OREDA Offshore Reliability Data Handbook 2nd Edition Published by: OREDA PARTICIPANTS. Distributed by: DET NORSKE VERITAS INDUSTRI NORGE AS DNV TECHNICAOREDA.92 0 OREDA.92 Copyright © 1992 by BP Norway Limited U.A. BIf Aquitaine Norge A/S Esso Norge as Norsk Agip A/S AIS Norske Shell Norsk Hydro a.s Phillips Petroleum Company Norway Den norske stats oljeselskap a.s. Saga Petroleum as ‘Total Oil Marine p.lc. All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise, without prior written permission from the copyright holders. Requests and orders may be forwarded to: DET NORSKE VERITAS INDUSTRI NORGE AS DNV TECHNICA P.O. Box 300 N - 1322 HOVIK, NORWAY Print DET NORSKE VERITAS EIENDOM AS, ISBN 82 S15 0188 4OREDA-92 1 OREDA-92 NOTICE Information in this document is intended to permit data utilisation in the interests of evaluating and improving safety and reliability in offshore platform operations and design. Publication of said information does not imply verification or endorsement of the information, Neither the publishers nor the originators of data included in this document assume any liability to parties adopting any product, process, or practice based upon the usage of the information. The correctness of data listed in this document is assured only to the limits that the producers of each individual chapter, and ‘heir sources, can ensure correctness, AA listing, description, or definition of any item in this document is not to be regarded, by implication or otherwise, as in any manner licensing any person or corporation, or conveying any rights or permission to manufacture, use, or sell any device or item that may in any way be related thereto. This document may not be employed in any manner which might be construed as en- dorsement or censure of any item listed herein, and should only be used within the scope of the intent stated above.OREDA-92 wv OREDA-92 DISCLAIMER ‘This OREDA handbook was established from a consensus of ideas using the OREDA-84 handbook, the OREDA phase II database and the OREDA software. ‘The existence of the OREDA-92 handbook does not imply that there are no other ways to present the offshore reliability data compiled in this book. Furthermore, the viewpoint or technical perspective expressed in this publication is subject to changes brought about by technological developments and comments received from users of the OREDA-84 handbook. It is anticipated that the handbook will be subjected to revisions. Users are therefore cautioned to verify that they have the latest edition of the handbook or any OREDA project document. Comments for revision of the OREDA-92 handbook are welcome from any interested party, Suggestions for changes in documents should be in the form of a proposed change of text, together with the appropriate supporting comments. Requests for interpretation may arise regarding the meaning of parts of the handbook as, they relate to specific applications. When the need for interpretations is brought to the attention of the OREDA Steering Committee, the Committee will initiate action to pre- pare appropriate responses. Since the documents issued by the OREDA project represent ‘a consensus of all concerned interests, itis important to ensure that any interpretation has also received the joint agreement of a balance of interests. For this reason, the OREDA Steering Committee will not be able to provide an instant response to interpretation requests, except in those cases where the matter has previously received formal consid- eration. Comments and requests for interpretations should be addressed to De NORSKE VERITAS INDUSTRI NORGE AS DNV TECHNICA P.O. Box 300 N - 1322 HOVIK, NORWAYOREDA-92 yv OREDA.92 PREFACE Safety, reliability, availability and maintainability of offshore oil drilling and production platforms are of considerable concern to employees, companies and authorities. Risk and reliability analyses are applied to an increasing extent as a means of providing a basis for decisions in offshore engineering, fabrication and operations. ‘The increase in offshore activities, such as exploration, drilling and production, together with the increase in number of platforms, have made it possible to provide suitable historical data for safety, reliability, availability and maintainability analysis. These data could be used for maintaining and iinproving the current safety level and availability of offshore oil production and related activities. However, in order to allow these analyses to be conducted, a source of reliability data is required. ‘The OREDA participating companies have responded to this need by publishing the OREDA handbook. The first edition of the OREDA handbook was published in 1984. ‘The handbook provides an immediate source of reliability data including significant failure modes, failure rate and repair data. ‘While cach new edition of the handbook is considered to be a step forward, it is realised that the quality and quantity of the data presented in the sub chapters of the handbook may be inadequate for certain applications. The OREDA Steering Committee's intention is therefore to maintain this handbook current with the state of technology by publishing new editions. ‘The handbook, after several editions, is expected to contain estimates of statistical parameters based on a comprehensive data base developed from a significant number of offshore installations. The specific updating procedures to be used for revisions will be determined and approved based on feedback from the industry and handbook users. The activities leading up to the OREDA work started in 1980. A project was established under the sponsorship of the "Safety Procedures and Surveillance" (SPO), funded by the Royal Ministry of Local Goverment and Labour in Norway. In 1982 the project was sponsored by Norwegian Industry Assosiation for Oil Companies (NIFO) and administered by the Royal Norwegian Council for Scientific and Industrial Research (NTNF). The project examined the feasibility of establishing a base of reliability data from the maintenance records of the companies involved in offshore operations, specifically exploration, drilling, and production in the North Sea. The pre-project period ‘commenced from Autumn 1981 and consisted of: (1) studying existing reliability data banks, both successful and some which failed; (2) the development of approach, methods of collection and analysis of data, and the format for presentation; and (3) discussions/meetings with the industry. Modifications were also made to the original plan based on the discussions with the oil industry. The study reached completion in 1982 which resulted in several case studies proving the feasibility of an operational programme. Once the project moved into an operational phase in the beginning of 1983, the management and funding were transferred to the OREDA Steering Committee, which is composed of members representing operating companies. Each company contributedOREDA-92 Mt OREDA-92 funds to support the project. This central fund supported all project activities. Phase I of the project consisted of specific activities such as secretariat functions, administration, data collection, data analysis, and the publication of the OREDA-84 handbook. Data were collected from installations located in the Norwegian and UK sector of the North Sea, as well as from installations in the Adriatic Sea, Publishing of the OREDA-84 handbook was a first step in a continuing effort to collect data on the reliability of offshore systems. ‘The OREDA Steering