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GLOBAL SERVICES TO THE MARITIME, OIL & GAS AND ENERGY INDUSTRIES
■■ Asset risk management ■■ Ship classification
■■ Enterprise risk management ■■ Technology qualification
■■ Offshore classification ■■ Verification
■■ Safety, health and environmental risk management
I quantified risk assessment I PROCESS INDUSTRY I 03
CONTENTS
04 1. Introduction 12 5. Calculating Release Rate
05 2. Background on HCRD 16 6. Leak Frequency Datasheets
06 3. Application of Data 38 7. References
08 4. Methodology
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1. INTRODUCTION
Frequency estimates are recognised as one of the largest sources of uncertainty in Quantitative Risk
Assessment studies.
There are a few sources of data for failure frequency data for ator. While the data is ‘noisy’, typical for real data, DNV has
process equipment loss of containment: Netherlands and applied a smoothing function to cover all leak sizes. Leaks
Belgium have issued two different onshore frequency data- are differentiated for 17 equipment types. This analysis and
sets for use in Seveso Directive risk assessments, and some interpretation is complex: considerable effort is required to
companies and consultants have their own data. In many obtain generic leak frequency data that are suitable for use
cases the provenance of these data is uncertain and exam- in Quantified Risk Assessment (QRA).
ples exist of frequencies that are too low and do not match
historical accident frequencies. It is detrimental to QRA DNV believes that process industry will benefit from consist-
methodology that such old or inconsistent data is routinely ent application of these generic leak frequencies in QRA,
used. DNV is therefore publishing this booklet in order to and is therefore publishing its preferred dataset in order to
put best practice process equipment leak frequency data encourage standardisation across different users.
into the public domain.
The booklet describes DNV’s methods for interpreting the
DNV’s data is derived from the Hydrocarbon Release HCRD and describes its application to offshore, onshore
Database (HCRD) which has been compiled by the UK and LNG plant. The booklet also presents tabulations of
Health and Safety Executive (HSE) over a 20 year period. generic leak frequency data for different equipment types.
The database [2] contains details of over 4000 leak events at
oil and gas installations in the UK Continental Shelf. It The booklet compares the DNV dataset against some alter-
identifies 78 different types and size categories of process native sources of leak frequency data and describes some
equipment, and records the quantity of the release and the important reasons why the DNV interpretation of the HCRD
release hole size. This is considered the most extensive should be preferred.
dataset of its type and superior to current published datasets
which often have much smaller and older data which do not DNV was commissioned by Statoil to define the model pre-
reflect current integrity management programs. DNV has sented in this document, involving contractors Scandpower
assessed this data for several years on behalf of a major oper- and Safetec in the work.
I quantified risk assessment I PROCESS INDUSTRY I 05
2. BACKGROUND ON HCRD
The Piper Alpha incident occurred in 1988 and resulted in 167 people losing their lives. As a result of this
disaster Lord Cullen conducted an inquiry [1].
The inquiry made 106 recommendations including the and industry committed to reducing its number of hydrocar-
requirement to report leaks to the HSE through the report- bon emissions by 50% in 3 years. Two years into the three
ing of injuries, diseases and dangerous occurrences regula- year programme there has been a 40% reduction in the
tions (RIDDOR). The HSE organises this data and makes it number of leaks [1].
publically available through the Hydrocarbon Release
Database (HCRD). The database started to be compiled in Determining the number of leaks that have occurred off-
October 1992 and now contains 20 years of experience in shore provides only one part of the data that is required to
hydrocarbon releases from the UK Continental Shelf. calculate leak frequency. The number of different types of
equipment offshore has also been recorded and quantified
Figure 1 shows the number of recorded leaks per year since since 1992, although HSE has recorded no change in the
1992. (For each bar in the graph, the reporting period for equipment count since 2003 (Regarding system and equip-
leaks is between April 1st and March 31st in the following ment population data, HSE notes that the responsibility for
year. The first bar contains data for a six month period 1st of maintaining the currency of this data rests with duty holders.
October 1992 and the 31st of March 1993). The population data in HCRD is provided by duty holders
on a voluntary database and it is not HSE’s role to update,
Figure 2 shows the breakdown of these leaks into three or verify this particular data. Use of this population data
categories as defined by HSE: minor, significant and major. would need to be made with caution). It is questionable that
The average number of minor leaks per year between April the amount of equipment has remained the same offshore
1st 1993 and March 31st 1998 is 82, whereas there were an since 2003. Maintaining an accurate equipment count is not
average of 109 minor leaks per year between April 1st 2006 straightforward, for example the count of equipment on
and March 31st 2010. This increase may be due to an actual mobile rigs would require the database operators to keep
increase in minor leaks or an improvement in the reporting track of the position of MOUs and their movements. The
of these leaks. Detection of smaller leaks may also have equipment count on the UKCS is provided by the operators
improved. The number of significant and major leaks has on a voluntary database and it is not part of HSE’s role to
decreased over the period, particularly major leaks which monitor or verify the equipment count. Therefore there are
have decreased by a factor of 12. In 2010 in the UK the oil uncertainties associated with the equipment count.
250
350
300 200
250
150
No. of Leaks
200
150 100
100
50
50
0 0
1993 1995 1997 1999 2001 2003 2005 2007 2009 1993 1995 1997 1999 2001 2003 2005 2007 2009
1994 1996 1998 2000 2002 2004 2006 2008 2010 1994 1996 1998 2000 2002 2004 2006 2008 2010
Year
Minor Significant Major
Figure 1 Number of Leaks per year Figure 2 Number of leaks per leak category per year
06 I PROCESS INDUSTRY I quantified risk assessment I
3. APPLICATION OF DATA
3.1 OFFSHORE Another possible explanation could be differences in data
The data in this booklet is based upon data from the UK quality. The HSE offshore data set is a high-quality database,
sector of the North Sea which has been collected by the HSE collected recently, covering a large population, with well-
in the hydrocarbon release database (HCRD). The data is defined hole sizes, comprehensive equipment counts, and
based on approximately 4000 recorded leaks recorded open for scrutiny by the operators and their consultants. Most
between October 1992 and March 2010. This database has of the available onshore leak frequencies come from small
been analysed by DNV to produce generic leak frequencies sample sizes. In fact in the case of onshore pipe leak frequen-
applicable for use with offshore installations that are oper- cies it is concluded that the most widely accepted data set is of
ated to UK North Sea standards. The methodology of DNVs eight leaks in U.S. nuclear plants in 1972, or earlier collec-
approach is presented in the 2009 HAZARDS XXI tions whose size and origin are now unknown. [3].
Conference [4].
