ANALYSIS OF RELIABILITY, MAINTENANCE AND RISK BASED INSPECTION OF PRESSURE SAFETY VALVES
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1 ANALYSIS OF RELIABILITY, MAINTENANCE AND RISK BASED INSPECTION OF PRESSURE SAFETY VALVES Venilon Forunao Francisco Machado Mechanical Engineering Dep, Insiuo Superior Técnico, Av. Rovisco Pais, , Lisboa, Porugal, 204 Absrac The presen sudy focused on doing a survey abou he curren sae of he ar of applying he RBI (Risk Based Inspecion) mehodology on pressure safey valves (PSVs) in he process indusry, as well as, analyzing he reliabiliy of applying he Weibull disribuion according o sandard API RP 58 and deermining an opimum inspecion inerval of PSVs. From he mainenance repors daa of wo companies (a perochemical and oil company), i was possible o analyze he reliabiliy and deermine he Weibull parameers (shape parameer and life characerisic) of he PSVs and also o deermine he failure probabiliy of he PSV as described in he API RP 58. In addiion, he opimal inspecion inervals for PSVs were also calculaed. Inroducion There is a general quesion in he oil and gas indusry, as well as, in he chemical indusry: how long should he pressure safey valve (PSV) be allowed o operae before being inspeced and esed? This quesion has no been seen as a serious problem so far, bu wih he recen global financial crisis and some accidens, many companies dealing wih PSVs have come o realize he need o reduce spending by eradicaing unnecessary inspecions and ess, while mainaining he inegriy of he PSV. The need for inspecion and mainenance is due o several facors such as he degradaion of wear or corrosion, low reliabiliy of componens, human errors, legislaive or exernal facors, (e.g.) aggressive or emporal environmens. In hese acions, mosly based on ime, many resources are spen, wheher human or maerial.
2 Pressure safey valves The pressure safey valve as shown in figure, also called PRD (Pressure Relief Valve), pressure relief or simply as safey valve, is an auomaic device, moved by a spring which opens wih a pre-esablished pressure, relieving excess he of pressure and closes providing good seal when condiions reurn o normal. I is widely used in he process indusry. A PSV is, in many cases, he ulimae proecive device for he equipmen inegriy. I is imporan o ensure ha he PSV can operae a all imes and all circumsances, and should also be undersood as a valve for overpressure proecion. Pressure safey valves are subdivided ino wo groups: convenional PSV figure a) and Balanced PSV figure b). a) b) Figure - a) Convencional PSV; b) Balanced PSV Sandard API RP 580 and 58 applied o PSVs The sandard API RP 580 is ofen used o ensure he smooh operaion and proper insallaion of PSVs projec. This sandard provides informaion on he use of risk analysis o develop an effecive inspecion plan. The sandard API RP 58 provides quaniaive procedures o esablish an inspecion program using risk-based mehods for pressurized fixed equipmen, including pressure vessel, piping, ankage, pressure relief devices and hea exchanger ube bundles. 2
3 Esimaion of opimum and esing inerval for PSV- Case sudy In he hree case sudies hereby presened, i was analysed he repor daa of wo companies, a perochemical and an oil company. The aim of his sudy was o esimae an opimal inspecion inerval of PSVs. All ables used in he hree cases are described in API RP 58. The duraion of inspecion ime considered was 5 years. Case From he mainenance repor of a Perochemical Indusry was possible o obain he daa as shown in able. Table - Daa of perochemical company Toal of PSVs 37 PSV opens below Se Pressure 7 PSVs wih leakage 5 PSV opens a (0.9 TP/SP <.3) 8 PSV opens above se pressure.3 SP 7 Fluid Temperaure T < 260 The 37 PSVs operaed under he following condiions: - Severiy: mild T < 500 (< 260 ); - Types of PSVs: Convenional; from graph 7.6 