Gas and Oil Reliability Engineering

by Calixto

• ISBN13: 9780123919144
• ISBN10: 0123919142
• Format: Hardcover
• Copyright: 2012-09-26
• Publisher: Elsevier Science

Summary

The advent of reliability engineering tools coupled with the cost of oil and gas operations has changed the paradigm of maintenance technology. A simple strategy of efficient replacement of failed equipment/component has been transformed into a more complex but proactive approach for keeping equipment running at peak efficiency concept of "total process" reliability engineering and maintenance. Applied Oil and Gas Reliability Engineering: Modeling and Analysis is the first book to apply reliability value improvement practices and process enterprises lifecycle analysis to the Oil and gas Industry. With this book in hand, engineers also gain a powerful guide to the most commonly used software modeling tools which aid in the planning and execution of an effective maintenance program. Easy to understand, the book identifies equipment and procedural problems inherent to oil and gas operations then applied a systematic approach for solving them. In this book, the author combines qualitative and quantitative methods with powerful software modeling tools to assist engineers in formulating a custom maintenance policy which will ensure process efficiency, reduce projects cost, reduce redundancies and optimum equipment replacement time. Mathematic methods for analyzing failure historical data Instruction for utilizing modeling systems such as MAROS, TARO, and BLOCKSIM and interpret results Step by Step approach for formulating an cost effective maintenance program Identifies equipment and procedural problems inherent to oil and gas operations Easily understood methods and software tools that will save time and money Provides a tutorial for using the most used software programs such as: MAROS, TARO, and BLOCKSIM Step by step instruction to create a custom maintenance policy Reduce project cost, reduce redundancies and optimize equipment life