A third factor affecting the comparison is that the HSE
3.2 ONSHORE offshore data set includes some leaks that occurred while
DNV normally also use these data for QRA at onshore facili- the equipment was depressurised, and others that were
ties. In general, the HSE data set gives higher leak frequen- quickly isolated. The onshore frequencies are applicable to
cies than most of the onshore sources of data. There are holes with process fluid at the full operating pressure. The
several possible explanations for this. frequencies based on HCRD data should be used with out-
flow models that take account of the variation in operating
Process equipment on offshore installations might experi- circumstances at the time of the leak.
ence higher leak frequencies than on onshore plants.
Possible reasons might be extra external corrosion from A further complicating factor is that onshore and offshore
salt-water spray, internal erosion from entrained sand, or management systems in the UK must address different regu-
impacts resulting from the more compact equipment lay- latory requirements. The Offshore Safety Case requirements
outs. However, offshore installations have safety manage- are more onerous than those required of onshore refineries
ment systems that would be expected to counter such evi- (e.g. offshore requirements for identification of safety criti-
dent hazards. The HSE data set on leak causes shows that cal elements, performance standards and written schemes,
corrosion/erosion is a minor contributor, with operational/ plus the rigorous leak reporting requirements).
procedural faults and mechanical defects being the primary
causes. Table 1 indicates the causes of leaks offshore Overall, it is considered that the HSE offshore data provides
between the 1st October 1992 to the 31st of March 2002. the best available estimate of leak frequencies for both
onshore and offshore process equipment. However, it does recognised that this is an engineering judgement assump-
require that the outflow model should take account of the tion, based on acknowledging operational experience that
possibility of the equipment being depressurised or quickly inter-unit pipework fails very rarely (in comparison to the
isolated at the time of the leak. process pipework within the main process areas). This
revised basis can be of particular relevance to loading lines,
3.3 LNG FACILITIES although should not substitute for consideration of all
The main risk drivers on an LNG site are events that are potential loads (and hence potential frequency modification
unlikely to be within the direct experience of individual factors) that may apply to a particular facility, or particular
plants and terminals. Establishing the frequency of such loading line.
events is difficult, precisely because of their rarity. It requires
systematic data collection, for leaks and the exposed equip- In summary:
ment population, over many plants for many years. Such
data collection is time-consuming and hence unusual. ■■ The DNV analysis of HCRD is recommended as the basis
Alternative methods such as fault tree analysis are possible for the process and pipework failure data – as per all QRA
for plant-specific applications, but have not yet delivered studies.
generic leak frequencies suitable for routine use in QRA
studies. ■■ There is no statistically sound basis for modifying the
source failure data to account for cryogenic or LNG-
Data sets exist that attempt to provide failure rates for cryo- specific application.
genic pipework, or for LNG-specific operating experience in
general, but these are not considered to be sufficiently ■■ It is considered justifiable – albeit by engineering judge-
robust to justify any modification to the generic data derived ment – to reduce the process pipework failure rates by a
from the HCRD. That is, any argument that offshore data factor of 10 for inter-unit piping.
such as the HCRD is not relevant to LNG facilities is consid-
ered to be compensated for by the weight of statistical data ■■ It should not be assumed that valves are flanged but this is
supporting the derived failure rates for specific equipment an area where LNG applications may have the opportu-
items, compared to the very limited data supporting any nity to reduce the parts count and hence the calculated
specific cryogenic / LNG failures that have occurred. leak frequency.
4. METHODOLOGY
4.1 GENERAL 5. Pig traps
This booklet provides hole size frequency data for use in 6. Process Pipes
Quantified Risks Assessment (QRA) of process facilities. The 7. Pumps
methodology shown in this document was developed as in • Centrifugal pumps
conjunction with Statoil and was presented in the 2009 • Reciprocating pumps
HAZARDS XXI conference. The frequency data highlighted 8. Instruments
in this document uses the same methodology but uses data 9. Valves
up to 2010 from the database. The booklet contains generic • Actuated valves
leak frequencies for each of the following process equip- • Manual valves
ment types: 10. Pressurized process vessels
1. Compressors 11. Atmospheric storage tanks
• Centrifugal compressors
• Reciprocating compressors This analysis represents the leak size distribution by an ana-
2. Filters lytical frequency function, which ensures non-zero leak
3. Flanges frequencies for all holes size ranges between 1 mm and the
4. Heat Exchangers (Including Coolers, Heaters diameter of the inlet pipe to the equipment. In the follow-
and condensers) ing paragraphs a short presentation of the analysis is given.
• Air Cooled Heat Exchangers
• Plate heat exchangers The methodology for obtaining leak frequencies from
• Shell side heat exchangers HCRD consists of three main steps:
• Tube side heat exchangers
■■ Grouping data for different types and sizes of equipment,
where there is insufficient experience to show significant
differences between them.
DNV equipment type HCRD equipment types
Steel pipes Piping, steel (3 sizes) ■■ Fitting analytical leak frequency functions to the data, in order
Flanged joints Flanges (3 sizes) to obtain a smooth variation of leak frequency with equip-
Manual valves Valve, manual (10 types & sizes) ment and hole size.
Most HCRD equipment types have been used as defined by F(D) = f(D) Dm + Frup Eqn 3
HSE, but some, with relatively little leak experience, have
been combined into the following groups: For pipes, flanges, valves and pig traps, HCRD provides data
■■ All types of manual valves (bleed, block, check and for different equipment size groups. Analysis of these
choke). showed significant variations in leak frequency with equip-
■■ All other types of non-pipeline actuated valves (block, ment size for pipes, flanges valves, whereas the population
blowdown, choke, control, ESDV and relief, but not pipe- was too small to show any significant variation of leak fre-
line ESDV and SSIV). quency with equipment size for pig traps. Size dependence
■■ All types of pressure vessel (horizontal/vertical adsorber, is represented in the leak frequency function using the
KO drum, other, reboiler, scrubber, stabiliser, separator following general form:
and stabiliser).
f(D) = C(1 + aDn) Eqn 4
Leak frequency function
HCRD data, being real data, is very noisy as can be seen in where:
Figure 3. DNV overlays a realistic distribution function that C, a, n = constants for each equipment type
fits the data to obtain average leak frequencies. In raw data
there are gaps (e.g. a particular equipment dimension may The HCRD provides sufficient data to determine estimates
have zero leak events, but we would not predict zero for its for the a and n parameters for f(D) for pipes, flanges, man-
actual leak likelihood) forcing a distribution of results in ual valves and actuated valves. For the other equipment
realistic predictions. types, f(D) is equal to the constant C.