Committee decided to continue the successful cooperation, now with the main objective to establish a computerised data bank which is tailored for current updating and improvement of reliability data. Phase II of the OREDA project focused on process equipment, and the quality of failure data was significantly improved. Improved component specification and more failure records have allowed the data bank operators to analyze the failure statistics for a variety of purposes. ‘The present issue of the handbook contains data collected during this phase of the project. Phase III is currently (1992) continuing, and three more platform operators have joined the project. Emphasis is now on increased data quality and gathering of maintenance information which will allow for more extensive use toward maintenance optimisation and planning. The number of equipment classes has been extended to include generators, fire & gas detectors, process sensors, control logics and sub sea equipment. In this edition of the handbook, the process data is from the Phase II collection, while the rest of the handbook contains data from the Phase I collection. ‘All comments and suggestions for changes received from users of the OREDA-84 handbook have been incorporated in the OREDA-92 handbook. Which data to present in this handbook is supervised and approved by the OREDA Steering Committee. At the time of publication the members of the committee were: + Hans J. Grundt, Chairman + Torvald Sande Statoil AVS Norske Shell + Jan Baka + Donald Lloyd Norsk Agip A/S Total Oil Marine p.Le + George F. Cammack + David Colclough BP Engineering Elf Aquitaine Norge A/S + Aud Bergo + Kenneth Dickson Norsk Hydro a.s Exxon Production Research Co. + Tor Heimiy + Bjorn Saxvik Saga Petroleum a.s Phillips Petroleum Company-NorwayOREDA-92 vu OREDA-92 OREDA Project Leader of the time of publication: + Helge Sandtory ‘The Foundation for Scientific and Industrial Research at the Norwegian Institute of Technology, SINTEF ‘Subcontractors and main representatives: + TLR. Moss RM Consultants Ltd. * Claudio Pratella CREA s.r. progettazione ¢ consulenza + JA. Grammeltvedt Norsk Hydro a.s Research Centre Porsgrunn + Stian Ruud Det Norske Veritas Industri Norge AS, DNV Techni + Ragnar Aang SINTER, Safety and Reliability Responsible for preparation of the OREDA-92 handbook: + Det Norske Veritas Industri Norge AS, DNV Technica: Rune Reinertsen Olav Bakken Erik OstbyOREDA.92 var OREDA-92 TABLE OF CONTENTS Page 1 INTRODUCTION 1.1 Scope . . 1.2 Purpose of Handbook 1.3 Limitations : 1.4 Historical Summary of the OREDA Activities wees 2. USE OF HANDBOOK 2.1 Definitions 2.2 Use of the Handbook . 3 DATA COLLECTION AND STATISTICAL METHODS 14 3.1 Structure ..... weve 14 3.1 Taxonomy»... - 14 3.1.2 Boundary Specific - 16 3.1.3 Failure Mode . + 16 3.2 Data Collection Meth: 17 3.3 Data Verification - 1B 3.4 Statistical Methods - 20 3.4.1 Introduction sees 20 3.42 Estimators and Uncertainty Limits for One Sample Problem. 20 3.43 Testing of Equality Between Failure Rates from Several Samples ... 22 3.44 Estimators and Uncertainty Limits for Multi-Sample Problems 4 3.4.5 Erimators and Uncertalnty Limits for Saeples with no Rallres 29 3.4.6 Repair Time : : 29 4 RELIABILITY DATA PRESENTATION 31 PARTI 4.1 Process Systems ............ cee ee es ceeeeeeees BI AA Vessels 0.0 eee 31 Items included: LI Vessels . cic eee eee eens 32 LLL Vessels, Separator... .. cite et eee ee ees BF LLL Vessels, Separator, (1.0- 2/0) meter cee ee ees 36 1.1.1.2 Vessels, Separator, ( 2.1- 5.0) meter .......... 38 1.11.3. Vessels, Separator, ( 5.1-10.0) meter cetceeeee ees 40 1.1.14 Vessels, Separator, (10.1-15.0) meter ..... 2 1 2 Vessels, Coalescer ... 26-0 eee eee ee eee ec reese eens 444.1.2 Valves OREDA-92 Ix 3 Vessels, Flash Drum . 4 Vessels, Scrubber... . 1 Vessels, Scrubber, (2.0-4.0) meter 2 Vessels, Scrubber, (4.1-6.5) meter. 5 Vessels, Surge Tank . . . 12 Valves... 4.1.2.1 Valves (Described by application) Items included: 1.2.1.1 Valves, Bypass 1.2.1.2. Valves, Control : 1.21.21 Valves, Control, Gas 12.12.11 Valves, Control, Gas, ((0.1- 4.0) inch. 1.2.1.2.12 Valves, Control, Gas, ( 6.0-10.0) inch 2.1.3. Valves, Control, Gas, (10.1-18.0) inch 2.2 Valves, Control, Oil . 22.1 Valves, Control, Oil, (1.0- 2.0) inch 2.2.2 Valves, Control, Oil, ( 6.0-10.0) inch 2.2.3. Valves, Control, Oil, (10.1-18.0) inch 2.3 Valves, Control, Water ...... 2.3.1 Valves, Control, Water, (8.0-10.0) inch 2. 2.1.3 Valves, ESD ..... 2.13.1 Valves, ESD, Gas : wee 3.1.1 Valves, ESD, Gas, ( 2.0- 3.0) inch 3.1.2 Valves, ESD, Gas, ( 8.0-12.0) inch 2.1.3.1.3 Valves, ESD, Gas, (30.0-34.0) inch 3.2 Valves, ESD, Oil... teens 3.3. Valves, ESD, Water . 4 Valves, Shutoff . . . 4.1 Valves, Shut-off, Gas 2.14.1.1 Valves, Shut-off, Gas, ( 6.0-10.0) inch . 2.1.4.1.2 Valves, Shut-off, Gas, (12.0-24.0) inch 4.1.3. Valves, Shut-off, Gas, (30.0-34.0) inch A.2 Valves, Shut-off, Oil .. : (42.1 Valves, Shut-off, Oil, (4.0- 6.0) inch. 4.2.2. Valves, Shut-off, Oil, ( 9.0-12.0) inch . 1.2.3.2 Valves, Control, Water, ons 0-26. 60) inch . OREDA.92 . 46 +. 48 - 50 52 54 37 - 58 100 102 104 - 106 - 108 110 112 114 116OREDA-92, x OREDA-92 4.1.2.2 Valves (Described by type) 119 Items included: 1.2.2.1 Valves, Ball........ see ves 120 1.2.2.1.1 Valves, Ball, Hydraulically Operated . + 122 1.2.2.1.1.1 Valves, Ball, Hydraulically Opereated, ( 8.0-12.0) inch... 124 1,2.2.1.1.2 Valves, Ball, Hydraulically Operated, (30.0-34.0) inch... 126 1.22.1.2 Valves, Ball, Motor Operated. . 128 1.2.2.12.1 Valves, Ball, Motor Operated, ( 8.0-12.0) inch... 130 1.2.2.1.2.2 Valves, Ball, Motor Operated, (18.0-32.0) inch ..... 132 1.2.2.1.3 Valves, Ball, Pneamatically Operated 134 1.2.2.1.3.1 Valves, Ball, Pneumatically Operated, (1.0-6.0) inch 136 2, Nalves, Bal, Prenmatcally Operated (80-120) inch . ... 138 12.2.1. Valves, Ball, Self Acting ......... teveereees 140 1.2.2.2. Valves, Gate fetes e eet ee eee ee eee 142 1.2.2.3 Valves, Globe, (Not included, see taxonomy 1.2.2.3.1) 1.2.23.1 Valves, Globe, Pneumatically Operated . 144 1 Valves, Globe, Pneumatically Operated, (1.0-2.0) inch 146 2. Valves, Globe, Pneumatically Operated, (3.0-6.0) inch 148 1.2.2.3.1.3 Valves, Globe, Pneumatically Operated, (8,0-12.0) inch». .* 150 1.2.2.4 Valves, Flapper . 152 1.22.5 Valves, Butterfly .. seveees 154 1.2.2.5.1 Valves, Butterfly, Motor Operated, (6,0-10,0) inch... 156 1.2.2.5.2 Valves, Butterfly, Pneumatically Operated, (6,0-10,0) inch .. 158 4.1.3 Pumps . 160 Items included: 1.3 Pumps...... 162 1.3.4 Pumps, Electric Motor Driven. . 166 1 Pumps, El. Motor Driven, Water Fire-fighting : - 170 1.1 Pumps, El. Motor Driven, Water Fire-fighting, I-stage ..... 174 1.3.1.1.2 Pumps, El. Motor Driven, Water Fire-fighting, 2-stage 176 13.1.1.3. Pumps, El. Motor Driven, Water Fire-fighting, 4-stage ..... 178 1.3.1.1.4 Pumps, El. Motor Driven, Water Fire-fighting, (7-9)- 180 1.3.1.2 Pumps, El. Motor Driven, Gas Processing . cece ees 182 1.3.1.3 Pumps, El. Motor Driven, Sea Water Injection ........... 184 Pumps, El. Motor Driven, Sea Water Injection, I-stage .... 188 Pumps, El. Motor Driven, Sea Water Injection, 3-stage .... 190 Pumps, El. Motor Driven, Sea Water Injection, 4-stage .... 192 Pumps, El. Motor Driven, Sea Water Injection, 7-stage .... 196 Pumps, El. Motor Driven, Sea Water Injection, 8-stage .... 200 Pumps, El. Motor Driven, Sea Water Injection, 9-stage .... 204 13.1.4 Pumps, El, Motor Driven, Oil Handling ................ 206 1.3.1.4.1 Pumps, El, Motor Driven, Oil Handling, Lstage .. .. 