Risk Assessment Data Directory Report No. 434 A1 March 2010 Appendix 1 I n t e r n a t i o n a l A s s o c i a t i o n o f O i l & G a s P r o d u c e r s
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Appendix I Data Presented in 1996 Datasheet: ESD and Blowdown Systems This Appendix presents data previously given in the OGP (then E&P Forum) QRA datasheet ESD and Blowdown Systems. The current data is copyright, as stated in Section 2.1; the data previously presented is given in Table I.1 and Table I.2 for reference but should be regarded as illustrative and checked against one of the current sources listed in Table 2.1. Table I.1 Illustrative Data for a Riser ESD Valves System Item Description Failure rate (per year) Pilot Valve Pilot Valve Pilot Valve PO Check Valve PO Check Valve PO Check Valve PO Check Valve PO Check Valve Check Valve ESD SOV ESD SOV ESD SOV ESD SOV ESDV ESDV Valve Actuator Actuator Actuator Ball Valve Ball Valve Valve Limit Switch Switch Switch Pilot Line Regulator Accumulator Accumulator Accumulator Annunciator Air Supply Air Supply Pump Filter Filter Filter Gauge Pipework All Failures Fail energised Fail de-energised Fail energised fixed Fail de-energised fixed Fail de-energised dynamic Blocked or pilot signal lost Internal leakage Hydraulic; All failures All failures Fail energised Fail de-energised Reset pin failure Fail to close position Fail to re-open Needle, Hydraulic Hydraulic, fail to close Hydraulic, fail to open Hydraulic, all failures + incipient Fail to close All failures Hydraulic manually activated Failure, closed circuit Level; all failures inc. incipient Press; all failures inc. incipient Failure Spring induced failure Hydraulic Leaking Hydraulic no operation/piston fail Minor leakage Microprocessor based; fail to alarm Instrument air supply failure 3 50% Compressor system Hydraulic Air Fluid Blocked, (Pre filter low concentration level) Pressure: Faulty indication Instrument Connection Leakage 0.018 0.012 0.006 0.012 0.012 0.006 0.00804 0.0107 0.0268 0.0115 0.0077 0.0038 1.15E-4 0.0219 0.00817 0.0119 not given 0.0278 0.00692 0.1458 0.00578 0.05589 0.0211 0.0021 0.0841 0.1139 0.0001 0.0230 0.0912 0.0120 0.0026 0.0860 0.6220 0.0296 0.0147 0.0105 0.0263 0.03416 0.1752 8.76E-5 OGP 1
Appendix II Data Presented in 1996 Datasheet: Active Fire Protection Systems This Appendix presents data previously given in the OGP (then E&P Forum) QRA datasheet Active Fire Protection Systems. The current data is copyright, as stated in Section 2.1Error! Reference source not found.; the data previously presented is given in Table II.1 to Table II.9 for reference but should be regarded as illustrative and checked against one of the current sources listed in Table 2.1. Table II.1 Typical failure rates for fire protection systems Equipment Type Failures (per 10 6 hrs) Failures (per demand) Firewater system 9.7 0.01 Water supply - diesel engine driven pumpset Water supply - electric motor driven pumpset 0.025 0.004 Deluge system 0.015 Sprinkler system 0.005 Foam mixing system 0.01 Foam supply system 0.02 Halon system 87.0 0.02 CO2 system 8.0 0.02 Table II.2 Failure rates for pumps (source 1, oil and gas industry) Pump type Electric motor (offshore) Failures per demand (process industry) 0.043 Failures per 10 6 hrs operating Failures per 10 6 hrs calendar 0.0033 4719 56 Diesel engine (offshore) 0.023 25808 185 (process industry) 0.019 Table II.3 Failure rates for pumps Pump type Failure mode Failures per 10 6 calendar hrs Positive displacement Failures per demand All 22 0.094 While running 1.9 0.019 Fail to start 1.9 Centrifugal All 99 0.033 2 OGP