A feature of the distribution function is that it allows any It is important to be aware that the leak frequency form is
hole size distribution to be employed without biasing the imposed on the data and that this is a mathematical repre-
result. In early coarse risk assessments we may only choose sentation of historical data. The data itself does not directly
two hole sizes – small and large, whereas in detailed studies support a separate frequency for ruptures. The historical
we may choose to employ 5 hole sizes for greater resolu- data related to releases from large hole sizes is very limited
tion. The equations allow any number of hole sizes to be and the uncertainty related to estimation of such leaks is
selected and the total release frequency will always stay the therefore considerable The additional rupture frequency
same. The actual hole size feeds the consequence mod- Frup and the slope parameter m are assumed to be constants,
eling and the more sizes used the greater the computa- i.e. not to be dependent on equipment size, for any equip-
tional effort. ment type.
The analysis represents the variation of leak frequency with The function is used to calculate separate hole size frequen-
equipment and hole size by the following general leak fre- cies for three types of leak scenario:
quency function: ■■ Total leak frequency
Full pressure leaks reflect that these events involve reduced release mass and
This scenario category is intended to be consistent durations.
with QRA models that assume a leak through the defined
hole, beginning at the normal operating pressure, until Zero pressure leaks
controlled by isolation and blowdown, with a probability This scenario includes all leaks where the pressure inside
of isolation/blowdown failure. This is subdivided as the leaking equipment is virtually zero (0.01 barg or less).
follows: This may be because the equipment has a normal operating
pressure of zero (e.g. open drains), or because the equip-
■■ Full leaks which are intended to be consistent with QRA ment has been depressurised for maintenance, but not
models that assume a leak through the defined hole, de-inventoried.
beginning at the normal operating pressure, until con-
trolled by ESD1 and blowdown, with a small probability of These leaks may typically be very small gas releases, short
ESD/blowdown failure. These are subdivided as follows lasting oil spills, or liquid releases from atmospheric tanks.
Most likely they represent a significantly reduced major
– ESD isolated leaks, which are defined as cases where the accident risk potential relative to a pressurised release
outflow quantity is comparable with that predicted for through the same hole size (although they do pose occupa-
a leak at the operational pressure. tional safety issues) and the contribution to the overall risk
level as predicted in QRA studies is considered negligible.
– Late isolated leaks, presumed to be cases where there is
no effective ESD of the leaking system, resulting in a 4.3 UNCERTAINTIES
greater outflow quantity. Late isolated leaks are defined There are several significant uncertainties in fitting a curve
as cases where the outflow is greater than predicted for to the available leak data. Some uncertainties are due to the
a leak at the operational pressure controlled by the way that leak data is reported to the HSE and the lack of
slowest credible ESD and no blowdown. data for larger events. Other sources of uncertainty include
issues about an accurate population count and the accuracy
■■ Limited leaks, presumed to be cases where the outflow with which the operator records the data. The sources of
quantity is significantly less than from a leak at the opera- uncertainty are illustrated in Figure 3.
tional pressure controlled by the quickest credible ESD
(after 30 seconds) and blowdown (according to API) 4.4 ALLOCATION OF LEAK EVENTS
initiated 60 seconds later. This is presumed to be cases The method of allocating leak records in HCRD into the
where there exist restrictions in the flow from the system scenarios is as follows:
inventory, as a result of local isolation valves initiated by ■■ Identify the zero pressure leak events in order to dis-
human intervention or process safety systems other that count them from the analysis
ESD and blowdown. ■■ Estimate the initial release rate Qo from the hole, based
leaks are full leaks because these have the potential of devel- REmax, based on typical ESD and blowdown response
oping into serious events endangering personnel and criti- ■■ Compare the recorded release quantity in HCRD to the
cal safety functions. From these leak frequencies the analyst estimated release quantity range to determine the
can use a standard event tree approach for the subsequent scenario.
consequence assessment. This includes probabilities for ESD
and BD failure. The scenario allocation criteria are (in order):
■■ Zero pressure leaks – actual pressure in HCRD < 0.01
Limited leaks may be of as much concern for personnel risk barg.
as full leaks in the period immediately following the start of ■■ Limited leaks – recorded release quantity in HCRD <
the release, but they will have a shorter duration. Hence the REmin·/ D
potential for them developing into any major concern for ■■ ESD isolated leaks – recorded release quantity in HCRD
other safety functions, such as structural integrity, evacua- in the range REmin / D to REmax·
tion means, escalation, etc. Any consequence calculations ■■ Late isolated leaks – recorded release quantity in HCRD
should be modelled as for ESD and late isolated leaks, but > REmax·
1
With the assumption that process shutdown (PSD) is the shutdown of a particular section rather than the whole platform the PSD system may have
the same effect as far as QRA modelling of release rates is concerned.
I quantified risk assessment I PROCESS INDUSTRY I 11
1.E-04
1.E-05
0.1 1 10 100
D is a disproportion factor. It is used to ensure that the clas- As a simple indication of the relative importance of each leak
sification of limited leaks is appropriate. The value given to D scenario using the methods and criteria above, Figure 4
is typically 4 and this is the value which has been used in the shows the breakdown of all leaks in HCRD for the period
calculation of the tables in this document. 1992-2010. This shows that approximately 6% of leaks are at
zero pressure, and that 48% are
limited leaks. Of the remaining
Late isolated 7% 3% 46% leaks, 3% are consistent
with late isolation.
Full leak 49%
Figure 4 can be further sub-
divided to produce Table 3. This
Full pressure leaks 94% ESD isolated 93% 43%
indicates the effects that each
individual fluid has on the leak
HCRD Leak Limited leak 51% 48%
(Total) type. Table 3 can be used in
conjunction with the data sheets
to obtain an estimate of the
Zero pressure leaks 6% 6% frequencies of limited leaks.
Release Type Total GAS LEAK OIL LEAK CONDEN- 2-PHASE NON-
SATE LEAK LEAK PROCESS
Zero Pressure leak 6% 6% 7% 7% 2% 8%
Full Limited leak 48% 33% 75% 64% 67% 53%
pressure
Full ESD isolated 43% 57% 16% 27% 30% 36%
leak
leaks
Late Isolated 3% 4% 2% 2% 1% 3%
Total 100% 100% 100% 100% 100% 100%
Table 3 Proportion Distribution of leak incidents in the HCRD database2 (%)3 [4]
2
The figures take account of HCRD data until March 2010.
3
The data that supports the distribution of 2-Phase leaks and condensate leaks are not very comprehensive and the uncertainty in these numbers is
therefore larger than for the other phases e.g. gas and oil leaks. The given distribution for 2-phase leaks and condensate leaks represents a best
estimate.
12 I PROCESS INDUSTRY I quantified risk assessment I
!
=
!
!!
!! noting
Rearranging the above and !that
!
= gives:
gives: L = initial pressure of liquid (bar gauge)
! = !!! !!
! !!!
!!
! !!!!!= ρ
!
!+! !!! !!! This equation may be used for oil, condensate and non-
!! ! !!! ! !+!
