Failure Data

Equipment Failure Rate Data

To see all equipment types, select "All" from the drop-down menu on the Equipment list

Equipment Description Failure Mode Failure Rate Specific Failure Rate* Assumed SF* Units Reference
Alarms Buzzer All 2.0E-02 6.6E-03 1 yr-1 Dupont
Alarms Bell All 2.0E-02 6.6E-03 1 yr-1 Dupont
Alarms Horn All 6.0E-02 2.0E-02 1 yr-1 Dupont
Analyzers Transmitter All 8.0E-02 2.6E-02 1 yr-1 Dupont
Analyzers Differential Pressure All 7.6E-01 2.5E-01 1 yr-1 Dupont
Analyzers Oxygen Analyzer All 6.0E+00 2.0E+00 1 yr-1 Dupont
Analyzers Oxygen Paramagnetic All 6.0E+00 2.0E+00 1 yr-1 Dupont
Analyzers pH Meter All 6.0E+00 2.0E+00 1 yr-1 Dupont
Analyzers Gas-liquid Chromatograph All 2.8E+01 9.2E+00 1 yr-1 Dupont
Analyzers Electrical conductivity All 1.5E+01 5.0E+00 1 yr-1 Dupont
Analyzers Hydrogen All 1.0E+00 3.3E-01 1 yr-1 Dupont
Analyzers Water vapor (in gases) All 8.0E+00 2.6E+00 1 yr-1 Dupont
Bearings Ball All 5.0E-02 1.7E-02 1 yr-1 Dupont
Bearings Sleeve All 1.4E-01 4.6E-02 1 yr-1 Dupont
Bearings Journal All 8.0E-02 2.6E-02 1 yr-1 Dupont
Bearings Thrust All 7.0E-02 2.3E-02 1 yr-1 Dupont
Bearings Roller All 1.4E-02 4.6E-03 1 yr-1 Dupont
Bellows Expansion All 4.0E-02 1.3E-02 1 yr-1 Dupont
Blowers Air (entire system) All 1.0E+00 3.3E-01 1 yr-1 Dupont
Boilers Explosion All 3.6E-03 1.2E-03 1 yr-1 Dupont
Boilers Tube leaks All 1.0E-03 3.3E-04 1 yr-1 Dupont
Boilers Oil fired Fire 1.0E-02 N/A 1 yr-1 Dupont
Circuit Breakers General service Fails to close 1.0E-02 N/A 1 yr-1 Dupont
Circuit Breakers General service Fails to trip 5.0E-03 N/A 1 yr-1 Dupont
Circuit Breakers General service Spurious trip 1.0E-03 N/A 1 yr-1 Dupont
Circuit Breakers General service Premature transfer 9.0E-03 N/A 1 yr-1 Dupont
Compressors Centrifugal, turbine driven or reciprocating All 2.0E+00 6.6E-01 1 yr-1 Lees (1996)
Compressors Electric motor driven All 2.0E+00 6.6E-01 1 yr-1 Lees (1996)
Compressors Reciprocating air (excl motor) All 3.0E+00 9.9E-01 1 yr-1 Dupont
Compressors Centrifugal air (excl motor) All 3.0E+00 9.9E-01 1 yr-1 Dupont
Compressors Recycle All 2.0E-01 6.6E-02 1 yr-1 Dupont
Compressors Waste gas All 1.0E+00 3.3E-01 1 yr-1 Dupont
Control Loop General service All 1.0E+00 3.3E-01 1 yr-1 Dupont
Couplings Flexible All 6.0E-03 2.0E-03 1 yr-1 Dupont
Couplings Rigid All 2.2E-04 7.3E-05 1 yr-1 Dupont
Detectors Flame Failure All 1.7E+00 5.6E-01 1 yr-1 Dupont
Electrical Battery supply in standby mode No output 9.0E-03 N/A 1 yr-1 Lees (1996)
Electrical Power supply battery All 2.6E-02 8.6E-03 1 yr-1 Dupont
Electrical Motors Failure to start 3.0E-04 N/A 1 demand-1 Lees (1996)
Electrical Motors Failure to run 6.0E-02 N/A 1 yr-1 Lees (1996)