210 1.3.14.2 Pumps, El. Motor Driven, Oil Handling, 2staze . .. 214xL OREDA-92 4.3. Pumps, El. Motor Driven, Oil Handling, 3-stage 13.1.4.4 Pumps, Bl. Motot Driven, Oil Handling, 4-stage . 1.3.1.4.5 Pumps, El. Motor Driven, Oil Handling, 10-stage ........ 1.3.2 Pumps, Turbine Driven 13.2.1 Pumps, Turbine Driven, Sea Water Injection 1.3.2.1.1 Pumps, Turbine Driven, Sea Water Injection, S-stage 1.3.2.1.2 Pumps, Turbine Driven, Sea Water Injection, 6-stage 1.3.2.2 Pumps, Turbine Driven, Oil Handling 1.3.2.2.1 -Pumps, Turbine Driven, Oil Handling, I-stage 1.3.2.2.2 Pumps, Turbine Driven, Oil Handling, 2-stage 1.3.3 Pumps, Diesel Engine Driven . 3.1 Pumps, Diesel Engine Driven, Water Fire-fighting 3.1.1 Pumps, Diesel Engine Driven, Water Fire-fighting, 2-stage . 3.1.2 Pumps, Diesel Engine Driven, Water Fire-fighting, 3-stage . . 3.1.3 Pumps, Diesel Engine Driven, Water Fire-fighting, 4-stage . . 3.3.14 Pumps, Diesel Engine Driven, Water Fire-fighting, 7-stage .. 1 1 Le 1 1 4.1.4-Heat Exchangers .. Items included: 1.4 Heat Exchangers. 1.4.1 Heat Exchangers, Shell-and-tube : 1.4.1.1 Heat Exch., Shell-and-tube, Gas Processing... 1.4.1.1.1 Heat Exch., Shell-and-tube, Gas Pro., (200-800) kW 1.4.1.1.2 Heat Exch., Shell-and-tube, Gas Pro., ( 801-3000) kW 1.4.1.1.3 Heat Exch., Shell-and-tube, Gas Pro., (3001-5000) kW. 1.4.1.14 Heat Exch., Shell-and-tube, Gas Pro., (5001-8000) kW 1.4.1.2 Heat Exch., Shell-and-tube, Oil Processing... . 1.4.1.2.1 Heat Exch., Shell-and-tube, Oil Pro., (300- 400) KW. . 1.4.1.2.2 Heat Exch., Shell-and-tube, Oil Pro., (4500- 5700) KW 1.4.2 Heat Exchangers, Plate : ween 1.4.2.1 Heat Exch., Plate, Oil Processing... . 1.4.2.1.1 Heat Exch., Plate, Oil Processing, (1300- 3500) kW. 1.4.2.1.2 Heat Exch, Plate, Oil Processing, (3501-11500) kW 1422. Heat Exch. Pate, Cooling Water (closed circuit) 1.4.3 Heat Exch., Double Pipe . ve 4.1.5 Compressors, . Items included: 1.5 Compressor . 1.5.1 Compressor, Centrifugal 15.1.1 Compressor, Centr., Electric Motor Driven : 1.5.1.1. Compressor, Centr., El. Motor Driven, (1600-3600) KW « 1.5.1.1.2. Compressor, Centr., El. Motor Driven, (4800-7100) kW - 28 220 222 224 228 230 232 234 236 238 240 244 248 250 254 256 - 259 - 260 - 262 - 264 - 266 268 - 270 272 274 276 278 - 280 ~ 282 - 284 286 288 290 293 294 298 2. 302 304 2. 306OREDAS2 xm OREDA-92 | 3.1.2.3 Detectors, IR =. 392 | 3.1.24 Detectors, Heat .. 2. 304 i 3.1.2.4.1 Heat, Rate-of-tise . cicvtec ees 304 3.1.24.2 Fusible Plugs/Fixed Temperature, Pneumatic ..... 396 3.1.2.5. Fire Panel, Test, Calibration and Monitoring Panel . 398 .2. Process Alarm Systems ve cetteteette ents . 401 Items included: 3.2.1 Pressure Sensors 402 3.2.1.1 Switches 402 3.2.1.1.1 Pneumatic, Low Pressure (less than 1500 psig) 402 32.112 Preumat, High Pressure (1500 pig or greater) 2 404 3.21.13 Electric . 406 2 Transducers (analog signals out). veces 408 - 2.1 Pneumatic, Low Pressure (less than 1500 psig) ....... ++. 408 22 Pocumatic, High Pres (1500 pig or greater) « + 410 2.3, Blectric . : + 412 3.22. Temperature Sensors . 414 3.2.2.1 Switches ........ : 414 3.2.2.1. Pneumatic 414 416 3.2.2.2" Transducers (analog signals out, electric) 418 3.2.3 Flow Sensors .. 420 3.23.1 Switches... + 420 3.23.1. Pneumatic, Gas Flow » 420 3.23.12 Electric, Gas Flow » 422 3.23.13 Electric, Liquid Flow 424 3.2.3.2 Transducers (analog signals out) 426 3.2.3.2.1 Pneumatic, Gas Flow 426 3.23.22 Electric, Gas Flow .. + 428 3.23.23 Electric, Liquid Flow + 430 3.24 Level Sensors : 432 3.24.1 Switches ... 2. 432 3.2.4.1.1 Pneumatic . 2. 432 3.24.12 Electric . + 434 3.2.4.2 Transducers (analog signals out, electric) 436OREDA-92 xn OREDA-92 1.5.1.2 Compressor, Centr., Turbine Driven .. 1'5.1.2.1 Compressor, Cenir., Turbine Driven, ( 3800- 8900) KW’. 1 1.5.2. Compressor, Reciprocating 1.5.2.1 Compressor, Recipr., Electric Motor Driven. 113.2.1.1 Compressor, Recipr., El. Motor Driven, ( 500-3200) kW. 1.5.2.1.2 Compressor, Recipr., El. Motor Driven, (4100-9300) kW 4.1.6 Gas Turbines tems included: 1.6 Gas Turbine . . . 1 Gas Turbine, Industrial 1.1 Gas Turbine, Industrial, Blectric Generation... 1.1 Gas Turbine, Industrial, Electric Gen., ( 1000- 1500) kW 1.1.2 Gas Turbine, Industrial, Electric Gen., ( 3000- 4000) kW 6.1.1.3. Gas Turbine, Industrial, 6.1.2 Gas Turbine, Industrial, Gas Export and Compression 1 1 1 1 1 1 LL 1.6.1.4 Gas Turbine, Industrial, Oil Handling . 1.6.1.5 Gas Turbine, Industrial, Water Injection 1.6.2 Gas Turbine, Aeroderivative . : : 1.6.2.1 Gas Turbine, Aeroderivative, Electric Generation 1.6.2.2 Gas Turbine, Aeroderivative, Gas Export and Compression . 1.6.2.3 Gas Turbine, Aeroderivative, Oil Handling . .. PART IT 4.2 Process Systems . .. 4.2.1 Pig/Sphere Launching/Receiver Stations .. Items included: 2.1 Pig/Sphere Launching/Receiver Stations 4.3 Safety Systems . . 43.1 Gas and Fire Detection Systems ......... Items included: 3.1.1 Gas Detection Systems . 3.1.1.1 Detectors, Hydrocarbon, Gas : 3.1.12 Gas Panel, Test, Calibration and Monitoring Pane! 3.1.2 Fire Detection Systems 3.1.2.1 Detectors, Smoke 3.1.22 Detectors, UV 1.2.2 Compressor, Centr., Turbine Driven, 200004 28000) kW. lectric Gen., (13500-30000) KW 6.1.3 Gas Turbine, Industrial, Gas Processing and Compression . . 308 312 314 318, 322 326 328 331 332 336 340 344, 346 350 354 1356 360 364 = 366 - 370 . 374 376 . 379 379 . 380 383 - 383 384 384 386 - 388 388 - 390OREDA-92 xIv OREDA.92 4.33 Fire Fighting Systems . 0.0.0.0... 060000 ce eee cece 439 Items included: 3.3.1 Deluge Valves . 440 3.3.11 Pneumatically Operated 2... s sili tev viesees eee, 440 3.3.2 Nozzles (normally open) ...... : seen 442 3.3.3 CO, Systems : ne 444 3.3.4 Halon Systems oo. 0.0... 0ee cece eee eens + 446 4.3.4 Emergency Shut-Down Systems .... . 449 Items included: 3.4.1 DHSV (Down Hole Safety Valves) . . : ~ 450 3.4.1.1, Wireline Retrievable, Flapper... 2... .-.+000 0+ + 450 3.4.1.1.1 Hydrocarbon, Gas cee 450 3.4.2. XMV (Automatic Master Valves) re + 452 3.42.1 Hydraulically Operated, Gate, Less than 24” 452, 3.4.2.1.1 Hydrocarbon, Gas . . ~ 452 3.43. ARV (Automatic Flow (Wing) Valves) en 454 3.4.3.1 Hydraulically Operated, Gate, Less than 24" . . ween 454 3.4.3.1.1 Hydrocarbon, Gas ........ 454 4.3.5 Pressure Relieving Systems... 0.00.00. 0000 0ee0eeeeee sees 457 Items included: 3.5.1 Blow-Down Valves ..... . cee ee ee eee ees 458 3.5.1.1 Pneumatically Operated. Globe/Gate/ Ball » 458 5.1.1.1 Hydrocarbon, Gas : : - 458 3.5.2 Safety Relief Valves .. ~ 460 3.5.2.1. Pilot Operated Valves . ~ 460 3.5.2.1.1 Hydrocarbon, Gas . ~ 460 4.3.6 General Alarm and Communication Systems ...........+-.++++ 463 Items included: 3.6.1 Alarm Systems 464 3.62 Communication Systems ~ 466OREDA-92 xv OREDA.92 4.3.7 Evacuation Systems ....... 469 Items included: 3.71 Life Boas (inc. Launching/Releae Equipment). 470 3.7.1.1 Conventional Type . : 470 4.4 Electrical Systems... 0.6. 473 4.4.1 Power Generation 473 Items included: 4-141 ‘Main Power Gen, Gael. Drive), Tux, Driven, Indasial Type. 474 4.1.1.1 Less than 7 MW vee : we 474 4.1.1.1. Gas Fuel 474 4.11.12 Dual Fuel . 476 4.1.2 Main Power Gen, (incl. Drive), Turb. Driven, 478 4.1.2.1 7 MW or greater . tees 478 4.1.2.1.1 Gas Fuel 478 4.13 Main Power Generators (incl. Drive), Engine Driven. 480 4.1.3.1 Less than 7 MW... wees 480 4.14 Emergency Power Generators (incl. Drive), Engine Driven... . 482 4.4.2 Power Conditioning, Protection and Circuit Breakers . 485 Items included: 4.2.1 Transformers . 486 421.1 221.V-440V. : 486 42.12 441 V - 5.5 KV/6.6 kV 488 4.2.2 Inverters - 490 4.2.3. Rectifiers ........ : 2 492 4.2.4 Battery Chargers - 494 4.2.5 Batteries/Battery Banks ....... : » 496 4.26 Power Protection, Circuit Breakers - 498 4.26.1 220 V or less... . 498, 426.2 221V-440V . = 500 4263 441 V5.5 KVI6.6 kV + 502 4.5 Utility Systems ............ weet ee ees 505 Items included: 5.1 Slop and Drainage Systems 506 S.L.1 Oily Water Separators . .. . + 506 52 Ventilation and Heating Systems 508 5.2.1 Fans ..... . 508 5.22 Dampers (incl. Actuators). + 510 5.2.3 Filters rn 512ee OREDA-92 xvI OREDA-92 5.3. Hydraulic Power Supply Systems . 514 5.3.1 Pumps and Accumulators . . 514 5.4 Pneumatic Power Supply Systems 516 5.4.1, Compressors and Accumulators 516 5.5 Control Instrumentation . . . : . oe .. SEB 5.5.1 Remote Control Transmission Systems . . 518 5.5.2 Programmable Logic Controllers 520 4.6 Crane Systems 60.0.0 6.6... eee rere 523 Items included: 6.1 Diesel Hydraulic Driven . 524 4.7 Drilling Equipments . . 527 4.7.1 Drawworks 527 Items included: TAA Auxiliary Brakes . . 71.1.1 Eddy Current Brakes 7.1.2 Mechanical Brakes 7.13 Main Drums and Drum Shafts 7.14 Spline Clutches 528 528 530 532 534 7.15 High/Low Drum Clutches’. 536 4.7.2 Hoisting Equipment .. . vette e eee e eee es 539 Items included: 7.2.1 Hooks ... 540 7.22 Blevators ....... 542 7.2.3. Travelling Blocks 544 7.2.4. Drill-string/Heave Compensators . 546 4.73 Diverter Systems ..... - 549 Items included: 73.1 Diverters (incl. Valves) 6.6.06 e cece eee ee reese een es 550 7.3.2. Diverter Control Systems ..... . sees s 552OREDA-92 xvi OREDA-92 4.74 Drilling Risers 0.0... 60.060 e cece cece eee . 554 Items included: 7A4.A Risers (incl, Connections) 0.2.6.2 06e eee eeees . 556 74.2 Riser Joints... 0.66.0. 558 7421 Telescopic Joints ...... 02.6... cieeeeee ees 558 74.2.2 Ball Joints seen 560 7.4.23 Pin Connectors. 562 7.4.3 Well Control Lines +. 564 7.4.3.1 Choke Lines (incl. Connections) + 504 7.4.3.2. Kill Lines (incl. Connections) 566 7.4.3.3. Booster Lines (incl. Connections) ++ 568 7.44 Riser Tensioner Systems . . 570 4.7.5 BOP Systems - 572 ‘tems included: 7.5.1 BOP Stacks . 574 75.1.1 Flexible Joints . . 574 75.1.2. Annular Preventers . .. a ceeeees 516 3 Marine Riser Package Connectors... cieveees 5B 4 Shear/Blind Rams wees 580 5 Pipe Rams ....... 582 6 Choke/Kill Valves . +. 584 7. Wellhead Connectors. - 586 75.2. BOP Control Sys ~ 588 752. Pilot Operated Hydraulic Systems .. 588 75.2.2 Acoustic Operated Back-up Systems . + 590 4.7.6 Mud Systems .. 593 Items included: 7.6.1 Mud Pumps .. . 7.62. Feed Pumps (incl. Drive) . 598 7.6.3 Cement Pumps (incl. Drive) 764 Kelly Valves... 600 7.65 Choke’ Manifold Valves - ‘602 4.7.7 Rotary Tables = 605 Items included: 7.7 Rotary Tables ....... feet ene ne ee 606OREDA-92 xvi OREDA-92 609 4.78 Pipe Handl Items included: 7.8.1 Iron Roughnecks . 7.8.2 Stand Lift Arms . 610 612 5. REFERENCES . . 614OREDA-92 1 OREDA.92 1 INTRODUCTION 1.41 SCOPE Reliability analysis and risk assessment are applied to an increasing extent as a means of providing a basis for decisions in offshore engineering. Despite the considerable interest in safety, risk, reliability, availability and maintainability studies related to offshore systems, no authenticated source of information on equipment failures existed for offshore installations prior to issue of the OREDA-84 handbook. In previous studies it was necessary to have the resources to generate data from onshore petroleum facilities and other industries. ‘A number of offshore platforms had been in operation in Europe for @ significant length of time, and the Offshore REliability DAta (OREDA) handbook project was established to compile a comprehensive basis of reliability information from failure and repair records already existing in company files and records. ‘The scope of this second edition of the OREDA handbook is to present the improved high quality data for offshore process systems collected under the Phase II collection. The intention is to give both quantitative and qualitative information to use for safety, risk, reliability, availability and maintainability analysis. For each item covered, the quantitative generic information consists of: + Failure modes, + Failure rate for each failure mode with associated uncertainty limits. + Repair, e.g. repair time in manhours. * Active repair, e.g. the average time required to analyze the failure, repair and restore the equipment. ‘+ Supportive information. e.g. number of events, time in service, population, In addition to the quantitative information, the handbook presents the following qualitative information: Item descriptions. Offshore applications. Environmental and operational conditions. Failure causes and additional description of failure modes. Item boundary specifications.OREDA-92 2 OREDA-92 ‘The information covered by this handbook is grouped under the following headings: Process Systems. Safety Systems, Electrical Systems. Utility Systems. Crane Systems. Drilling Equipment. 1.2. PURPOSE OF HANDBOOK ‘The handbook was developed in order to enhance safety, risk, reliability, availability and maintainability studies of offshore systems by providing a sound base of generic reliability data gathered from maintenance systems, test records, operational logbooks and other technical information systems. The data published in this handbook also provides a unique source of experience data for many other areas of interest, e.g. design audits, maintenance planning, safety system testing, plant availability and cost-benefit studies. ‘The methods and techniques for parameter estimation and the evaluation of data gathered from various sources are well documented, This enables the user of the handbook to make an individual evaluation of the validity of the information included. 13 LIMITATIONS Information released from each participating company has been kept confidential by rendering it anonymous. Only generic data are published. The single event information which is the basis of the estimates is (in most cases) gathered ftom two or more installations, and consequently the figures in the handbook reflect a weighted average of the experience. ‘The OREDA project is so far restricted to data gathering on hardware components and systems; human reliability information is not included. Nevertheless, component failures may have been caused by human errors and, therefore implicitly, they are included in the estimates of the failure rates. For the Phase I data collection (data presented in part II of the handbook), a pre-project revealed that the type and details of the information recorded varied widely for different types of equipment and from company to company. In order to produce a generic data base, a standardised form for recording feilure events and inventories was required prior to starting the data collection. In addition, it was found necessary to pre-define failure modes and the component boundary specifications. Part II of the handbook includesOREDA-92 OREDA-92 data for a restricted number of items, and the taxonomy developed reflects the extent of the data base. Consequently, the taxonomy does not give a general classification of components and systems on ofishore platforms, but it reflects the items for which historical failure data could be made available within the frame of the project. For the Phase II data collection (data presented in part I of the handbook), all available data were coded and collected in data bases. All codes e.g. the taxonomy code, failure modes, repair etc. and the boundary specifications, were predefined as in the Phase I collection. Use of OREDA software on