PFD calculations for Amal Steam Project (On-plot)

Function No: 1 Function description: Degasser V-7501 HH pressure protection function Overall PFD

Fault tree analysis:

TestInt PFDind
[yrs] PFDcom

Test Interval Initiator 2

Test Interval FE 2

75-PIZA-005 2 1.59E-02
4.42E-04

75-UZV-002 2 4.63E-02
3oo3
1.21E-03 6.24E-02 = SIL 1

LS 10 1.77E-04
5.01E-06

1) Conclusion is that the SIL1 requirement can be met with above configuration with above test frequencies.
2) Only primary final element is considered only for PFD calculation. Other final elements, 75-UZV-001, 75-XZ-305, 75-XZ-310 are tripped/closed for convenience.

Notes:
Amal Steam Project
IPF Implementation
Date : Oct' 10 Revision : 02 Fault Tree Analysis
 Instructions 47 65 50 50 65 4
Contactor Logic Solver Alarm Alarm Contactor
Vlv ball Vlv ball
P Smart. - on/off - PLC Any PLC Any on/off - Contactor Any
ls safe failure rate 1.90E-02 year -1
5.00E-02 year -1
1.00E-03 year -1
1.00E-03 year -1
5.00E-02 year-1 6.60E-03 year-1
ld dangerous failure rate 1.60E-02 year-1 4.70E-02 year-1 4.00E-05 year-1 4.00E-05 year-1 4.70E-02 year-1 2.60E-03 year-1
Cdt Coverage factor diagnostic test 4.0% 0.0% 0.0% 0.0% 0.0% 0.0%
Tpi Diagnostics test interval 24.0 hours 168.0 hours 24.0 hours 168.0 hours 24.0 hours 168.0 hours
Cpt Coverage factor proof test 95.0% 99.0% 99.0% 99.0% 99.0% 100.0%
Tpi Proof test interval 2.0 year 2.0 year 10.0 year 0.0 year 2.0 year 2.0 year
Tr Repair time 4.0 hours 0.0 hours 4.0 hours 4.0 hours 0.0 hours 0.0 hours
Tp Proof test duration 4.0 hours 0.0 hours 1.0 hours 1.0 hours 0.0 hours 2.0 hours
Tlife Shutdown interval 4.0 year 4.0 year 4.0 year 4.0 year 4.0 year 4.0 year
Q Human error ratio 0.5% 0.5% 0.5% 0.5% 0.5% 0.5%
b Beta factor 5.0% assume b << 1 5.0% assume b << 1 5.0% assume b << 1 5.0% assume b << 1 assume b << 1
5.0% 5.0% assume b << 1
PFD individual 1.55E-02 4.51E-02 1.72E-04 #DIV/0! 4.51E-02 2.53E-03
RFR individual 1.81E-02 4.75E-02 9.50E-04 #DIV/0! 4.75E-02 0.00E+00
PFD common 4.42E-04 1.21E-03 5.01E-06 6.37E-08 1.21E-03 6.50E-05
RFR common 9.50E-04 2.50E-03 5.00E-05 #DIV/0! 2.50E-03 3.30E-04

Overall PFD 1oo1 1.59E-02 4.63E-02 1.77E-04 #DIV/0! 4.63E-02 2.59E-03

Overall RFR 1.90E-02 5.00E-02 1.00E-03 #DIV/0! 5.00E-02 3.30E-04
Overall PFD 1oo2 6.81E-04 3.24E-03 5.04E-06 #DIV/0! 3.24E-03 7.14E-05
Overall RFR 3.71E-02 9.75E-02 1.95E-03 #DIV/0! 9.75E-02 3.30E-04
Overall PFD 2oo2 3.13E-02 9.14E-02 3.49E-04 #DIV/0! 9.14E-02 5.12E-03
Overall RFR 9.50E-04 2.50E-03 5.00E-05 #DIV/0! 2.50E-03 3.30E-04
Overall PFD 2oo3 1.16E-03 7.31E-03 5.10E-06 #DIV/0! 7.31E-03 8.42E-05
Overall RFR 9.51E-04 2.50E-03 5.00E-05 #DIV/0! 2.50E-03 3.30E-04

Assumptions: 6.22E-02 = SIL 1

- Shell default failures rates are used 3.93E-03 = SIL 2
- Valve repair is not possible on-line
- Valve prooftests are not possible on-line
- The valve is still avialable for the safety function during the diagnostic test.
#REF!
Note: These calculations are not validated. Shell does not assume any responsibility for the content.

