptive failure probabilities using U Sa n d Foreign data.DATA BO UNDARY : P o w e r boilers and unfired pressure vessels per Sections Iand VIII of A S M E Cod e .DATA ACCESS:Contact: A m e r i c a n Society o f Mechanical Engineers ( A S M E )34 5 E . 4 7 t h St . , N ew Y o r k , N Y 10017P h o n e : (212) 7 0 5 - 7 7 9 4

Order f r o m : A S M E Order Dept . P h o n e : (201) 882-1167

D E S C R I P T I O N :The purpose of this study was to examine limitations in US and foreign chemicalprocess and p o w er industry pressure vessel data to determine if it can beencoded. In Germany the Institut fur Reaktorsicherheit der TechnischenU b e r w a c h u n g s - V e r e i n e , ( T U V ) , requires data collection on pressure vessels. Inthe US, data f r o m the A m e r i c a n Boiler Manufacturers Association ( A B M A )concerning the A S M E Boiler and Pressure Vessel Code Section I Boilers isavailable but is not inclusive en o u g h for data encoding. The US appears to havea lower incidence of operational failures than the foreign sources report butstudy of the variors data does not indicate why . Relevant comparative data existso n nuclear reactor pressure vessels.

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PROCESS EQUIPMENT DATA SOURCESTITLE:

Safety of Interstate Natura l Gas PipelinesSPONSOR/AUTHOR:Federal Power CommissionI N D U S T R Y :

PowerTYPE:

Report

NO.: 4 .4 -2TIME FRAME:

1950 to 1965F R E Q U E N C Y OF UPDATE:

NoneN U M B E R AND TYPE OF RECORDS: 87 Casuali t ies /Approx. 3000 pipe failures.

D A T A B O U N D A R Y : U . S . interstate Natural Gas large diameter, high pressuretransmission pipelines.

D A T A ACCESS:Contact: Available only through public libraries. Thereport is not retainedby Government Printing Office

Report accessibility: Public Information; Recorded in the 2nd Session of the89th Congress as a Report for the U.S. Senate Committeeon Conmmerce, April 19, 1966.

DESCRIPTION:Military/government type publication. It lists accidents with fatalityscenarios that occurred during operation and maintenance of U . S . interstategas pipelines from 1950 to 1965 . Also listed are individual pipework failuresduring that time, about 3000 entries, that have been compiled from var ioussources by the study committee.

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PROCESS EQUIPMENT DATA SOURCESTITLE: Some Data on the Reliability of Pressure Equipment in the ChemicalPlant EnvironmentSPONSOR/AUTHOR:

D.C. Arulanantham & F. P. LeesINDUSTRY:

Chemical ProcessTYPE:

Journal Article

I NO.: 4.4-3TIME FRAME:

1950's to 1970'sFREQUENCY OF UPDATE:

NoneN U M B E R AND TYPE OF RECORDS: Data derived from 1.4xl0 4 vessel-years.

D A T A B O U N D A R Y : Process pressure vessels, pressure storage vessels, and heatexchangers .

D A T A ACCESS:Contact: I N T . J. Pressure Vessel & PipingElse vie r Applied Science Pu blis hers L T D , Great Britain, 1981Report accessibility: Available Through Library Sources.

D E S C R I P T I O N :This is a survey of pressure equipment failure rate data including pressurevessels and heat exchangers. Overall failure rates given as 4 x l O ~ 3 f /yr withan upper bound of 6.3xlO"3 f /yr at a 99%confidence level. No disruptive failureswere recorded but an upper bound of 2 . 8 x l O ~ 4 f /yr at 99%confidence level isreported. Other items covered in the surve y include non-pres sure storage vesselsand fired heaters. The data are also analysed to determine the effect ofoperating conditions such as high and low temperature and corrosiveenvironments .

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PROCESS EQUIPMENT DATA SOURCEST I T L E :

Causes of Ammonia Plant S h u t d o w n s : Survey VS P O N S O R / A U T H O R :G . P . Williams, W . W . Hoehing and R. G. ByingtonI N D U S T R Y :

Chemical ProcessTYP E:

Report

I NO.: 4 . 4 - 6TIME FRAME:1965 to 1984

FREQUENCY OF UPDATE:None

NUMBER A N D TYPE O F RECORDS: Records of 5884 shutdowns over 98 yearsoperating timeDATA BOUN DAR Y: Ammonia Plant

DATA ACCESS:Contact: Engineering Society LibraryA m e r i c a n Institute of Chemical Engineers345 East 47th Street

N e w Y o r k , NY 10017

DES CRIP TION:This report addresses ammonia plant shutdowns over the listed time period in40 countries. It provides a basis for comparing plant performance area byarea leading to better control of reliability efforts while reducing maintenancea nd unplanned s h u t d o w n costs. Data are presented for shutdowns due topower, equipment, instrumentation, feedstock and product inventory control.