the Phase II data bases (the Phase II data base is only available for the OREDA participants), enables the user to select the item he or she wants. For this handbook, the OREDA software and OREDA Phase II data bases hhave been used to create the data for the generic groups of components presented in part L In 1984, when the first edition of the OREDA handbook was made, the extent of detailed information contained in most of the data sources did not allow estimation of time dependent failure rates, and consequently exponential failure distributions were assumed. However, statistical tests were performed to check whether the component failure data stem from different exponential distributions. In the Phase II data collection, time between failures for each component has been recorded and in principle makes possible estimation of time-dependent failure rates. However, the confidence of the statistical data varies between the different generic groups, and time-independent failure rates (exponential distribution) are a relevant approximation for most purposes. Consequently, the same method is applied for estimation of failure rates in the OREDA-92 handbook as in the OREDA-84 handbook. Details of the methods used are described in chapter 3. This chapter also outlines the method used for pooling of data from several samples for the purpose of obtaining the best reliability estimates. 1.4 HISTORICAL SUMMARY OF THE OREDA ACTIVITIES ‘The original idea of the OREDA Project was developed in a pre-project sponsored by Norwegian authorities and cartied out by Rogaland Research Institute and Det Norske Veritas with consultative assistance from RM Consultants Ltd. As part of the pre-project Phase a visit was made to a number of organisations in the USA engaged in reliability data activities. The aim was to study the organisation, documentation and analytical methods used in data collection projects, and the relevance of these to the preparation of an offshore reliability handbook.OREDA-92 4 OREDA-92 In February 1981 the pre-project report was completed. This report gave a fairly detailed presentation of the project and expected problem areas were identified and discussed. ‘A number of case-studies for specific components showed that the information stored in company files was of a sufficient quality to permit the estimation of reliability data. (Experience from the OREDA-84 handbook has shown that the approach was highly feasible). At this stage several oil companies expressed interest and took an active part in the work for carrying the project into effect. The remaining tasks were mainly connected with the organisation of the project team and the development of an agreement which could be accepted by all participants with respect (o confidential information requirements. In May 1983 the project started with six participating oil companies, each being prepared to release failure event information for use in a handbook. Later two more companies joined the project. Each participating oil company elected one delegate to a Steering Committee with authority to approve work plans and budgets, and to require changes within the terms of the agreement. The Steering Committee also reviewed the progress of the project and approved the results. Det Norske Veritas as Main Contractor was responsible for the execution for both Phase Land Phase II of the project pursuant to work plans and budget approved by the Steering Committee. This work involved coordinating the data collection, the development of unified methods for coding and analysis of data, development of the software program, the generation of generic reliability data and production of the handbook. The data collection within the individual oil company was performed by the company itself and/or a subcontractor according to the respective oil company’s wishes. The table below shows the eight companies involved in the first data collection: Oil companies: BP Norway Limited U.A. EIf Aquitaine Norge A/S Norsk Agip A/S AIS Norske Shell Norsk Hydro as Den norske stats oljeselskap ass. Saga Petroleum a.s Total Oil Marine p.Le.OREDA-92 5 OREDA92 In the Phase I data collection, six oil companies contributed with reliability data. The data are from the UK sector of the North Sea, the Norwegian sector of the North Sea, and the Adriatic Sea. The contributors are: From the UK sector of the North Sea: + BP Norway Limited U.A. + AIS Norske Shel + Total Oil Marine p.le. From the Norwegian sector of the North Sea: + Norsk Hydro as + Statoil From the Adriatic Sea: + Norsk Agip A/SOREDA-92 6 OREDA.92 2. USE OF HANDBOOK 2.1. DEFINITIONS Ttem: A subsystem (or system) within the boundary specified for each system. Subsystem: ‘The smallest constituent of an item as defined in the data collection. System: ‘The total set of subsystems which constitute the system according to the boundary specification. Boundary: ‘The interface between an item and its surroundings. Calendar time: ‘The period of time between the dates of data surveillance for one particular item. Note: On the data forms the calendar time is specified as the accumulated calendar time for all items in the population of interest. Failure: The termination of the ability of an item to perform its required function. Failures may be unannounced and not detected until the next test or demand, or they may be announced and detected at the instant of occurrence. Failure mode: ‘The effect by which a failure is observed on the failed item. The failure modes describe the loss of required function(s) that result from failures. On the right hand pages, the failure modes are divided into three main types. These three types of failure modes are: Critical failure: A failure which is both sudden and causes cessation of one or more fundamental functions. This failure requires immediate corrective action in order to return the item to a satisfactory condition. Degraded failure: A failure which is gradual, partial, or both, Such a failure does not cease the fundamental functions, but compromises one or several functions. The function may be compromised by any combination of reduced, increased, or erratic out puts. In time, such a failure may develop into a critical failure.OREDA92 Failure rate: Number of demands: Operational time: Population: Repair time: 1 OREDA-92 Incipient failure: An imperfection in the state or condition of an item or equipment so that a degraded or critical failure can be expected to result if corrective action is not taken. The rate at which failures occur as a function of time or as a function of demands. In this handbook the failure rate is expressed as the expected number of failures of a given failure ‘mode, per item, in a given time interval (calendar or operational time), or as the expected number of failures of a given failure mode, per item, in a given number of operations. These interpretations of the definition imply the assumption that the failure rate is constant, i. independent of time. The failure rate is expressed as failures per million item hours or per thousand demands, More information about how failure rates are established is found in chapter 3. ‘The total number of times an item is required to perform its required function(s) during the period of the event data surveillance. On the data forms the total number of demands is given for the population for which the number of demands was recorded. ‘The period of time during which an active item performs its intended function, i.e. the accumulated time in service during the period of the event