Instructions:
First 4 columns of sheet "Subsystem PFD" are protected to ensure the integrity of the formula's and therefore only the white
cells in column C can be changed.
Columns E and upwards are not protected against changing of the contents and therefore the default data in these columns can
be changed if required. To restore and return to the Shell defaults simply copy columns C and D again.
The combobox with pull down list can be used to select an initiator or final element from the IPF default equipment list. A
reference index number to the selected equipment is then automatically entered in cell C1. You can copy the equipment data to
another column by typing this index number in cell E1 or G1 or I1, etc.

Simple formulae with defaults v3.xls

OGLA, 07 February 2003

Instructions

Jan Wiegerinck (c) Shell Global Solutions OGES 04/25/2020

 ls ld Cdt
Equipment type I/L/F Instr Operating Simple/ Saf failure safe failure dangerous Coverage
Service Group complex fraction rate failure rate factor
diagnostic
test
year-1 year-1
0 Alarm FE Any Complex None 1.00E-01 2.50E-01 0.00%
1 CO Tx IN Flue gas Complex None 4.00E-02 2.40E-02 0.00%
2 CO2 Tx IN Flue gas Complex None 4.00E-02 2.40E-02 0.00%
3 Conductivity Tx IN - Complex None 4.00E-02 2.40E-02 0.00%
4 Contactor FE Any Simple Low 6.60E-03 2.60E-03 0.00%
5 DCS LS Any Complex None 1.00E-02 2.00E-03 0.00%
6 Earth Leak IN Any Simple Low 4.00E-02 2.40E-02 0.00%
7 F Coriolis IN - Simple Low 5.00E-02 2.00E-02 0.00%
8 F dP E. IN - Simple Low 4.00E-02 2.40E-02 0.00%
9 F dP Pn. IN - Simple Low 4.00E-02 6.00E-02 0.00%
10 F dP SIL IN - Simple Low 4.00E-02 2.40E-02 40.00%
11 F dP Smart. IN - Simple Low 4.00E-02 2.40E-02 12.00%
12 F Rota IN - Simple Low 4.00E-02 2.40E-02 0.00%
13 F Sw. E IN - Simple Low 4.00E-02 2.40E-02 0.00%
14 F Sw. mech IN - Simple Low 4.00E-02 2.40E-02 0.00%
15 F US IN - Simple Low 4.00E-02 2.40E-02 0.00%
16 F Vx IN - Simple Low 4.00E-02 2.40E-02 0.00%
17 Flame Detector IN Flue gas Simple Low 1.00E-01 4.00E-02 0.00%
18 Flame Rod IN Flue gas Simple Low 1.00E-01 4.00E-02 0.00%
19 H2S det. IN Gas -general Simple Low 4.00E-02 2.40E-02 0.00%
20 HC det. CC IN Gas -general Simple Low 4.00E-02 2.40E-02 0.00%
21 HC det. IR IN Gas -general Complex Low 4.00E-02 2.40E-02 0.00%
22 Horn FE Any Simple Low 1.00E-01 2.50E-01 0.00%
23 I Tx IN Any Simple Low 4.00E-02 3.30E-02 0.00%
24 Interm. In IN Any Simple Low 1.00E-09 1.00E-09 0.00%
25 Interm. Out FE Any Simple Low 1.00E-09 1.00E-09 0.00%
26 L Cap IN - Simple Low 4.00E-02 2.40E-02 0.00%
27 L Displ E IN - Simple Low 4.00E-02 2.40E-02 0.00%
28 L Displ Pn. IN - Simple Low 4.00E-02 2.40E-02 0.00%
29 L dP E. IN - Simple Low 4.00E-02 2.40E-02 0.00%
30 L dP Pn. IN - Simple Low 4.00E-02 2.40E-02 0.00%