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PROCESS EQUIPMENT DATA SOURCESTITLE: Pipeline Reliability: An Investigation of Pipeline FailureCharacteristics and Analysis of Pipeline Failure Rates

SPONSOR/AUTHOR: Terje Andersen and AsbjornMisund Det norske Veritas

INDUSTRY:Petroleum and Natura l Gas

TYPE:Journal Article

I NO.: 4.4-8TIME FRAME:

1966 to 1981F R E Q U E N C Y OF UPDATE:

NoneN U M B E R AND TYPE OF RECORDS: Data on frequency and cause of pipeline

failuresD A T A B O U N D A R Y : Data is specific to submarine and cross-country oil andna tura l gas pipelines

D A T A ACCESS:Contact : Journal of Petroleum Technology, Vol. 35, No. 4, April 1983,

pgs. 709-717

DESCRIPTION:This article presents an overview of the causes and frequency of failuresfor submarine and cross-countrypipelines handling oil and natural gas. Itgives several tables and charts which include information on the type ofpipeline, the cause of the failure, and the number of failures. Data fromfailures in the US and the North Sea are included. Failure rates basedon the total length of piping are calculated.

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PROCESS EQUIPMENT DATA SOURCESTITLE: Data Base Development and Equipment Reliability for Phase 1 of theProbabilistic Risk Analysis DPST-87-642SPONSOR/AUTHOR:Technical Division Savannah R iver LabsINDUSTRY: Chemical Process,

Nuclear Fuel CycleTYPE:Report

I NO.: 4.4-10TIME FRAME:1970 to mid 1985

FREQUENCY OF UPDATE:Every 5 years

NUMBER AND TYPE OF RECORDS: About 250 component failure rates and 95%upper boundsDATA BOUNDARY: Pumps, valves, pipe, motors, diesels, heat exchangers,relays, fans for systems given below.

DATA ACCESS:Contact: D. S. Cramer, Savannah River Plant, Aiken, SC 29868Phone: (803) 725-1491Ordering Address: National Technical Information Service (NTIS)

Springfield, VA 22161(703) 487-4650Cost: $20 - $50 paper copy, $7 microfiche copyAccessibility: No restrictionsDESCRIPTION:The failure events were obtained from Savannah R iver Plant sources suchas R eactor Incident Reports, daily logs, and operating summaries. The recordsinclude over 4,400 events going back to 1970 for an effective average of3 operating nuclear reactors. Some entries represent data averaging about110 reactor years experience accumulated since operation began.Systems covered include primary, secondary and emergency core cooling systems,control rod, refueling, scram, electrical power, and lube oil, airsupply,battery supplies.Components include items like pumps, pipes, valves, motors, gear trains, heatexchangers, relays, switches, fans, thermocouples, and diesel generators.Some general types of Human Errors are also included.

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PROCESS EQUIPMENT DATA SOURCESTITLE:

Reliability Analysis of P u m p s for Uranium SolutionsS P O N S O R / A U T H O R :J. A. HoffmeisterI N D U S T R Y :

C h e m i c a l Process, N u c l e a rT Y P E :

Journal Article

NO.: 4.4-11TIME FRAME:

Unknown (prior t o 1 9 8 7 )FREQUENCY OF UPDATE:None

NUMBER A N D TYPE O F RECORDS: Operating life repair frequency & cost data

DATA B OU N D A R Y: D u a l - d i a p h r a g m pumps in u r a n i u m solution service.

DATA ACCESS:Contact: J . A . H o f f m e i s t e r , P EBuilding 9 1 0 6 , M a r t i n Marietta Energy Sys temsP . O . B o x 2 0 0 9 , O ak Ridge, T N 3 78 3 1 - 8 024Bibliographic D a t a : IEEE Transactions o n Reliability, V ol . 3 7 , No . 2June 1988 ( p . 1 4 4 - 1 4 8 )

D E S C R I P T I O N :This paper describes a reliability analysis of dual - diaphragm pumps inu r a n i u m solution service. It is part of the output f rom a failure modes andeffects analysis of the design for a system to be installed at the OakRidge Y-12 plant. The study involved collecting data on pumps with Vitonand T e f l on d i a ph r a gm s at 10 gpm and 15 gpm .

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PROCESS EQUIPMENT DATA SOURCESTITLE:Reliabil i ty Assessment of Safety/Relief ValvesS P O N S O R / A U T H O R :

Aird, R.J.I N D U S T R Y :

Chemical ProcessT Y P E :

Journal Article

I NO.: 4.4-14TI M E F R A ME :2 years

F R E Q U E N C Y OF UPDATE:N / A

N U MB E R A N D T YP E OF R E C OR D S : 86 6 Records

DAT A B O U N D A R Y : Safety and Relief Valves

DATA ACCESS:Bibliographic Data: R . J. Aird

"Reliability Assessment of Safety/Relief Valves"Trans. Institute of Chemical Engineers,VoI 60, 1982, pp 314-318

D E S C R I P T I O N :86 6 safety relief valve test records were analyzed for 10% deviation f r o m setpoint .