Electrical Diesel generator Failure to start 9.0E-03 N/A 1 demand-1 Lees (1996)
Electrical Diesel generator Failure to run 8.0E+00 N/A 1 yr-1 Lees (1996)
Fans Exhaust All 8.0E-02 2.6E-02 1 yr-1 Dupont
Filters General service Blockage 8.8E-03 N/A 1 yr-1 Dupont
Filters Process Feed Blockage 1.0E-03 N/A 1 yr-1 Dupont
Gauges Pressure All 1.5E-01 5.0E-02 1 yr-1 Dupont
Gauges Strain Open circuit 2.0E-01 N/A 1 yr-1 Dupont
Generators D.C. All 4.3E-02 1.4E-02 1 yr-1 Dupont
Generators A.C. All 6.1E-02 2.0E-02 1 yr-1 Dupont
Generators Steam turbine All 3.2E-02 1.1E-02 1 yr-1 Dupont
Generators Gas turbine All 6.4E-01 2.1E-01 1 yr-1 Dupont
Generators Motor, diesel or gas engine All 6.7E-02 2.2E-02 1 yr-1 Dupont
Heat Exchangers Air / oil cooler All 7.0E-02 2.3E-02 1 yr-1 Dupont
Heat Exchangers General service Leaks 1.3E-01 N/A 1 yr-1 Dupont
Heat Exchangers Gas / liquid - general Leaks 7.5E-01 N/A 1 yr-1 Dupont
Heat Exchangers Liquid / liquid - general Leaks 6.7E-02 N/A 1 yr-1 Dupont
Heat Exchangers Liquid / liquid - shell and tube < 1500 ft2 Leaks 6.7E-02 N/A 1 yr-1 Dupont
Heat Exchangers Brine cooler All 2.0E-01 6.6E-02 1 yr-1 Dupont
Heaters Superheater Leaks, normal duty 5.6E-02 N/A 1 yr-1 Dupont
Heaters Start-up All 2.5E-01 8.3E-02 1 yr-1 Dupont
Hoses General service Heavily stressed 3.5E-01 N/A 1 yr-1 Greene & Bourne
Hoses General service Lightly stressed 3.5E-02 N/A 1 yr-1 Greene & Bourne
Hoses Liquid chlorine Ruptures 2.0E-02 N/A 1 yr-1 Mond
Loading Arms General service Leakage 2.6E-02 N/A 1 yr-1 Lees (1996)
Loading Arms General service Catastrophic rupture 2.6E-04 N/A 1 yr-1 Lees (1996)
Pipework 10 meter section, all pipe diameters Serious leakage 9.0E-05 N/A 1 yr-1 Lees (1996)
Pipework 10 meter section, all pipe diameters Catastrophic rupture 9.0E-06 N/A 1 yr-1 Lees (1996)
Pipework Joints Leakage 4.4E-03 N/A 1 yr-1 Lees (1996)
Pipework Gaskets Leakage 4.4E-03 N/A 1 yr-1 Lees (1996)
Pumps Centrifugal Failure to run normally 2.6E-01 N/A 1 yr-1 Lees (1996)
Pumps Boiler Failure to run normally 2.0E+00 N/A 1 yr-1 Lees (1996)
Pumps Fire water Failure to run normally 7.0E+00 N/A 1 yr-1 Lees (1996)
Pumps Fuel Failure to run normally 4.4E-01 N/A 1 yr-1 Lees (1996)
Pumps Oil lubrication Failure to run normally 2.6E-01 N/A 1 yr-1 Lees (1996)
Pumps Vacuum Failure to run normally 1.8E-01 N/A 1 yr-1 Lees (1996)
Pumps All other pump types or failure modes Failure to start 1.0E-03 N/A 1 demand-1 Lees (1996)
Pumps All other pump types or failure modes Failure to run normally 2.6E-01 N/A 1 yr-1 Lees (1996)
Pumps All other pump types or failure modes Failure to stop 1.0E-04 N/A 1 demand-1 Lees (1996)
Pumps All other pump types or failure modes Catastrophic failure 1.0E-04 N/A 1 yr-1 Lees (1996)