P f,j = 0.5 (see API RP 58) - Discharge for closed sysem and he demand rae(dr j ): 0.25 (assuming he average values for all overpressure condiions). From able, daa of leakage PSVs will no be used, since i is inended o esablish an opimum inspecion inerval of PSVs ha fails o open. The resuls of he 32 PSVs ess are shown in able 2, ranked in increasing order of division on TP/SP where TP is he es pressure and SP is he se pressure. Table 2 - Pressure ess resuls TP/SP Frequency Relaive Frequency[%] Cumulaive Frequency [%] 0,7 3,25 3,25 0,73 2 6,25 9,375 0,75 3,25 2,5 0,8 3,25 5,625 0,85 2 6,25 2,875 0,9 3 9,375 3,25 0 3,25 62,5,03 2 6,25 68,75, 2 6,25 75,2 3,25 78,25,3 2 6,25 84,375,35 2 6,25 90,625,4 2 6,25 96,875,5 3,
4 Considering a range of sudy of 0.7 TP/SP.5, wih pressure ess resuls, a graph was buil (TP/SP raio and he cumulaive frequency), as shown in figure 2. Cumulaive disribuiion Curve TP/SP,50,40,35,30,20,0,03,00 0,90 0,85 0,80 0,75 0,73 0,70 3,3% 2,9% 5,6% 2,5% 9,4% 3,% 00,0% 96,9% 90,6% 84,4% 78,% 75,0% 68,8% 62,5% Figure 2 - Raio TP/SP and cumulaive frequency According o fluid severiy: mild, T < 500 (< 260 ) of he PSVs daa, i is deermined he Weibull parameers from able 7.5 (see API 58), herefore, =.8 and η def = years. Table 3 presens he calculaions according o sandard API RP 58. Table 3 Calculaion according o API RP 58 Formulas Resuls F c See API RP F op F op = o MAWP o~4 MAWP 0.8 F env Table 7.6 η mod η mod = F c F op F env η def [years] P f,prior = e η mod 6.34% = 93.66% = CF pass 4.3% P f,wg P f,wg = P η f,cond 6.69% mod η mod η = upd ln P [years] f,wg P fod,j P f,j insp P fod,j = e 6.69% = P fod,j DR j P f,j 0.25% P f,j insp = ln P f,j 0 [monhs] For he firs case of sudy (case), which is he case of a perochemical Indusry, 32 PSVs were sudied. The resuls show ha for he curren case of he Company, which operaes under mild condiions in erms of severiy of fluid (T < 260 ), i has small probabiliy of failure a 4
5 opening of 0.25 % in a range of 5 years of inspecion, and he opimum inspecion ime for his case is once every 0 monhs. Case 2 From he mainenance repor of he oil company, i was possible o obain he daa shown in able 4. Table 4 - Daa of PSVs from an Oil Company Toal de PSVs 34 PSV Opens a (0.9 TP/SP <.3) 26 Opens above se pressure.3 SP 2 PSVs wih leakage 6 Fluid Temperaure T > 260 The 28 PSVs operaed under he following condiions: - Severiy service: severe T > 500 (> 260 ); - Types of PSVs: Convenional - Discharge for closed sysem and he demand rae (DR j ): 0.25 (average overpressure). From able 4, daa of leakage PSVs will no be used, since i is inended o esablish an opimum inspecion inerval of PSVs ha fails o open. The resuls of he 28 PSVs ess are shown in able 5, ranked in increasing order of division on TP/SP. Table 5 - Pressure es resuls TP/SP Frequency %Frequency Cumulaive Frequency 0,923 3,57 3,57 0, ,4 0,7 0,945 3,57 4,29 0,954 3,57 7,86 0,959 3,57 2,43 0, ,4 28,57 0,963 3,57 32,4 0,966 3,57 35,7 0,97 2 7,4 42,86 0, ,4 50,00 0,973 3,57 53,57 0,978 3,57 57,4 0, ,86 75,00 0,98 3,57 78,57 0,985 3,57 82,4 0, ,4 89,29,03 3,57 92,86,302 3,57 96,43,352 3,57 00,00 5
6 Considering a range of sudy of 0.92 TP/SP.35, wih pressure es resuls a graph was buil (TP/SP raio and he cumulaive frequency), as shown in figure 3. Cumulaive frequency[%] 00,0 80,0 60,0 40,0 20,0 0,0 0,8,2,4 TP/SP Figure 3 - Raio TP/SP and cumulaive frequency. According o fluid severiy service: severe T > 500 (> 260 ) of he PSVs daa, i is deermined he Weibull parameers from able 7.5 (see API 58), herefore, =.8 and η def = 3.2 years. From graph 7.6 (see API 58) P f,j = 0.5 and able 6 presens he calculaions according o API RP 58. Formulas Resuls F c F op F op = o MAWP o~4 MAWP 0.8 F env Table 7.6 η mod η mod = F c F op F env η def [years] = e η mod 35.40% = 64.60% = CF pass 2.3% P f,wg P fod,j P f,j insp P f,wg = 0.2 = P η f,cond mod ln P f,wg η mod 3.2% 8.63 [years] P fod,j = e 3.20% = P fod,j DR j P f,j.2% P f,j insp = ln P f,j 9 [monhs] For he second case of sudy (case 2), which is he case of he oil indusry, 28 PSVs were sudied. The resuls show ha for he curren case of he company, which operaes under severe condiions in erms of severiy of fluid (T > 260 ), i has a probabiliy of failure a 6