Table II.4 Failure rates for firewater distribution valves Type Failures per demand Failures per 10 6 operating hrs Air/hydraulic 0.0003 10 Motorised 0.001 10 Solenoid 0.001 10 Pressure regulating 50 Pressure relief 2.3 Table II.5 Failure rates for firewater distribution mains Equipment Leaks per 10 6 hrs type Medium Serious Large Fire main 0.04/m Joint (>2 in ND) 0.014 0.0015 Joint (<2 in ND) 0.0015 Valve (>2 in ND) Valve (<2 in ND) 0.009 0.001 0.001 Pipe (>2 in ND) 0.0015/100 m 0.0002/100 m Equipment type Table II.6 Failure rates for sprinklers Failure per demand System 0.005 Failures per 10 6 hrs Control valve 0.001 10 Automatic head 0.001 Equipment type Table II.7 Failure rates for deluge sets Failure per demand System 0.015 Failures per 10 6 hrs Butterfly valve 0.001 10 Swing type valve Pneumatic valve 0.001 10 0.0099 21 OGP 3
Equipment type Table II.8 Failure rates for foam supply systems Foam compound supply Failure per demand Failure per 10 6 hrs Centrifugal electric pump 0.007 200 Pelton wheel motor 0.007 200 Supply system 0.02 Foam compound proportioning negligible In-line proportioner 0.005 negligible Nozzle eductor 0.005 negligible Metered proportioner 0.005 negligible Pressure proportioning tank 0.005 negligible Around-the-pump proportioner 0.005 negligible Foam generation Low expansion foam maker 0.005 negligible back- foam maker 0.005 negligible Table II.9 Failure rates for gaseous systems Equipment type Failure per demand Halon System 0.0004* 0.02* Failure per 10 6 hrs Discharge nozzle 0.27 CO2 System 8 * 2 values quoted from different sources 87 4 OGP
Appendix III Data Presented in 1996 Datasheet: Fire and Gas Detection This Appendix presents data previously given in the OGP (then E&P Forum) QRA datasheet Fire and Gas Detection. The current data is copyright, as stated in Section 2.1; the data previously presented is given in Table III.1 for reference but should be regarded as illustrative and checked against one of the current sources listed in Table 2.1. Table III.1 Typical failure rates for fire and gas detection systems Component Gas detector, conventional catalytic Gas detector, conventional IR λ crit per 10 6 hrs Coverage Failure rate per 10 6 hrs c λ det λ SO λ FTO TIF (Test Independent Failures) 5.5 50% 3.0 1.0 1.5 3 10-4 - 0.1 4.0 70% 2.9 0.1 1.0 3 10-4 to 0.1 Gas detector, beam 7 70% 5 1 1 3 10-4 to 0.1 Smoke detector 4.0 40% 1.5 2.0 0.5 10-3 to 0.05 Heat detector 2.5 40% 1.0 1.0 0.5 0.05 to 0.5 Flame detector 7.0 40% 2.5 3.0 1.5 3 10-4 to 0.5 ESD push button 1.0 20% 0.2 0.6 0.2 10-5 FGD node (single PLC system) 80.0 90% 72.0 6.0 2.0 5 10-5 to 5 10-4 Field bus coupler 0.2 90% 0.18 0.02 0.001 10-5 Field bus CPU/ Communications unit 0.2 90% 0.18 0.02 0.001 10-5 λ crit = Total critical failure rate of the component. Rate of failures that will cause either trip or unavailability of safety function (unless detected and prevented from causing such failure). λ det = Rate of critical failure which will be detected by automatic self-test or by control room monitoring. The effect of these failures on the Spurious Trip Rate (STR) depends on the operational philosophy of the system. c = det / crit = Coverage of the automatic self-test + control room operator. λ SO = Rate of Spurious Operation (SO) failures, undetectable by automatic self-test. The rate of Spurious Operation (SO) failures of a component contributes to the STR of the system (independent of operation philosophy). λ FTO = Rate of failures causing Fail-To-Operate (FTO) failures, undetectable by automatic self-test. The FTO failures contribute to the Critical Safety Unavailability (CSU) of the component/system. TIF = Test Independent Failures. The probability that a component which has just been functionally tested will fail on demand (applies for FTO failures only). The TIF probability is the probability that a component which has just been tested will fail on demand. This will include failures caused by for example improper location or inadequate design (software error or inadequate detection principle). An imperfect functional testing procedure will also contribute. Finally, the OGP 5