!! = !! ! !! !!!
!+! ! !!! !! Eqn 6 process releases.
! ! ! =!!!
!! !! !+!
!!! !
! ! !! !
! = ! !! ! !! !! !!!
! !! ! ! !!!
!! = !! !
! ! !!!!!!
! !!! !!!!!
!+!
! !!
!
! !!!
!! = !! ! ! !
! !! substituting γ
Two-phase releases are less amenable to simple approxima-
Approximating the gauge pressure ! to absolute
!!! pressure, !"# !
Approximating the gauge pressure to absolute pressure, ! ! =but
tion, γ !!they!"#!!
since form a!small
! proportion of HCRD, they
γγ !"#!!
!"#
substituting g = 1.31, CD = 0.85, and converting the units of ! ! = !"#!! !!
are represented by: ! !!
pressure to bar and noting that the units of the diameter are
γ !"#!!
!"# !
in mm we have:!! ! !! = !"#!! !! !"#!! !! Eqn 11
!! = 1.4 x 10 ! !! !! !! !
!! != 1.4 x 10 ! !! !!
!!
! = 1.4 x 10
!!! = 1.4 x 10!! !! !
! !!! !
!!! Eqn 7 where:
!! = 1.4 x 10!! ! ! !! !!
Qo = initial release rate (kg/s)
Where: Where: Qg = release rate (kg/s)
ρ
d = hole diameter (mm) QL = release rate (kg/s)
rg
ρ = initialρdensity of gas (kg/m3) GOR = gas oil ratio (kg gas per kg oil)
ρ
Pg =ρ initial pressure of gas (bar gauge)
The initial release rate is assumed to continue at a constant
For liquid releases, the initial release rate is given by: rate until the inventory is isolated. After isolation, the
!! = !! ! 2!! !! − !! !! !ℎ release rate declines as the isolated section is depressurised
!! = !! ! 2!! !! − !! !! !ℎ
!
!!! =
=!!!
!!! 2! ! − !
2!!! !!! − !!! !
!!! !ℎ
!ℎ Eqn 8 through the leak. Blowdown of isolated sections can then
!! = !! ! 2!! !! − !! !! !ℎ further increase the rate at which the section is depressur-
Where: ized and hence decrease the release rate through the hole.
QL = initial liquid release rate (kg/s)
CD = discharge coefficient
A = hole area (m2)
rL = liquid density (kg/m3)
Po = initial pressure of liquid (N/m2) (absolute)
I quantified risk assessment I PROCESS INDUSTRY I 13
Isolation Blowdown
Equipment No. Size
QT
Process Vessel 0.5 8”
QO Centripetal Compressor 1 6”
Shell and Tube Heat Exchanger 1 6”
QB
Flange 11 8”
Release Rate
Flange 5 6”
Leak Flow
Actuated Valve 2 8”
Small Bore Fittings 2 ½”
Manual Valve 3 8”
tI tB Time Process Pipe 10 8”
Process Pipe 5 6”
Figure 5 Decline of release rate with time
Table 4 Parts Count of Isolatable System
!!! − !!!!!! !
!
!!! =
= !!!! ! 1
1− +!!!
!
!
!!
! ! Eqn 12
! ! ! !
!!! !!!
!! = !! !! + I 1 − ! + !! !
! !
Where: Where:
HP
!!! !! !!! Section
!
! ! =! ! exp !!
!!! !!! !! ! Scrubber
HP Gas
!!! =
=!!!! exp I! !!!
! Compressor
exp I Eqn 13
!!! !I! !!!
!! = !!!!exp
!
! ! =
= III !!!!!!
! I
!!! = !
Eqn 14
!!!
! = I !!!!
!!!
KEY
!! =
! ! !!
!! !! Eqn 15
!! = !! !! M anual Valv e
!! = ! ! !
! ! !
! ! !!
!! ! !!
!!! ! !! !
= != release
! rate
Actuated Valve
Q
!!B
Q = release ! !!through
rate !! leakthrough leak when blowdown
when blowdown starts
starts (kg/s)
(kg/s) Flange
QT = total release rate through leak and blowdown Small Bore Fitting Figure 6: Sample Isolatable Section
valve when blowdown starts ( kg/s)
I = inventory in isolated section (kg)
MB = mass remaining when blowdown starts
t = time from start of leak (s) 5.1 SAMPLE CALCULATION
tI = time from start of leak to isolation (s) Figure 6 shows a sample isolated section and Table 4 displays
ρ
ρ = time from start of leak to blowdown (s) the part count for this simplified system. Process pipe is
ρ tB
ρ rd = density factor length in metres, not number of pipes. There are 2 pipe
RE = expected ESD-limited outflow (kg) sizes in the system. The 6” pipe connects the scrubber to the
b = blowdown valve diameter compressor and on to the cooler. The remaining pipework
is 8”. The leak analysis is being conducted on a gas stream.
The density factor is set to 1 for gas and 2-phase releases,
!!
but for liquid releases the following formula is used: There are a number of assumptions that are made in count-
!
! ! =!
!!
!
!!! =
=!! !!!!!! ing the parts:
!!
!! = ! ! Eqn 16
!!
■■ For parts that are independent of equipment size (all
Where: Where: items except for valves, pipe and flanges) the largest pipe
ρf = density number (0.5) diameter that is connected to the piece of equipment is
ρ
ρrg = gas density (kg/m3) taken to be the size.
ρ
ρ
ρrl = liquid density (kg/m3)
ρ ■■ Only half the scrubber is counted since only the top half
Once the frequency of a hole size occurring is determined is in contact with gas under normal operating conditions.
the release rate for that particular diameter of hole can be (The lower half of the scrubber is included in a separate
calculated thereby finding the frequency of that release rate. count for the liquid stream).
14 I PROCESS INDUSTRY I quantified risk assessment I
■■ Two flanges are counted on each valve. (The base leak The results are shown in Table 3.
frequency of the valve does not account for flange
connections). Then by applying Eqn 1 to each type of equipment, the
contribution of each hole size can be examined.
■■ The actuated valves at the boundaries of the system are
ESDVs. These isolate the section. Only half these valves
are counted and one flange connection.
5.2 ALTERNATIVE SOURCES OF LEAK FREQUENCY Data source & methodology Leak frequency (per year)
DATA HCRD (DNV) 0.021
The leak frequency data and methodology presented in this
Dutch government 0.006
document are based on analysis and application of data in
Belgian government 0.012
the HSE Hydrocarbon Release Database. A number of other
data sources and methodologies have been published, but Table 6: Comparison of Estimated Leak Frequencies
DNV considers the HSE database to be the best available for
most QRA applications.