31 L dP SIL IN - Simple Low 4.00E-02 2.40E-02 50.00%
32 L dP Smart. IN - Simple Low 4.00E-02 2.40E-02 15.00%
33 L radar IN - Complex Low 4.00E-02 2.40E-02 0.00%
34 L Sw. E IN - Simple Low 3.00E-02 2.50E-02 0.00%
35 L Sw. mech IN - Simple Low 3.00E-02 2.50E-02 0.00%
36 L US IN - Complex Low 4.00E-02 2.40E-02 0.00%
37 Limit Sw. micro- IN Any Simple Low 4.00E-02 2.40E-02 0.00%
38 Limit Sw. prox- IN Any Simple Low 4.00E-02 2.40E-02 0.00%
39 Logic Solver LS Any Simple Low 3.20E-02 7.00E-03 0.00%
40 Manual Switch IN Any Simple Low 5.00E-03 1.00E-03 0.00%
41 Not def. FE FE Any Simple Low 5.00E-02 4.70E-02 0.00%
42 Not def. Init IN Any Simple Low 4.00E-02 2.40E-02 0.00%
43 O2 Tx IN Flue gas Simple Low 4.00E-02 2.40E-02 0.00%
44 P E. IN - Simple Low 1.90E-02 1.60E-02 0.00%
45 P Pn. IN - Simple Low 1.90E-02 1.60E-02 0.00%
46 P SIL IN - Simple Low 1.90E-02 1.60E-02 15.00%
47 P Smart. IN - Simple Low 1.90E-02 1.60E-02 4.00%
48 P Sw. IN - Simple Low 6.00E-02 3.60E-02 0.00%
49 PH Tx IN Water Simple Low 4.00E-02 2.40E-02 0.00%
50 PLC LS Any Complex Low 1.00E-03 4.00E-05 0.00%
51 Pos. Tx IN Any Simple Low 4.00E-02 2.40E-02 0.00%
52 QMI IN Any Complex None 4.00E-02 2.40E-02 0.00%
53 R-contact IN Any Simple Low 5.00E-03 1.00E-03 0.00%
54 SC-SSSV FE - Simple Low 5.00E-02 1.58E-02 0.00%
55 Smoke Tx IN Gas -general Simple Low 4.00E-02 2.40E-02 0.00%
56 Speed/ Displ. IN Any Simple Low 6.00E-02 3.75E-02 0.00%
57 SSV FE Heavy liquid HC’s Simple Low 5.00E-02 1.14E-02 0.00%
58 SSV FE Dirty Liquid HC's Simple Low 5.00E-02 1.58E-02 0.00%
59 SSV FE Sour Gas Simple Low 5.00E-02 1.58E-02 0.00%
60 SSV FE Wet Gas Simple Low 5.00E-02 1.58E-02 0.00%
61 T Sw. IN Any Simple Low 8.08E-02 6.67E-02 0.00%
62 T Tx IN Any Simple Low 1.33E-02 1.33E-02 0.00%
63 Tc IN Any Simple Low 1.33E-02 1.33E-02 0.00%
64 V Tx IN Any Simple Low 4.00E-02 2.40E-02 0.00%
65 Vlv ball on/off FE - Simple Low 5.00E-02 4.70E-02 0.00%
66 Vlv ball TSO on/off FE - Simple Low 5.00E-02 4.70E-02 0.00%
67 Vlv butt on/off FE - Simple Low 5.00E-02 4.70E-02 0.00%
68 Vlv butt TSO on/off FE - Simple Low 5.00E-02 4.70E-02 0.00%
69 Vlv Control FE - Simple Low 5.00E-02 4.70E-02 0.00%
70 Vlv ecc on/off' FE - Simple Low 5.00E-02 4.70E-02 0.00%
71 Vlv globe on/off' FE - Simple Low 5.00E-02 4.70E-02 0.00%
72 Vlv globe TSO on/off' FE - Simple Low 5.00E-02 4.70E-02 0.00%
73 Vlv hydr. FE - Simple Low 5.00E-02 4.70E-02 0.00%
74 Vlv Louvre FE - Simple Low 5.00E-02 4.70E-02 0.00%
75 Vlv Mokveld FE - Simple Low 5.00E-02 4.38E-03 0.00%
76 Vlv Mokveld TSO FE - Simple Low 5.00E-02 4.38E-03 0.00%
77 Weight IN Any Complex Low 4.00E-02 2.40E-02 0.00%
 Tpi Cpt Tpi Tr Tp Tlife Q b
Diagnostics Coverage Proof Repair Proof Shut Human Beta
test interval factor proof test time test down error factor
test interval duration interval ratio