possibility that the maintenance crew perform an erroneous functional test or fail to return the component to a working state (which is usually not detected before the next test) also contributes to the TIF probability. 6 OGP
Appendix IV Data Presented in 1996 Datasheet: Blowout Prevention Equipment This Appendix presents data previously given in the OGP (then E&P Forum) QRA datasheet Blowout Prevention Equipment. The current data is copyright, as stated in Section 2.1; the data previously presented is given in Table IV.1 to Table IV.5 for reference but should be regarded as illustrative and checked against one of the current sources listed in Table 2.1. Notes: BOP item Table IV.1 Subsea BOP item specific average downtime No of failures Total down-time (hrs) Average downtime (hrs) per BOP-day per rig-day Flexible joints 0 - - - Annular preventers 8 534.5 0.203 0.177 Ram preventers 4 146.5 0.056 0.048 Hydraulic connectors 6 111.5 0.042 0.037 Failsafe valves 2 67.0 0.025 0.022 Choke and kill lines 19 627.0 0.238 0.207 Hydraulic control system 28 521.5 0.198 0.173 Acoustic control system 7 134.0 0.051 0.044 Total 74 2142.0 0.813 0.708 1. BOP-days are all days from the time the BOP is first landed on the wellhead, until it is pulled the last time. 2. Rig-days is the time from when the rig arrives on location and drops the anchors, until the last anchor is pulled prior to leaving the location. OGP 7
Table IV.2 Subsea BOP item specific failure rate with 90% confidence limits BOP item Flexible joints Annular preventers Ram type preventers Hydraulic connectors Failsafe valves Choke and kill lines Hydraulic control system Failure mode Failure rate per 10 6 hours Lower limit Estimate Upper limit 0.0 0.0 36.4 Failed to open fully 23.6 54.1 94.8 Hydraulic leakage 0.5 9.0 27.0 Unknown 0.5 9.0 27.0 Total 35.9 72.1 118.5 Internal leakage (seal failures) 1.4 7.9 18.7 Internal leakage (seal and blade failure) 0.2 4.0 11.8 External leakage (door seal) 0.0 0.0 9.1 Failed to fully open 0.2 4.0 11.8 Total 5.4 15.8 30.6 External leakage 10.8 31.6 61.3 Failed to unlock 0.4 7.9 23.7 Hydraulic failure in locking device (minor) 0.4 7.9 23.7 Total 20.7 47.4 83.1 Internal leakage 0.1 2.6 7.9 External leakage 0.0 0.0 6.1 Unknown leakage 0.1 2.6 7.9 Total 0.9 5.3 12.5 Leakage to environment 85.6 134.4 192.1 Plugged line (ice) 0.4 7.9 23.7 Unknown 0.4 7.9 23.7 Total riser related failures 54.7 94.8 143.9 Total flexible jumper hose failures 20.7 47.4 83.1 Total BOP flexible hose failures 0.4 7.9 23.7 Total choke kill line system 98.3 150.2 211.0 Spurious activation of BOP function 0.8 15.8 47.4 Loss of all functions one pod 41.3 94.8 166.2 Loss of several functions one pod 5.6 31.6 75.0 Loss of one function both pods 5.6 31.6 75.0 Loss of one function one pod 85.8 158.1 248.2 Loss of one topside panel 0.8 15.8 47.4 Loss of one function topside panel 0.8 15.8 47.4 Topside minor failures 5.6 31.6 75.0 Other 0.8 15.8 47.4 Unknown 5.6 31.6 75.0 Total 314.6 442.6 588.6 8 OGP
BOP item Acoustic control system Failure mode Failure rate per 10 6 hours Lower limit Estimate Upper limit Failed to operate BOP 5.6 31.6 75.0 Spurious operation one BOP function 0.8 15.8 47.4 One subsea transponder failed to function 0.8 15.8 47.4 Portable unit failed 0.8 15.8 47.4 Function failure LMRP function 0.8 15.8 47.4 Transducer arm failed 0.8 15.8 47.4 Total 51.9 110.6 187.2 Total subsea BOP system 955.4 1169.7 1402.5 Table IV.3 Detection of subsea BOP failures BOP Item Activity when failure detected Total BOP on rig Running BOP Installation test Regular tests/ drilling Flexible joints 0 - - - - Annular preventers 8 0 0 1 7 Ram preventers 4 1 0 3 0 Hydraulic connectors 6 3 0 1 2 Failsafe valves 2 1 0 1 0 Choke and kill lines 19 1 5 1 12 Hydraulic. Control system 28 4 3 9 12 Acoustic control system 7 0 1 5 1 Total 74 10 9 21 34 OGP 9