The experience base of the Dutch and Belgian methodolo-
Other available databases include the handbook for failure gies does not match the large experience of leaks contained
frequencies which was developed by the Flemish (Belgian) in the HCRD; leak frequencies derived from the HCRD are
Government [5], and the Reference Manual Bevi Risk more accurate primarily because HCRD is the largest data-
Assessments which was developed by the Dutch National base with information for over 70 different sizes and types of
Institute of Public Health and the Environment[5] [6]. equipment, collected systematically over the last 20 years.
DNV has compared the leak frequency result from these DNV notes that the absence of separate frequencies for
sources against the DNV methodology. A comparison of flanges, valves and instruments in the Belgian and Dutch
results based on the sample isolatable section is shown in methodologies also means that risk assessments performed
Table 4. using these methods are insensitive to some design deci-
sions, such as the benefits of all-welded designs.
The comparison of results shows that the leak frequency
estimated using DNV’s method for this case is greater than Figures 7 and 8 illustrate these points. They show the ratios
that obtained by the Dutch and Belgian methodologies. The of frequencies for each type of equipment obtained by divid-
Belgian and Dutch methodologies present leak frequency ing the DNV frequency by the Dutch/Belgian frequency for
data for equipment systems; and omit any explicit counts of each type of equipment. The figures show for the majority
the flanges, valves and instruments associated with major of equipment types the DNV methodology quotes higher
equipment items. This is the main reason why the Dutch frequencies. The figures highlight the large difference
and Belgian methodologies produce lower estimate of leak between the frequencies. The explanations of the differ-
frequency. ences are as discussed in Section 3.2.
I quantified risk assessment I PROCESS INDUSTRY I 15
Storage Vessel
Centrifugal Compressor
Recipricating Compressors
Centrifugal Pump
Process Vessel
Storage Vessel
Recipricating Compressors
Centrifugal Compressor
Recipricating Pump
Centrifugal Pump
Process Vessel
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Centrifugal Compressors
Definition:
The scope includes the compressor itself, but excludes all attached valves, piping, flanges, instruments and fittings
beyond the first flange. The first flange itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 5.802E‐03 5.583E‐03 1.324E‐04
3 ‐ 10 mm 2.462E‐03 2.316E‐03 1.052E‐04
10 ‐ 50 mm 1.435E‐03 1.300E‐03 2.624E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.699E‐03 9.199E‐03 5.000E‐04
1 ‐ 3 mm 5.802E‐03 5.583E‐03 1.324E‐04
3 ‐ 10 mm 2.462E‐03 2.316E‐03 1.052E‐04
10 ‐ 50 mm 1.435E‐03 1.300E‐03 2.624E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.699E‐03 9.199E‐03 5.000E‐04
1 ‐ 3 mm 5.802E‐03 5.583E‐03 1.324E‐04
3 ‐ 10 mm 2.462E‐03 2.316E‐03 1.052E‐04
10 ‐ 50 mm 1.057E‐03 9.686E‐04 9.519E‐05
2 in
50 ‐ 150 mm 3.772E‐04 3.309E‐04 1.672E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.699E‐03 9.199E‐03 5.000E‐04
1 ‐ 3 mm 5.802E‐03 5.583E‐03 1.324E‐04
3 ‐ 10 mm 2.462E‐03 2.316E‐03 1.052E‐04
10 ‐ 50 mm 1.057E‐03 9.686E‐04 9.519E‐05
4 in
50 ‐ 150 mm 3.772E‐04 3.309E‐04 1.672E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.699E‐03 9.199E‐03 5.000E‐04
1 ‐ 3 mm 5.802E‐03 5.583E‐03 1.324E‐04
3 ‐ 10 mm 2.462E‐03 2.316E‐03 1.052E‐04
10 ‐ 50 mm 1.057E‐03 9.686E‐04 9.519E‐05
6 in
50 ‐ 150 mm 2.257E‐04 2.008E‐04 4.428E‐05
> 150 mm 1.516E‐04 1.300E‐04 1.229E‐04
Total 9.699E‐03 9.199E‐03 5.000E‐04
18 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Reciprocating Compressors
Definition:
The scope includes the compressor itself, but excludes all attached valves, piping, flanges, instruments and fittings
beyond the first flange. The first flange itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 3.641E‐02 3.685E‐02 0.000E+00
3 ‐ 10 mm 1.581E‐02 1.512E‐02 0.000E+00
10 ‐ 50 mm 9.572E‐03 8.324E‐03 0.000E+00
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.179E‐02 6.029E‐02 0.000E+00
1 ‐ 3 mm 3.641E‐02 3.685E‐02 0.000E+00
3 ‐ 10 mm 1.581E‐02 1.512E‐02 0.000E+00
10 ‐ 50 mm 9.572E‐03 8.324E‐03 0.000E+00
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.179E‐02 6.029E‐02 0.000E+00
1 ‐ 3 mm 3.641E‐02 3.685E‐02 0.000E+00
3 ‐ 10 mm 1.581E‐02 1.512E‐02 0.000E+00
10 ‐ 50 mm 6.973E‐03 6.238E‐03 0.000E+00
2 in
50 ‐ 150 mm 2.599E‐03 2.085E‐03 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.179E‐02 6.029E‐02 0.000E+00
1 ‐ 3 mm 3.641E‐02 3.685E‐02 0.000E+00
3 ‐ 10 mm 1.581E‐02 1.512E‐02 0.000E+00