hours year hours hours year

100.00% 0.5 0.1 0.50% 5.00% 5 40 1
99.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
100.00% 1E-15 1E-15 0.50% 5.00% Test /repair duration very short because no override during tes
99.00% 4 1 0.50% 5.00% Effect of logic solver type is embedded in the way RRM calcul
99.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00% Moore claims 98% cov.fac for Tx. In RRC 20-60% of the failur
95.00% 4 4 0.50% 5.00% Estimated 30% cov.fac for Tx and transmission only. In RRC 2
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00% Full calibration check with reference gas assumed
99.00% 4 4 0.50% 5.00% Full calibration check with reference gas assumed
99.00% 4 4 0.50% 5.00% Full calibration check with reference gas assumed
100.00% 4 0.1 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
100.00% 4 0.1 0.50% 5.00%
100.00% 0.5 0.1 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00% Moore claims 98% cov.fac for Tx. In RRC 35-50% of the failur
95.00% 4 4 0.50% 5.00% Estimated 30% cov.fac for Tx and transmission only. In RRC 3
99.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 1 0.50% 5.00% Effect of logic solver type is embedded in the way RRM calcul
100.00% 4 1E-15 0.50% 3.00%
99.00% 8 1 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00% Full calibration check with reference gas assumed
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00% Moore claims 98% cov.fac for Tx. In RRC 35-85% of the failur
95.00% 4 4 0.50% 5.00% Estimated 30% cov.fac for Tx and transmission only. In RRC 3
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 4 1 0.50% 5.00% Effect of logic solver type is embedded in the way RRM calcul
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00% Full calibration check with reference gas assumed
95.00% 4 4 0.50% 5.00%
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
95.00% 4 4 0.50% 5.00%
99.00% 4 4 0.50% 5.00%
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
95.00% 4 4 0.50% 5.00%
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
99.00% 1E-15 1E-15 0.50% 5.00% Test/repair duration very short because no override during tes
95.00% 4 4 0.50% 5.00%
 1

hort because no override during test/repair

s embedded in the way RRM calculates the target PFD.

for Tx. In RRC 20-60% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.2)*98% to (1-0.6)*98% = 78% - 40%
Tx and transmission only. In RRC 20-60% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.2)*30% to (1-0.6)*30% = 24% - 12%

reference gas assumed

reference gas assumed
reference gas assumed

for Tx. In RRC 35-50% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.35)*98% to (1-0.5)*98% = 63% - 49%
Tx and transmission only. In RRC 35-50% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.35)*30% to (1-0.5)*30% = 20% - 15%

s embedded in the way RRM calculates the target PFD.

reference gas assumed

for Tx. In RRC 35-85% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.35)*98% to (1-0.85)*98% = 63% - 15%
Tx and transmission only. In RRC 35-85% of the failures are in the impulse lines. Hence Diag. Cov fac. for dang. fail = (1-0.35)*30% to (1-0.85)*30% = 20% - 4%
s embedded in the way RRM calculates the target PFD.

reference gas assumed

hort because no override during test/repair

hort because no override during test/repair

hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair

hort because no override during test/repair

hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
hort because no override during test/repair
% to (1-0.6)*30% = 24% - 12%