Table IV.4 Overview of surface BOP item specific number of failures and down times BOP item Annular preventers Shear/blind rams Pipe rams Control system BOP to high riser connection Riser conns. and wellhead connections Pressure class Days in servic e Number of failures Installation Operation Total Total down time (hrs) Averag e down time per day (hrs) Low 473 1 5 6 6 0.013 1891 6 9 15 50.5 0.027 Total 2364 7 14 21 56.5 0.024 Low 473 1 0 1 0.5 0.001 1891 1 7 8 62.5 0.033 Total 2364 2 7 9 63 0.027 Low 401 0 0 0-0.000 3782 2 1 3 10 0.003 Total 4183 2 1 3 10 0.002 Low 473 7 1 8 13 0.027 1891 7 12 19 66.5 0.035 Total 2364 14 13 27 79.5 0.034 Low 473 2 0 2 16.5 0.035 1891 5 0 5 32.5 0.017 Total 2364 7 0 7 49 0.021 Low 473 1 0 1 1 0.002 1891 6 1 7 10.5 0.006 Total 2364 7 1 8 11.5 0.005 Failsafe valves Total 5994 5 3 8 20 0.003 BOP stack clamps Choke/kill lines Total BOP system Low 473 2 0 2 5 0.011 1891 0 0 0-0.000 Total 2364 2 0 2 5 0.002 Low 473 1 0 1 3.5 0.007 1891 1 0 1 0 0.000 Total 2364 2 0 2 3.5 0.001 Low 473 17 6 23 49 0.104 1891 31 33 64 249 0.132 Total 2364 48 39 87 298 0.126 10 OGP
Table IV.5 Surface BOP item specific failure modes and frequencies with 90% confidence limits (all failures included) BOP Item Failure mode Failure rate per 10 6 hours Annular preventers Shear/blind rams Pipe rams Hydraulic control systems BOP to high riser connections Riser & wellhead connections Failsafe valves BOP stack clamps Choke/kill lines Total BOP system Lower limit Estimate Upper limit Failed to fully open 149.18 246.76 364.29 Leakage in closed position 46.06 105.75 185.30 Hydraulic leakage adapter ring (degraded) 0.90 17.63 52.80 External leakage 0.90 17.63 52.80 Leakage in closed position 46.06 105.75 185.30 Premature partly closure shear ram 0.90 17.63 52.80 Unknown 0.90 17.63 52.80 Leakage in closed position 3.54 19.92 47.25 Failed to fully open 0.51 9.96 29.84 Failed to operate BOP 34.72 88.13 161.34 Failed to operate one BOP function 70.16 141.00 231.74 Failed to operate BOP from remote panels 0.90 17.63 52.80 Spurious activation of BOP functions 0.90 17.63 52.80 Failed to operate rams from remote panels Failed to operate rams from remote panels 0.90 17.63 52.80 0.90 17.63 52.80 Hydraulic leakage 34.72 88.13 161.34 Unknown 14.41 52.88 110.97 Incipient 6.26 35.25 83.61 External leakage 57.91 123.38 208.73 External leakage 70.16 141.00 231.74 External leakage 0.36 6.95 20.82 External hydraulic leakage 0.36 6.95 20.82 Failed to operate valve 0.36 6.95 20.82 Leakage in closed position 5.68 20.85 43.76 Failed to fully open 0.36 6.95 20.82 Unknown 0.36 6.95 20.82 External leakage 6.26 35.25 83.61 External leakage 6.26 35.25 83.61 1273.39 1533.42 1813.47 OGP 11
Valve type Table IV.6 Overall failure categories for SCSSVs (production and injection wells) Wireline Retrievable Flapper Years in service No. of failures per category Total SCSSV Other Unknow n Failure rate per 10 6 hours Total SCSSV 1189.7 124 39 54 31 11.9 3.7 Wireline Retrievable Ball 508.9 84 36 42 6 18.7 8.1 All Wireline Retrievables 1698.6 208 75 96 37 13.9 5.1 Tubing Retrievable Flapper 1088.2 54 26 22 6 5.7 2.7 Tubing Retrievable Ball 52.7 5 4 1 0 10.9 8.6 All Tubing Retrievables 1140.9 59 30 23 6 5.9 3.0 Total, all valves 2839.5 267 105 119 43 10.8 4.2 Note: When SCSSV is stated, the valve itself failed mechanically. Other may typically be control line failure or scale in the well. 12 OGP
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