10 ‐ 50 mm 6.973E‐03 6.238E‐03 0.000E+00
4 in
50 ‐ 150 mm 2.599E‐03 2.085E‐03 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.179E‐02 6.029E‐02 0.000E+00
1 ‐ 3 mm 3.641E‐02 3.685E‐02 0.000E+00
3 ‐ 10 mm 1.581E‐02 1.512E‐02 0.000E+00
10 ‐ 50 mm 6.973E‐03 6.238E‐03 0.000E+00
6 in
50 ‐ 150 mm 1.532E‐03 1.275E‐03 0.000E+00
> 150 mm 1.067E‐03 8.107E‐04 0.000E+00
Total 6.179E‐02 6.029E‐02 0.000E+00
I quantified risk assessment I PROCESS INDUSTRY I 19
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Filters
Definition:
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 1.870E‐03 1.608E‐03 2.453E‐04
3 ‐ 10 mm 9.307E‐04 7.559E‐04 1.605E‐04
10 ‐ 50 mm 7.187E‐04 5.259E‐04 2.232E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.520E‐03 2.890E‐03 6.290E‐04
1 ‐ 3 mm 1.870E‐03 1.608E‐03 2.453E‐04
3 ‐ 10 mm 9.307E‐04 7.559E‐04 1.605E‐04
10 ‐ 50 mm 7.187E‐04 5.259E‐04 2.232E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.520E‐03 2.890E‐03 6.290E‐04
1 ‐ 3 mm 1.870E‐03 1.608E‐03 2.453E‐04
3 ‐ 10 mm 9.307E‐04 7.559E‐04 1.605E‐04
10 ‐ 50 mm 4.820E‐04 3.661E‐04 1.150E‐04
2 in
50 ‐ 150 mm 2.367E‐04 1.598E‐04 1.082E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.520E‐03 2.890E‐03 6.290E‐04
1 ‐ 3 mm 1.870E‐03 1.608E‐03 2.453E‐04
3 ‐ 10 mm 9.307E‐04 7.559E‐04 1.605E‐04
10 ‐ 50 mm 4.820E‐04 3.661E‐04 1.150E‐04
4 in
50 ‐ 150 mm 2.367E‐04 1.598E‐04 1.082E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.520E‐03 2.890E‐03 6.290E‐04
1 ‐ 3 mm 1.870E‐03 1.608E‐03 2.453E‐04
3 ‐ 10 mm 9.307E‐04 7.559E‐04 1.605E‐04
10 ‐ 50 mm 4.820E‐04 3.661E‐04 1.150E‐04
6 in
50 ‐ 150 mm 1.258E‐04 8.894E‐05 4.219E‐05
> 150 mm 1.109E‐04 7.089E‐05 6.598E‐05
Total 3.520E‐03 2.890E‐03 6.290E‐04
20 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Flange
Definition:
The following frequencies refer to a flanged joint, comprising two flange faces, a gasket (where fitted), and two
welds to the pipe. Flange types include ring type joint, spiral wound, clamp (Grayloc) and hammer union (Chicksan)
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 3.725E‐05 3.538E‐05 1.156E‐06
3 ‐ 10 mm 1.364E‐05 1.239E‐05 8.773E‐07
10 ‐ 50 mm 1.227E‐05 1.031E‐05 2.367E‐06
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.316E‐05 5.808E‐05 4.400E‐06
1 ‐ 3 mm 4.037E‐05 3.771E‐05 1.156E‐06
3 ‐ 10 mm 1.479E‐05 1.320E‐05 8.774E‐07
10 ‐ 50 mm 1.279E‐05 1.066E‐05 2.367E‐06
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.795E‐05 6.156E‐05 4.400E‐06
1 ‐ 3 mm 4.628E‐05 4.229E‐05 1.157E‐06
3 ‐ 10 mm 1.695E‐05 1.480E‐05 8.780E‐07
10 ‐ 50 mm 6.126E‐06 5.076E‐06 7.519E‐07
2 in
50 ‐ 150 mm 7.661E‐06 6.269E‐06 1.616E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 7.701E‐05 6.844E‐05 4.403E‐06
1 ‐ 3 mm 5.745E‐05 5.133E‐05 1.171E‐06
3 ‐ 10 mm 2.104E‐05 1.797E‐05 8.891E‐07
10 ‐ 50 mm 7.605E‐06 6.161E‐06 7.614E‐07
4 in
50 ‐ 150 mm 8.062E‐06 6.540E‐06 1.630E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.415E‐05 8.200E‐05 4.452E‐06
1 ‐ 3 mm 6.816E‐05 6.028E‐05 1.241E‐06
3 ‐ 10 mm 2.496E‐05 2.110E‐05 9.420E‐07
10 ‐ 50 mm 9.023E‐06 7.235E‐06 8.067E‐07
6 in
50 ‐ 150 mm 1.594E‐06 1.206E‐06 3.550E‐07
> 150 mm 6.852E‐06 5.603E‐06 1.343E‐06
Total 1.106E‐04 9.542E‐05 4.687E‐06
I quantified risk assessment I PROCESS INDUSTRY I 21
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Flange
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 8.880E‐05 7.801E‐05 1.884E‐06
3 ‐ 10 mm 3.252E‐05 2.731E‐05 1.430E‐06
10 ‐ 50 mm 1.176E‐05 9.362E‐06 1.225E‐06
10 in
50 ‐ 150 mm 2.077E‐06 1.560E‐06 5.388E‐07
> 150 mm 7.110E‐06 5.780E‐06 1.779E‐06
Total 1.423E‐04 1.220E‐04 6.856E‐06
1 ‐ 3 mm 1.088E‐04 9.559E‐05 4.148E‐06
3 ‐ 10 mm 3.984E‐05 3.346E‐05 3.148E‐06
10 ‐ 50 mm 1.440E‐05 1.147E‐05 2.696E‐06
14 in
50 ‐ 150 mm 2.544E‐06 1.912E‐06 1.186E‐06
> 150 mm 7.360E‐06 5.956E‐06 3.316E‐06
Total 1.729E‐04 1.484E‐04 1.449E‐05
1 ‐ 3 mm 1.379E‐04 1.218E‐04 1.454E‐05
3 ‐ 10 mm 5.051E‐05 4.263E‐05 1.103E‐05
10 ‐ 50 mm 1.826E‐05 1.462E‐05 9.450E‐06
20 in
50 ‐ 150 mm 3.226E‐06 2.436E‐06 4.158E‐06
> 150 mm 7.724E‐06 6.218E‐06 1.037E‐05
Total 2.176E‐04 1.877E‐04 4.955E‐05
22 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Fin Fan Heat Exchanger
Definition:
The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and
fittings beyond the first flange. The first flange is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 7.997E‐04 7.997E‐04 0.000E+00
3 ‐ 10 mm 3.802E‐04 3.802E‐04 0.000E+00
10 ‐ 50 mm 2.700E‐04 2.700E‐04 0.000E+00
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.450E‐03 1.450E‐03 0.000E+00
1 ‐ 3 mm 7.997E‐04 7.997E‐04 0.000E+00
3 ‐ 10 mm 3.802E‐04 3.802E‐04 0.000E+00
10 ‐ 50 mm 2.700E‐04 2.700E‐04 0.000E+00
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.450E‐03 1.450E‐03 0.000E+00