data surveillance. On the data forms the operational time is specified as the accumulated time in active operation for all items in the population of interest. The total number of items of one particular type in service during the period of the event data surveillance. Repair time is recorded in terms of manhours and active repair time. Manhours are the total number of manhours spent on the repair operation. Active repair time is the average time required to analyze the failure, repair and return the item to a state of readiness. Note: This excludes the time to detect the failure, time to isolate the equipment from the process before repair, delay and waiting for spare parts or tools, and any time after the repair has been completed even if the item is not put into service immediately. ‘Time for testing is, however, included when this is necessary because of the failure or the repair operation.OREDA.92 8 OREDA.92 Installations: ‘The number of installations from which data are collected for the particular item described by its taxonomy. Taxonomy: A system of arranging items into generic groups based on some factors common to each item, eg. functional type, ratings, medium handled, size, power, etc. 2.2 USE OF THE HANDBOOK General ‘When using the data in the handbook, consideration should be given to the extent of the data base, data treatment and analysis, boundary specification, application of the item offshore, assumptions made and experience gained through the data collection exercise. The main system of units used in this handbook is the International System (SD). However, other units are also used when these are common in the oil industry. The corresponding value in SI or coherent SI unit is then put in brackets. A general description of the methods followed for collection and analyses of the data made available from files and records within the oil companies is given in chapter 3. In addition chapter 3 outlines the general practice for specification of the boundary limits. When using the failure estimates presented in chapter 4, one should be aware of the variation of the failure rates and confidence limits for a subset of items included in the same generic group, i.e. taxonomy class, and it is recommended to compare the multi- sample estimator 6°, with the maximum likelihood estimator 6. See sub chapter 3.4 for definition of 6 and 6. Each data-sheet contains sufficient information for the user to estimate the maximum likelihood estimator for each failure mode. Deviations from the ‘maximum likelihood estimator are in this handbook found most evident when merging data for items with very large variations in operational time. While chapter 3 presents the general information which is in principle valid for all items, a detailed description of the specific characteristics of type of equipment and components is given in chapter 4. Both the quantitative and the qualitative results of the data collection task are presented and discussed in chapter 4. The following paragraphs describe the format of chapter 4 and the data report sheet which contains the quantitative failure data. Structure and content of the data chapter ‘The main seven sub chapters of the data chapter (chapter 4) correspond to the first level of the taxonomy, ie. process systems, safety systems, electrical systems, utility systems, crane systems and drilling equipment. Each of these equipment classes are further splitted. For the process equipment (Part I reliability data are given for all levels of the taxonomy, except the first level see fig. 2.1.oREDAS2 9 OREDA.92 Fr second Third and toner tet tert ‘orl ‘VESSELS f= VALVES — PUMPS £ Srsreus HEAT EXCHANGERS HE ‘COMPRESSORS. j= GAS TURBINES e PIG/SPHERE LAUNCHER/RECEIVER STATIONS—}-—|—F= Figure 2.1. Hierarchical breakdown, process systems. ‘The second level of the taxonomy identifies the type of major process equipment, various utility and auxiliary systems and major drilling equipment. The basis for the division varies slightly from sub chapter to sub chapter, but is usually based on functional differences. A preface to the data material following the second level of the taxonomy describes in general terms the type of equipment included and the application offshore. A detailed breakdown of the taxonomy for the items included in the specified sub chapter is also presented, and should be read as a list of contents for which item characteristics are presented. Qualitative information Generic reliability information for each item, i. for the generic group of items described by the taxonomy presented in the preface of each sub chapter, are presented on a double Page. A qualitative description of the item is given on the left hand page and the associated reliability data is on the right hand page. ‘The qualitative information is described under predefined headings which are used when applicable and when information has been made available. A short description of the content covered under the headings is given below. Taxonomy No. Each item is assigned a number according to its position in the taxonomy system. developed, ref. sub chapter 2.1OREDA-92 10 OREDA.92 Item Description of the item according to the taxonomy. Description Additional description of the item for further information when available. Application Description of any specific function and application of the items which have been examined during the period of data surveillance. Operational modes The following operational modes have been considered: * Continuous * Active, sleeping condition * Activated from stand-by condition Internal environment Internal conditions such as the medium handled, operating temperature, operating pressure, pollution of medium handled, etc. are described. External environment ‘The local conditions are described in general terms e.g. indoors/outdoors, open/sheltered, mechanically ventilated areas/naturally ventilated areas, etc. Testing and maintenance ‘Test intervals and service routines are specified when available. Failure cause Information on main failure causes is given when available. Failure cause: ‘The identified original cause of the failure; the circumstances during design, manufacturing, assembly, installation or use that have led to failure.OREDA.92 i OREDA-92 Failure mode Additional information or description of the predefined failure modes specified on the quantitative data form is given when available Data source References to the data sources may be given under this heading. Item boundary specification A figure is provided for each item specifying the interface between the particular item and its surroundings. The data presented are based on failures associated with equipment within the boundary. Data form Each data form contains an identification of the item and the estimated reliability parameters. The figures provided should be interpreted on the basis of the assumptions specified in each sub chapter preface and the analysis method applied. The format of the data form is shown in fig. 2.2. ‘The sections of the format are explained below: Taxonomy no. and item ‘Taxonomy number and item description are according to the list outlined in the preface. Only data from items of this generic class of components/equipment are input to the estimates presented in the quantitative part of the data form. Population Total number of items forming the basis for the estimates, Installations Total number of installations covered by the data surveillance for the item in question. Aggregated time in service ‘Two types of time scales