7 opening of.2% in a range of 5 years of inspecion, and he opimum inspecion ime for his case is once every 9 monhs. Case 3 In his case, daa from oil company (see able 4) is hereby analysed. 6 PSVs failed due o leakage, and herefore, i is esimaed and analysed he growh of he probabiliy of failure wih he inspecion ime duraion. The 6 PSVs operaed in a severe condiion in erms of fluid severiy (T > 500 (> 260 )), from able 7.2 (see API 58) have =.6 and η def = 3. years. Since he PSV has a meal sea, he adjusmen facor is F s =. Formulas Resuls F s - F env Table 7.6 (API 58) 0.6 η mod η mod = F s F env η def 7.86 [years] P l,wg P l insp P l,wg = = e η mod 38.43% = 6.57% = CF pass P η f,cond mod = ln P f,wg P l = e insp = ln P l 6.6% 34.32% η mod 8.59 [years] 34.32% 4.9 years For a beer undersanding of he resuls obained, figure 4 shows he growh of he probabiliy of failure due o leakage wih he opimal inspecion ime. Probabiliy of failure due o leakage vs Inspecion ime Inspecion ime [years] ,5 58,00% 55,49% 5,90% 47,5% 4,26% 34,32% 26,57% 8,42% 0,5% 3,78%,32% Figure 4 - growh of he probabiliy of failure due o leakage 7
8 For he presen case, if he company performs inspecions once every 0.5 years (6 monhs), he probabiliy of failure of PSV due o leakage is.32%, and if he company conducs inspecions once every 5 years, he probabiliy of failure is 34.32%. Conclusion Pressure safey valves play an imporan daily role in he process indusry by proecing faciliies, human lives and invesed capial. The only way o know if he PSV is operaing well is o develop an effecive inspecion plan. This plan mus guaranee he reliabiliy of he PSV and ensure ha he PSV can operae a all imes and all circumsances. The hree cases sudies analyzed in his aricle were used o deermine he probabiliy of failure of he PSVs and o esimae he opimal inspecion inervals according o sandard API 58. In he firs case (perochemical indusry), according o pressures es resuls and he severiy of he service (mild) i was possible o deermine he probabiliy of failure of he PSV and he opimal inspecion ime (once every 0 monhs). In he second case (oil company), according o pressure es resuls of he mainenance repors and he service s severiy (severe), he probabiliy of failure is grea han 35.40%. i is advised ha inspecion has o be performed wice a year, or once every 9 monhs for beer conrol of he failure. In he hird case (he same oil company), 6 PSVs failed due o leakage and he opimal inspecion ime esimaed is once every 6 monhs. The resuls show ha he proposed soluion, despie some limiaions, is feasible for he developmen of his work, hus leaving a solid basis for a beer risk analysis according o sandard API RP 58 Bibliography American Peroleum Insiue, Risk-Based Inspecion, API RP 580, November 2009 American Peroleum Insiue, Risk-Based Inspecion Technology, API RP 58, Sepember American Peroleum Insiue, Sea Tighness of Pressure Relief Valves, API 527, July, American Peroleum Insiue, Pressure Vessel Inspecion, code: In-Service Inspecion, Raing, Repair, and Aleraion, API 50-Downsream segmen, June,
9 Leser, LESER GmbH &Co.KG, 203. [Online].Available: Acedido [29 seembro 203]. M.S.Jones Inspeção Baseada no Risco Válvulas de segurança de Equipamenos sob pressão, Lisboa, R. Assis, Apoio à Decisão em gesão da Manuenção fiabilidade e manuibilidade, Lisboa, Lidel, 2004 R.B.Abernehy, The new Weibull handbook, norh Palm Beach, Florida,
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