1 ‐ 3 mm 7.997E‐04 7.997E‐04 0.000E+00
3 ‐ 10 mm 3.802E‐04 3.802E‐04 0.000E+00
10 ‐ 50 mm 1.866E‐04 1.866E‐04 0.000E+00
2 in
50 ‐ 150 mm 8.339E‐05 8.339E‐05 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.450E‐03 1.450E‐03 0.000E+00
1 ‐ 3 mm 7.997E‐04 7.997E‐04 0.000E+00
3 ‐ 10 mm 3.802E‐04 3.802E‐04 0.000E+00
10 ‐ 50 mm 1.866E‐04 1.866E‐04 0.000E+00
4 in
50 ‐ 150 mm 8.339E‐05 8.339E‐05 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.450E‐03 1.450E‐03 0.000E+00
1 ‐ 3 mm 7.997E‐04 7.997E‐04 0.000E+00
3 ‐ 10 mm 3.802E‐04 3.802E‐04 0.000E+00
10 ‐ 50 mm 1.866E‐04 1.866E‐04 0.000E+00
6 in
50 ‐ 150 mm 4.600E‐05 4.600E‐05 0.000E+00
> 150 mm 3.740E‐05 3.740E‐05 0.000E+00
Total 1.450E‐03 1.450E‐03 0.000E+00
I quantified risk assessment I PROCESS INDUSTRY I 23
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Plate Heat Exchanger
Definition:
The scope includes the heat exchanger itself, but excludes all attached valves, piping, flanges, instruments and
fittings beyond the first flange. The first flange is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 5.164E‐03 5.008E‐03 1.482E‐04
3 ‐ 10 mm 2.847E‐03 2.792E‐03 9.695E‐05
10 ‐ 50 mm 2.688E‐03 2.699E‐03 1.348E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.070E‐02 1.050E‐02 3.800E‐04
1 ‐ 3 mm 5.164E‐03 5.008E‐03 1.482E‐04
3 ‐ 10 mm 2.847E‐03 2.792E‐03 9.695E‐05
10 ‐ 50 mm 2.688E‐03 2.699E‐03 1.348E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.070E‐02 1.050E‐02 3.800E‐04
1 ‐ 3 mm 5.164E‐03 5.008E‐03 1.482E‐04
3 ‐ 10 mm 2.847E‐03 2.792E‐03 9.695E‐05
10 ‐ 50 mm 1.664E‐03 1.655E‐03 6.948E‐05
2 in
50 ‐ 150 mm 1.023E‐03 1.044E‐03 6.535E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.070E‐02 1.050E‐02 3.800E‐04
1 ‐ 3 mm 5.164E‐03 5.008E‐03 1.482E‐04
3 ‐ 10 mm 2.847E‐03 2.792E‐03 9.695E‐05
10 ‐ 50 mm 1.664E‐03 1.655E‐03 6.948E‐05
4 in
50 ‐ 150 mm 1.023E‐03 1.044E‐03 6.535E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.070E‐02 1.050E‐02 3.800E‐04
1 ‐ 3 mm 5.164E‐03 5.008E‐03 1.482E‐04
3 ‐ 10 mm 2.847E‐03 2.792E‐03 9.695E‐05
10 ‐ 50 mm 1.664E‐03 1.655E‐03 6.948E‐05
6 in
50 ‐ 150 mm 4.940E‐04 4.981E‐04 2.549E‐05
> 150 mm 5.293E‐04 5.461E‐04 3.986E‐05
Total 1.070E‐02 1.050E‐02 3.800E‐04
24 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Shell Side Heat Exchanger
Definition:
Shell & tube type heat exchangers with hydrocarbon in the shell side. The scope includes the heat exchanger itself,
but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange
itself is also excluded
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 2.011E‐03 1.827E‐03 2.339E‐04
3 ‐ 10 mm 1.035E‐03 9.847E‐04 1.027E‐04
10 ‐ 50 mm 8.532E‐04 8.876E‐04 6.340E‐05
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.900E‐03 3.700E‐03 4.000E‐04
1 ‐ 3 mm 2.011E‐03 1.827E‐03 2.339E‐04
3 ‐ 10 mm 1.035E‐03 9.847E‐04 1.027E‐04
10 ‐ 50 mm 8.532E‐04 8.876E‐04 6.340E‐05
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.900E‐03 3.700E‐03 4.000E‐04
1 ‐ 3 mm 2.011E‐03 1.827E‐03 2.339E‐04
3 ‐ 10 mm 1.035E‐03 9.847E‐04 1.027E‐04
10 ‐ 50 mm 5.583E‐04 5.603E‐04 4.590E‐05
2 in
50 ‐ 150 mm 2.949E‐04 3.272E‐04 1.749E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.900E‐03 3.700E‐03 4.000E‐04
1 ‐ 3 mm 2.011E‐03 1.827E‐03 2.339E‐04
3 ‐ 10 mm 1.035E‐03 9.847E‐04 1.027E‐04
10 ‐ 50 mm 5.583E‐04 5.603E‐04 4.590E‐05
4 in
50 ‐ 150 mm 2.949E‐04 3.272E‐04 1.749E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.900E‐03 3.700E‐03 4.000E‐04
1 ‐ 3 mm 2.011E‐03 1.827E‐03 2.339E‐04
3 ‐ 10 mm 1.035E‐03 9.847E‐04 1.027E‐04
10 ‐ 50 mm 5.583E‐04 5.603E‐04 4.590E‐05
6 in
50 ‐ 150 mm 1.521E‐04 1.616E‐04 1.023E‐05
> 150 mm 1.428E‐04 1.656E‐04 7.264E‐06
Total 3.900E‐03 3.700E‐03 4.000E‐04
I quantified risk assessment I PROCESS INDUSTRY I 25
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Tube Side Heat Exchanger
Definition:
Shell & tube type heat exchangers with hydrocarbon in the tube side. The scope includes the heat exchanger itself,
but excludes all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange
itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 1.721E‐03 1.473E‐03 1.665E‐04
3 ‐ 10 mm 7.729E‐04 6.618E‐04 1.089E‐04
10 ‐ 50 mm 5.462E‐04 4.749E‐04 1.515E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.040E‐03 2.610E‐03 4.270E‐04
1 ‐ 3 mm 1.721E‐03 1.473E‐03 1.665E‐04
3 ‐ 10 mm 7.729E‐04 6.618E‐04 1.089E‐04
10 ‐ 50 mm 5.462E‐04 4.749E‐04 1.515E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.040E‐03 2.610E‐03 4.270E‐04
1 ‐ 3 mm 1.721E‐03 1.473E‐03 1.665E‐04
3 ‐ 10 mm 7.729E‐04 6.618E‐04 1.089E‐04
10 ‐ 50 mm 3.548E‐04 3.038E‐04 7.807E‐05
2 in
50 ‐ 150 mm 1.914E‐04 1.711E‐04 7.343E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.040E‐03 2.610E‐03 4.270E‐04
