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Introduction
This chapter introduces the need for process equipment failure rate data, defines the scope
and organization of this book and the data it contains, and explains how to the use the
book.
1.1 Background
The Chemical Process Industry (CPI) uses various quantitative and qualitative techniques
to assess the reliability and risk of process equipment, process systems, and chemical
manufacturing operations. These techniques identify the interactions of equipment, systems, and persons that have potentially undesirable consequences. In the case of reliability
analyses, the undesirable consequences (e.g., plant shutdown, excessive downtime, or
production of off-specification product) are those incidents which reduce system profitability through loss of production and increased maintenance costs. In the case of risk
analyses, the primary concerns are human injuries, environmental impacts, and system
damage caused by occurrence of fires, explosions, toxic material releases, and related
hazards. Quantification of risk in terms of the severity of the consequences and the
likelihood of occurrence provides the manager of the system with an important decisionmaking tool. By using the results of a quantitative risk analysis, we are better able to
answer such questions as, "Which of several candidate systems poses the least risk?" "Are
risk reduction modifications necessary?" and "What modifications would be most effective in reducing risk?"
In performing such a risk analysis, the risk analyst first uses hazard identification
techniques such as those presented in Guidelines for Hazard Evaluation Procedures
(henceforth, HEP Guidelines) such as Failure Modes and Effects Analysis (FMEA) or
Hazard and Operability Studies (HAZOP) to identify the incidents or combinations of
incidents that must occur to create a given consequence. The analyst may also use
techniques such as fault tree analysis or event tree analysis to further define the particular
process or equipment failures that will result in the incidents of concern. Using procedures
contained in Guidelines for Chemical Process Quantitative Risk Analysis (henceforth,
CPQRA Guidelines), the severity of the consequences is then evaluated by considering
the environment in which the incident occurs and, if necessary, applying techniques such
as dispersion, blast, or heat radiation modeling. To evaluate the likelihood of occurrence
of the incident, the analyst must know how frequently the contributory failure incidents
are likely to occur. Consequently, failure rate data for the equipment involved in the
incidents is essential to the risk analysis.
INDUSTRYGENERIC
DATA
GENERIC
DATA SOURCE
SELECTION
OPERATINGAND
MAINTENANCE
PROCEDURES
SELECTED
GENERIC
DATA
SOURCES
PLANT
RECORDS
EQUIPMENTLISTS
OPERATIM
LOGS,
REPORTS
RAW DATA
COLLECTION
AND
REVIEW
RELEVANT
DATA
RAW DATA
CLASSIFICATION
AND SORTING
SORTED
DATA
DATA
REQUIREMENTS
IRRELEVANT
RECORDS
RECORDS
FROM
OTHER
PLANTS
PERMANENT TRACEABLE
RAW DATA & PROCESS FILES
CCPSGENERIC
DATABASE
GENERIC
DATA
EXTRACTION
INTEGRATIONAND
AGGREGATION OF
PLANT-SPECIFIC
AND GENERIC
DATA
CCPS
GENERIC
DATABASE
PROTOCOL
RAW DATA
ANALYSIS
AND
REDUCTION
REDUCED
DATA
ANALYSIS
Component
Populations
Demand Counts
Exposure Times
Failure Counts
REDUCTION
Failure Model and
Parameters
FAILURE RATE
AND
PROBABILITY
CALCULATIONS
CCPS
DATA SHEETS
DATA CLASS-
IIFICATION AND
SORTING
COMPUTER
ACCESSIBLE
DATABASE
(Future)
PLANT-SPECIFIC
DATA
PLANTSPECIFIC
RELIABILITY DATA
Time Related Failure Rates
Demand Related Failure Rates
Error Bounds
EXPERT
OPINION
ANALYSIS
DATABASE
INTEGRATION
AND
AGGREGATION
OF DATA
GENERIC
DATA
PREDICTED
DATA
CPQRA
COMPANY,
COMMUNITY,
REGULATORYAND
OTHER SPECIAL
REPORTS
may look in the Chapter 5 Data Tables once the taxonomy number has been located.
Readers who require additional sources of data should refer to the indexes at the beginning
of each resource section in Chapter 4 (Sections 4.3, 4.4, 4.5, 4.6, 4.7, or 4.8). These
indexes help the reader identify the most useful resources in terms of the type and extent
of data presented. Appendix C is also useful, as it provides additional detail about these
data resources.
When plant-specific data are required, Chapter 6 discusses how to collect and treat
the data so that the resulting failure rates can be used in a CPQRA or be combined with the
data in the CCPS Generic Failure Rate Data Base. Chapter 7 provides a form that can be
used to transfer these data to CCPS's Generic Failure Rate Data Base.