are presented as the basis for the failure rate estimates; the calendar time and the operational time. The accumulated time for the total population is given for both time scales. Number of demands ‘The accumulated number of demands/eycles for the total population is given when available.OREDA.92 2 OREDA-92 FFaxonomy no fre Population] Tasallaton | Aggregated time In service 10" hours) No of demands Calendar tine * ] Operational timer Failure mode ‘No of] Faitre rate (par 10" hours) | Relive | Repatr (manhours) me i ws ea eo] ne We soe: Th estimates fe fren ire mode ween some aes ate o dee slats of da, Thi ns om tea stil consistence een ems, sc so cher Figure 2.2 Data formOREDA-92 13 OREDA.92 Failure mode This column contains a brief description of the manner in which the failure occurred, when such information is available. A further discussion of the failure modes, the available data material and the failure mode distribution is presented in each sub chapter preface. No of failures The total number of identified failure events is presented for each failure mode. The accumulated number of failures is presented as "All modes". Failure rate The failure rate columns present estimates of the failure rate for each failure mode. The mean value represents an estimate based on the information made available for presentation in the handbook. The lower and upper values establish the uncertainty range, and represent a 90%-confidence interval. The methods used for estimation of failure rate values are presented in sub chapter 3.4. ‘The failure rate measured per 10° hours refers either to calendar time (marked *) or operational time (marked +). Active repair ‘This column contains the average calendar time (hours) required to analyze the failure, repair and return the item to a state of readiness. See also sub chapter 2.1: "Definitions" for the correct understanding and use of the repair parameters. Repair ‘The repair columns present various values of the repair time (manhours). The mean value represents an estimate based on the information made available for presentation in the handbook. The min and max values are the lowest and highest number of manhours recorded for the repair of the item, Comments When available, information regarding on-demand failure probabilities is given under this heading. The mean value represents an estimate based on the information made available for presentation in the handbook. The lower and upper values establish the uncertainty range, and represent a 90%-confidence interval. The methods used for the estimation of on-demand probabilities are presented in sub chapter 3.4. Comments on any item of information given on the data form may also be given here.OREDA-92 4 OREDA92 3. DATA COLLECTION AND STATISTICAL METHODS 3.1 STRUCTURE 3.1.1 TAXONOMY ‘The taxonomy is the system for arranging items into related generic groups based on factors common to each item, e.g. functional type, rating, medium handled etc. This system was developed from the information available in the database (Part 1), and prior to the collection of Part I data. It was outside the scope of work to make a complete classification of equipment, components, and systems used offshore. The taxonomy was, modified during the data collection due to experience gained about the availability of failure events and inventory data, and after detailed analyses of various subsets of data Using generic data sources for assessment of component reliability characteristics, ideally ‘a comprehensive and precise description of the components are desirable . In practice, this is often in conflict with the required confidence of statistical information to be presented in a handbook. The OREDA taxonomy describes component attributes which are relevant for most reliability studies carried out as part of field development planning and engineering work. Priority is given to develop a taxonomy which serve the purpose of data application in reliability studies regardless of which parameters explain the variation of failure rates among different generic groups of components. Though, due attention is paid to the definition of taxonomy classes which contain a minimum of background data even on the lower taxonomy levels to satisfy a certain confidence level. In order to obtain a better and more comprehensive knowledge of the reliability characteristics for one particular type of equipment the user is recommended to compare data with aggregated samples on higher levels in the hierarchy of generic group. The following list gives the highest and second highest order of headings in the taxonomy: PARTI 4.1 Process Systems LI Vessels 1.2 Valves 1.3 Pumps 1.4 Heat Exchangers 1.5 Compressors 1.6 Gas TurbinesOREDA-92 15 OREDA-92 PART I 4.2 Process Systems 2.1 Pig Sphere Launching/Receiving Stations 4.3 Safety Systems 3.1 Gas and Fire Detection Systems 3.2 Process Alarm Sensors 3.3 Fire-Fighting Systems 3.4 ESD (Emergency Shut-Down) Systems , 3.5 Pressure Relieving Systems 3.6 General Alarm and Communication Systems 3.7 Evacuation Systems 44 Electrical Systems 4.1 Power Generation 4.2 Power Conditioning, Protection and Circuit Breakers 4.5 Utility Systems 5.1 Slop and Drainage Systems 5.2 Ventilation and Heating Systems 5.3 Hydraulic Power Supply Systems 5.4 Pneumatic Power Supply Systems 5.5 Control Instrumentation 4.6 Crane Systems 6.1 Diesel Hydraulic Driven 6.2 Diesel Friction Driven 4.7 Drilling Equipment - 7.1 Drawworks 7.2 Hoisting Equipment 7.3 Diverter Systems 74 Drilling Risers 7.5 BOP Systems 7.6 Mud Systems 7.7 Rotary Tables 7.8 Pipe Handling Systems 2. OREDAOREDA-92 16 OREDA-92 3.1.2 BOUNDARY SPECIFICATION ‘The way the data collection was organized in the OREDA project implied that several teams were used for collection of data within the oil companies. It was of vital importance to have a specification of the interface boundaries for the items in the taxonomy, so that the data collection teams had the same understanding of which failures were to be considered within the boundary of a particular item. The boundary specification is also of vital importance to the user of the estimated reliability data because itis the only mechanism by which the user of the data can judge whether or not a failure has been included in the reliability data source. ‘An item may have several interfaces with other items. Prior to the data collection the boundary specification was given in a tabular form with corresponding schematic figures of each generic item illustrating what was included within the boundary of the item. ‘The figures alone gave sufficient information in most cases to the data collection teams to determine the boundaries. Only the boundary specification figures have therefore been included in this handbook. In most cases the boundary envelops parts of the component which are considered to be essential for its function, or which are sold by the manufacturer as a part of the item. For instance, the starter box and starter panel are included within the boundary of the fire pumps, and the local command, control, and monitoring units are included within the boundary of turbine driven pumps. 