Table of Contents

Preface	p. xi
Acknowledgments	p. xv
Life Cycle Analysis	p. 1
Quantitative Failure Data Analysis	p. 1
Probability Density Functions	p. 12
Exponential PDF	p. 19
Normal PDF	p. 22
Logistic PDF	p. 26
Lognormal PDF	p. 27
Loglogistic PDF	p. 31
Cumbel PDF	p. 33
Weibull PDF	p. 36
Gamma PDF	p. 37
Generalized Gamma PDF	p. 40
How to Define PDF Parameters and Choose Which PDF Fits Better with the Failure Data	p. 43
Plot Method	p. 45
Rank Regression	p. 48
Maximum Likelihood Method	p. 54
How Reliable Is the Reliability: The Confidence Bound Will Tell You	p. 56
References	p. 61
Accelerated Test and Reliability Growth Analysis Models	p. 63
Introduction	p. 63
Quantitative Accelerated Tests	p. 64
Arrhenius Life-Stress Model	p. 67
Eyring Life-Stress Model	p. 71
Inverse Power Law Life-Stress Model	p. 73
Temperature-Humidity Life-Stress Model	p. 76
Thermal-Nonthermal Life-Stress Model	p. 80
General Loglinear Life-Stress Model	p. 84
Proportional Hazard Life-Stress Model	p. 87
Cumulative Risk Life-Stress Model	p. 90
Qualitative Accelerated Tests (HALT and HASS)	p. 93
Reliability Growth Analysis	p. 95
Duanne Model	p. 96
Crow-Ansaa Model	p. 98
Lloyd-Lipow Model	p. 103
Gompertz Model	p. 106
Logistic Model	p. 109
Crow Extended Model	p. 111
Power Law Model	p. 115
References	p. 117
Reliability and Maintenance	p. 119
Introduction to Failure Mode Effects Analysis	p. 119
Design Failure Mode Effects Analysis	p. 123
Failure Mode Analysis: Process and Operational Applications	p. 129
Reliability Centered on Maintenance	p. 140
Risk-Based Inspection	p. 150
ReBI	p. 155
RGBI Analysis	p. 159
ORT Analysis	p. 162
References	p. 166
Reliability, Availability, and Maintainability Analysis	p. 169
Introduction to RAM Analysis	p. 169
Scope Definition	p. 171
Failure and Repair Data Analysis	p. 172
Modeling and Simulation	p. 175
Sensitivity Analysis	p. 179
Conclusions and Reports	p. 180
Modeling and Simulation	p. 182
RBD Configuration	p. 183
Markov Chain Methodology	p. 188
Simulation	p. 191
Reliability and Availability Performance Index	p. 198
Sensitivity Analysis: Redundancy Policies, Maintenance Plans, Stock Policies, and Logistics	p. 206
Redundancy Policies	p. 206
Maintenance Policies	p. 211
A General Renovation Process: Kijima Models I and II	p. 212
Stock Policies	p. 215
Logistics	p. 218
Improvement Allocation Based on Availability	p. 223
Case Studies	p. 228
Sensitivity Analysis in Critical Equipment: The Distillation Plant Case Study in the Brazilian Oil and Gas Industry	p. 229
Systems Availability Enhancement Methodology: A Refinery Hydrotreating Unit Case Study	p. 244
The Nonlinear Optimization Methodology Model: The Refinery Plant Availability Optimization Case Study	p. 256
CENPES II Project Reliability Analysis	p. 269:
The Operational Effects in Availability: Thermal Cracking Plant RAM Analysis Case Study	p. 285
Partial Availability Based on System Age: The Drill Facility System Case Study	p. 298
High-Performance System Requires Improvements? Compressor Optimum Replacement Time Case Study	p. 316
RAM+L Analysis: Refinery Case Study	p. 326
References	p. 345
Human Reliability Analysis	p. 349
Introduction	p. 349
Human Reliability Concepts	p. 351
Technique for Human Error Rate Prediction	p. 355
Operator Action Tree	p. 362
Accident Sequence Evaluation program	p. 364
Pre-Accident Analysis Methodology	p. 365
Post-Accident Analysis Methodology	p. 373
Human Error Assessment Reduction Technique	p. 376
Social Technical Analysis of Human Reliability	p. 384
Standardized Plant Analysis Risk-Human Reliability	p. 387
Bayesian Networks	p. 394
Case Study	p. 397
THERP Case Study Application	p. 398
OAT Case Study Application	p. 399
SPAR-H Case Study Application	p. 401
HEART Case Study Application	p. 404
STAH-R Case Study Application	p. 406
Bayesian Network Application	p. 411
Methodologies Similarities	p. 416
Conclusion	p. 417
References	p. 418
Reliability and Safety Processes	p. 421
Introduction	p. 421
Fault Tree Analysis	p. 426
Time Independent FTA	p. 428
Time Dependent FTA	p. 431
FTA as Qualitative Risk Analysis Support	p. 435
FTA as a Root Cause Analysis Tool	p. 437
Event Tree Analysis	p. 438
Time Independent Event Tree Analysis	p. 439
Time Dependent ETA	p. 441
Layers of Protection Analysis	p. 444
Independent Time LOPA	p. 446
Time Dependent LOPA	p. 447
Time Dependent LOPA as Qualitative Risk Analysis Support	p. 448
Safety Integrity Level Analysis	p. 450
Hazard Matrix Methodology	p. 455
Risk Graph Methodology	p. 459
Frequency Target Methodology	p. 460
Individual and Societal Risk Methodology	p. 462
Quantitative Approach to Defining Probability of Failure on Demand	p. 463
Bow Tie Analysis	p. 466
Time Independent Bow Tie Analysis	p. 468
Time Dependent Bow Tie Analysis	p. 470
Case Study 1: Applying LOPA Analysis to Decide Whether Risk Is Acceptable When Layers of Protection Are Not Available	p. 476
Case Study 2: Using RAMS Analysis Methodology to Measure Safety Process Effects on System Availability	p. 484
Safety Processes	p. 486
RAM Analysis Case Study	p. 487
Conclusions	p. 495
References	p. 495
Reliability Management	p. 497
Reliability Management over the Enterprise Life Cycle	p. 499
Reliability Management Success Factors	p. 501
Successful Reliability Engineering Implementation Case Study	p. 505
Bayer	p. 507
Successful Organization in Reliability Engineer Implementation	p. 509
USNRC (United States Nuclear Regulatory Commission)	p. 509
ESReDA (European Safety and Reliability and Data Association)	p. 510
ESRA (European Safety and Reliability Association)	p. 511
SINTEF (Stiftelsen for Industriell og Teknisk Forskning)	p. 511
Reliability Engineer Teaching and Research: Successful Universities and Research Center Cases	p. 512
Karlsruhe Institute Technology	p. 512
Indian Institute of Technology Kharagpur	p. 514
University of Strathclyde Business School	p. 515
University of Stavanger	p. 516
Final Thoughts	p. 516
References	p. 518
Index	p. 519
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