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 Failure Data

Equipment Failure Rate Data

To see all equipment types, select "All" from the drop-down menu on the Equipment list

Equipment Description Failure Mode Failure Rate Specific Failure Rate* Assumed SF* Units Reference
Sensors (Measurement) Flow, Load Cells (solids) All 3.8E+00 1.3E+00 3 yr-1 ICI
Sensors (Measurement) Flow, Belt speed control (solids) All 1.5E+01 5.0E+00 5 yr-1 ICI
Sensors (Measurement) Flow, Fluids All 1.1E+00 3.8E-01 1 yr-1 Lees (1996)
Sensors (Measurement) Level (solids) All 6.9E+00 2.3E+00 3 yr-1 ICI
Sensors (Measurement) Level (liquids) All 1.7E+00 5.6E-01 3 yr-1 Lees (1996)
Sensors (Measurement) Pressure All 1.4E+00 4.7E-01 3 yr-1 Lees (1996)
Sensors (Measurement) Temperature All 3.5E-01 1.2E-01 3 yr-1 Lees (1996)
Sensors (Measurement) Temperature, optical pyrometer All 9.7E+00 3.2E+00 3 yr-1 Lees (1996)
Sensors (Measurement) Temperature, thermistor All 1.3E-01 4.3E-02 1 yr-1 Greene & Bourne
Sensors (Measurement) Temperature, thermocouple All 4.5E-01 1.5E-01 3 yr-1 Greene & Bourne
Tanks and Vessels Pressure vessels Pressure vessels 1.0E-05 N/A 1 yr-1 Lees (1996)
Tanks and Vessels Pressure vessels Catastrophic rupture 1.0E-06 N/A 1 yr-1 Lees (1996)
Tanks and Vessels Atm. storage tanks Serious leakage 1.0E-04 N/A 1 yr-1 Lees (1996)
Tanks and Vessels Atm. storage tanks Catastrophic rupture 6.0E-06 N/A 1 yr-1 Lees (1996)
Tanks and Vessels Refrig. storage tanks (high integrity) Serious leakage 2.0E-05 N/A 1 yr-1 Lees (1996)
Tanks and Vessels Refrig. storage tanks (high integrity) Catastrophic rupture 1.0E-06 N/A 1 yr-1 Lees (1996)
Turbines Steam All 7.0E-01 2.3E-01 1 yr-1 Lees (1996)
Valve Actuators Pneumatic Fail open 3.5E-02 N/A 1 yr-1 Lees (1996)
Valve Actuators Pneumatic Spurious close 3.5E-01 N/A 1 yr-1 Lees (1996)
Valves PSV Fail dangerous 1.0E-02 N/A 1 yr-1 Lees (1996)
Valves PSV Blocked 1.0E-03 N/A 1 yr-1 Lees (1996)
Valves PSV Lifts heavy 4.0E-03 N/A 1 yr-1 Lees (1996)
Valves PSV Lifts light 6.0E-02 N/A 1 yr-1 Lees (1996)
Valves Vacuum relief Lifts heavy 5.0E-03 N/A 1 yr-1 Lees (1996)
Valves Ball All 1.8E-01 5.9E-02 1 yr-1 Lees (1996)
Valves Butterfly All 3.0E-02 9.9E-03 1 yr-1 Lees (1996)
Valves Gate All 1.3E-01 4.3E-02 1 yr-1 Lees (1996)
Valves Non-return (Check) All 4.0E-02 1.3E-02 1 yr-1 Lees (1996)
Valves Isolation All 2.6E-01 8.6E-02 1 yr-1 Lees (1996)
Valves Solenoid All 9.0E-02 3.0E-02 1 yr-1 Lees (1996)

*Specific Failure Rate: For equipment with all modes failure data, this value is 1/3 of the total.
*Assumed SF: Service Factor included in the data

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