3.1.3 FAILURE MODE ‘A failure mode is defined as the effect by which a failure is observed on the item, rather than the effect a failure has on the system containing the item. For instance, if a gas detector fails to respond when the gas concentration increases substantially, the failure mode for that particular gas detector is defined as critical. The effect on the gas detection system may not be critical if other detectors in the system detect and respond correctly to the increased gas concentration. This approach was chosen since it is impossible to anticipate all the present and future configurations of a particular item within a system. ‘The failure modes are categorized for each item according to failure severity class, ie. critical, degraded or incipient, and segregated according to time related and demand related modes. The failure modes are further divided into sub-mode classes which are intended to provide more knowledge of the nature of the failure or of the portion of the item affected.The following changes in item operational conditions have been used as a base'for the subdivision of the failure modes: + Change in operation, e.g, failure to operate once started, low output, high output, + Change without command, e.g. spurious operation + No change on demand, e.g. failure to start, partially openOREDA-92 7 OREDA.92 To allow for the fact that the failure mode cannot always be identified from historical records or other available information sources, the failure mode "unknown" has been added to the list. A large part of the failure information collected has been extracted from maintenance and test reports which generally give insufficient information about failure modes. However, it has usually been possible to classify the failures within each severity class. Only failure modes for which failure data have been recorded have been included in the failure mode list on the data forms in chapter 4. 3.2 DATA COLLECTION METHODS ‘The basic information necessary for the production of the handbook is the property of the individual oil companies participating in the project. Traditionally, this kind of information, ie. failures, mistakes, misuse etc., has not been released to outside parties. ‘The data collection approach chosen ensured that the data were treated in a confidential ‘manner throughout the study. Information made available from the individual company records has been treated on two levels of confidentiality: One strictly confidential where the raw data from company records being analyzed were fed back to the company for their own information and approval before release; and a second level where pooling of data from several companies took place on a generic basis and provided the main output for the handbook. The first confidential level was obtained by cach individual oil company appointing a subcontractor. The subcontractor alone or together with personnel from the oil company formed a data collection team within the company. The extent of the data collection within each company, i.e. number of items to be covered by the exercise, was agreed upon on the basis of the expected availability of failure data within the company. The number of items covered was adjusted during the data collection according to the experience gained about availability of failure data information within each company. No firm procedures were established for the data collection since each company had its ‘own way of operatingits engineering and maintenance information system, and it was necessary to spend time forming a relationship between the company staff and the data collection team. ‘The method adopted was that the data collection within each company was to be guided by predefined codes (e.g. taxonomy, failure mode, boundary specification etc.) for each item covered by the data collection exercise.OREDA-92 18 OREDA-92 Failure and inventory information has mainly been extracted from: + Maintenance files/reports + Inspection and test reports + Work orders + Equipment histories + Daily drilling reports Only in a few cases has additional failure information been obtained from sources other than written historical files, i.e. by interviewing experienced people. In most cases, the main data sources have been made available onshore at company offices, but visits to offshore platforms have also been necessary. Data evaluation and verification were undertaken within each company, between companies and after merging of data samples from several companies, see further description in sub chapter 3.3. In cases where such evaluation and verification made it necessary, additional studies were initiated, e.g. when estimated repair times for a given generic item showed a large deviation between two or more statistical samples, or when part of the data base contained insufficient data for the estimation of reliability parameters. Because of the requirement of strict confidence placed on the data collection and presentation, important background information necessary for supplementing the data entries with qualitative information was processed and rendered anonymous, prior to release for preparation of the handbook. 3.3 DATA VERIFICATION Although the basic data collection approach was applied for all exercises, the detailed data collection had to be adapted to suit the structure and operation of the engineering information system within the individual oil company. Consequently, the data verification also had to be adjusted to the data collection within each company. The data verification was carried out on different levels. Routine checks were carried out on the data during the initial extraction of inventory data, during the transfer of failure data from historical records to data processing forms in Phase I, and to the computerized databases in Phase II. Random checks on population, failure frequencies etc. were also made against the original data sources. In some cases sampling exercises were carried out to compare the output from two different data sources within the same company covering the saine items, Estimates of failure rates were carried out in order to check the completeness of the information recorded.OREDA-92 19 OREDA-92 In some of the cases maintenance and teliability engineers within the companies were shown failure, repair and inventory data extracted from the historical records. All failure histories on drilling equipment were sent back to the rig operators for their verification and comments. Comparison of failure and repair data between subsets of items covered has been carried out. In some cases detection of wide discrepancies between items within the same generic group initiated extra checks of data involved. After completing the Phase II data collection, the OREDA project initiated a quality and completeness check of the entire data bases. Missing information which was found particular important, was obtained when possible, and the application of failure information codes were checked to ensure constancy between data from various companies. Further, all failure rates obtained by use of the multi-sample estimator, see sub chapter 3.4, are compared with the maximum likelihood estimator to check whether the defined generic groups of items contain subset of data which bias the mean failure rate, Deviations were most evident for failure rates obtained from samples which contain some items with very short time in service (less than 10 per cent of the sample average). ‘Those items were in some cases excluded from the statistical samples. ‘The results obtained from the data verification indicate that the estimated failure rates may be slightly optimistic (too low) for some items, mainly due to incompleteness of the data sources with respect to failure event information. However, the statistical methods developed for estimation of the failure rates account to some extent for this effect as they give a higher weight to the best samples.