0% to (1-0.5)*30% = 20% - 15%

0% to (1-0.85)*30% = 20% - 4%
TypeName I/L/S Description
CO Tx Initiator Flue gas CO measurment
CO2 Tx Initiator Flue gas CO2 measurment
Conductivity Tx Initiator Conductivity analyser
Earth Leak Initiator Earth Leak Detector
F Coriolis Initiator Coriolis type Flow measurement
F dP E. Initiator dP flow measurement- electronic
F dP Pn. Initiator dP flow measurement- pneumatic
F dP SIL Initiator dP flow measurement- SIL 2 certified Tx
F dP Smart. Initiator dP flow measurement- smart electronic
F Rota Initiator Var. Area Meter
F Sw. E Initiator Electronic Flow Switch
F Sw. mech Initiator Mechanical Flow Switch
F US Initiator Ultra Sonic type Flow measurement
F Vx Initiator Vortex type Flow measurement
Flame Detector Initiator UV/IR flame detector
Flame Rod Initiator Ionisation type flame detector
H2S det. Initiator H2S gas detector for ambient air
HC det. CC Initiator HC gas detector for ambinet air -Catalytic Combust
HC det. IR Initiator HC gas detector for ambient air - Infra Red
I Tx Initiator Electric Current monitor
Interm. In Initiator Intermediate input from other C&E
L Cap Initiator Capacitive Level measurement
L Displ E Initiator Displacer type level transmitter- Electronic
L Displ Pn. Initiator Displacer type level transmitter- Pneumatic
L dP E. Initiator dP level measurement- electronic
L dP Pn. Initiator dP level measurement- pneumatic
L dP SIL Initiator dP level measurement- SIL 2 certified Tx
L dP Smart. Initiator dP level measurement- smart electronic
L radar Initiator Radar type level measurement
L servo Initiator Servo gauge type level measurement
L Sw. E Initiator Level Switch, non mechanical types
L Sw. mech Initiator Float type Level Switch
L US Initiator Ultrasonic Tx Level
Limit Sw. micro- Initiator Limit Switch (micro switch/ reed relay)
Limit Sw. prox- Initiator Limit Switch (proximity & amplifier)
Manual Switch Initiator Manual Switch, rotary/pushbutton
Not def. Init Initiator Still to be defined
O2 Tx Initiator Flue gas Oxygen measurment
P E. Initiator P/dP measurement- electronic
P Pn. Initiator P/dP measurement- pneumatic
P SIL Initiator P/dP measurement- SIL 2 certified Tx
P Smart. Initiator P/dP measurement- smart electronic
P Sw. Initiator Mechanical Pressure Switch
PH Tx Initiator Ph Analyser
Pos. Tx Initiator Position Transmittor
QMI Initiator Analyser - unspecified
R-contact Initiator Running Contact from MCC
Smoke Tx Initiator Smoke detector
Speed/ Displ. Initiator Axial / Radial Displ. /Keyphasor /Speed probe & au
T Sw. Initiator Temperature Switch
T Tx Initiator Tc or RTD and Transmitter combination
Tc Initiator Thermo couple or RTD element only
V Tx Initiator Voltage Monitor
Weight Initiator Weight Transmitter
DCS Logic Solver DCS based device
Logic Solver Logic Solver Logic Solver
PLC Logic Solver Logic solver
Alarm Final Element Alarm System
Contactor Final Element Electric Motor switchgear (on/off)
Horn Final Element Horn / Siren
Interm. Out Final Element Intermediate output to other C&E
Not def. FE Final Element Still to be defined
SC-SSSV Final Element Surface controlled Sub surface safety valve
SSV Final Element Surface safety valve
Vlv ball on/off Final Element ESD pneumatic Ball valve On/Off non-TSO
Vlv ball TSO on/off Final Element ESD pneumatic ball valve On/Off TSO
Vlv butt on/off Final Element ESD pneumatic Butterfly valve On/Off non-TSO
Vlv butt TSO on/off Final Element ESD pneumatic Butterfly valve On/Off TSO
Vlv Control Final Element Control Valve non TSO
Vlv ecc on/off' Final Element ESD pneumatic eccentric valve non-On/Off TSO
Vlv globe on/off' Final Element ESD pneumatic globe valve non-On/Off TSO
Vlv globe TSO on/off' Final Element ESD pneumatic globe valve On/Off TSO
Vlv hydr. Final Element ESD Hydraulic Valve On/Off
Vlv Louvre Final Element ESD pneumatic Louvres
Vlv Mokveld Final Element Mokveld valve non TSO
Vlv Mokveld TSO Final Element Mokveld valve in TSO service