1 ‐ 3 mm 1.721E‐03 1.473E‐03 1.665E‐04
3 ‐ 10 mm 7.729E‐04 6.618E‐04 1.089E‐04
10 ‐ 50 mm 3.548E‐04 3.038E‐04 7.807E‐05
4 in
50 ‐ 150 mm 1.914E‐04 1.711E‐04 7.343E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 3.040E‐03 2.610E‐03 4.270E‐04
1 ‐ 3 mm 1.721E‐03 1.473E‐03 1.665E‐04
3 ‐ 10 mm 7.729E‐04 6.618E‐04 1.089E‐04
10 ‐ 50 mm 3.548E‐04 3.038E‐04 7.807E‐05
6 in
50 ‐ 150 mm 8.138E‐05 6.968E‐05 2.864E‐05
> 150 mm 1.100E‐04 1.014E‐04 4.479E‐05
Total 3.040E‐03 2.610E‐03 4.270E‐04
26 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Pig Trap
Definition:
Includes pig launchers and pig receivers. The scope includes the pig trap itself, but excludes all attached valves,
piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 3.253E‐03 3.271E‐03 4.815E‐05
3 ‐ 10 mm 1.814E‐03 1.591E‐03 4.936E‐05
10 ‐ 50 mm 1.753E‐03 1.178E‐03 6.825E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.820E‐03 6.039E‐03 7.800E‐04
1 ‐ 3 mm 3.253E‐03 3.271E‐03 4.815E‐05
3 ‐ 10 mm 1.814E‐03 1.591E‐03 4.936E‐05
10 ‐ 50 mm 1.753E‐03 1.178E‐03 6.825E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.820E‐03 6.039E‐03 7.800E‐04
1 ‐ 3 mm 3.253E‐03 3.271E‐03 4.815E‐05
3 ‐ 10 mm 1.814E‐03 1.591E‐03 4.936E‐05
10 ‐ 50 mm 1.075E‐03 8.021E‐04 6.082E‐05
2 in
50 ‐ 150 mm 6.783E‐04 3.756E‐04 6.217E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.820E‐03 6.039E‐03 7.800E‐04
1 ‐ 3 mm 3.253E‐03 3.271E‐03 4.815E‐05
3 ‐ 10 mm 1.814E‐03 1.591E‐03 4.936E‐05
10 ‐ 50 mm 1.075E‐03 8.021E‐04 6.082E‐05
4 in
50 ‐ 150 mm 6.783E‐04 3.756E‐04 6.217E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.820E‐03 6.039E‐03 7.800E‐04
1 ‐ 3 mm 3.253E‐03 3.271E‐03 4.815E‐05
3 ‐ 10 mm 1.814E‐03 1.591E‐03 4.936E‐05
10 ‐ 50 mm 1.075E‐03 8.021E‐04 6.082E‐05
6 in
50 ‐ 150 mm 3.235E‐04 2.034E‐04 3.838E‐05
> 150 mm 3.547E‐04 1.722E‐04 5.833E‐04
Total 6.820E‐03 6.039E‐03 7.800E‐04
I quantified risk assessment I PROCESS INDUSTRY I 27
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Process Pipe
Definition:
Includes pipes located on topsides (between well and riser) and subsea (between well and pipeline). The scope
includes welds but excludes all valves, flanges, and instruments.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 9.169E‐04 9.409E‐04 7.564E‐06
3 ‐ 10 mm 3.435E‐04 3.294E‐04 5.300E‐06
10 ‐ 50 mm 1.680E‐04 1.442E‐04 1.084E‐05
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.428E‐03 1.414E‐03 2.371E‐05
1 ‐ 3 mm 2.725E‐04 2.851E‐04 4.768E‐06
3 ‐ 10 mm 1.021E‐04 9.979E‐05 3.341E‐06
10 ‐ 50 mm 5.310E‐05 4.577E‐05 7.575E‐06
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 4.277E‐04 4.307E‐04 1.568E‐05
1 ‐ 3 mm 9.989E‐05 1.032E‐04 3.551E‐06
3 ‐ 10 mm 3.742E‐05 3.611E‐05 2.488E‐06
10 ‐ 50 mm 1.389E‐05 1.238E‐05 1.936E‐06
2 in
50 ‐ 150 mm 8.424E‐06 6.095E‐06 4.216E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.596E‐04 1.578E‐04 1.219E‐05
1 ‐ 3 mm 5.363E‐05 5.270E‐05 3.022E‐06
3 ‐ 10 mm 2.009E‐05 1.845E‐05 2.117E‐06
10 ‐ 50 mm 7.457E‐06 6.325E‐06 1.647E‐06
4 in
50 ‐ 150 mm 6.607E‐06 4.581E‐06 3.886E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 8.779E‐05 8.205E‐05 1.067E‐05
1 ‐ 3 mm 4.454E‐05 4.248E‐05 2.864E‐06
3 ‐ 10 mm 1.669E‐05 1.487E‐05 2.007E‐06
10 ‐ 50 mm 6.192E‐06 5.098E‐06 1.561E‐06
6 in
50 ‐ 150 mm 1.127E‐06 8.497E‐07 6.230E‐07
> 150 mm 5.123E‐06 3.425E‐06 3.165E‐06
Total 7.366E‐05 6.672E‐05 1.022E‐05
28 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Process Pipe
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 3.967E‐05 3.688E‐05 2.749E‐06
3 ‐ 10 mm 1.486E‐05 1.291E‐05 1.926E‐06
10 ‐ 50 mm 5.516E‐06 4.427E‐06 1.498E‐06
10 in
50 ‐ 150 mm 1.003E‐06 7.378E‐07 5.980E‐07
> 150 mm 5.055E‐06 3.369E‐06 3.118E‐06
Total 6.610E‐05 5.833E‐05 9.890E‐06
1 ‐ 3 mm 3.880E‐05 3.587E‐05 2.723E‐06
3 ‐ 10 mm 1.454E‐05 1.255E‐05 1.907E‐06
10 ‐ 50 mm 5.395E‐06 4.305E‐06 1.484E‐06
14 in
50 ‐ 150 mm 9.814E‐07 7.174E‐07 5.922E‐07
> 150 mm 5.043E‐06 3.359E‐06 3.107E‐06
Total 6.475E‐05 5.680E‐05 9.813E‐06
1 ‐ 3 mm 3.792E‐05 3.482E‐05 2.691E‐06
3 ‐ 10 mm 1.420E‐05 1.219E‐05 1.885E‐06
10 ‐ 50 mm 5.272E‐06 4.179E‐06 1.466E‐06
20 in
50 ‐ 150 mm 9.591E‐07 6.965E‐07 5.852E‐07
> 150 mm 5.030E‐06 3.348E‐06 3.094E‐06
Total 6.338E‐05 5.523E‐05 9.722E‐06
I quantified risk assessment I PROCESS INDUSTRY I 29
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Centrifugal Pump
Definition:
Centrifugal pumps including single‐seal and double‐seal types. The scope includes the pump itself, but excludes all
attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also
excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 4.204E‐03 4.044E‐03 1.566E‐04
3 ‐ 10 mm 1.575E‐03 1.432E‐03 1.073E‐04
10 ‐ 50 mm 7.497E‐04 6.242E‐04 1.681E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.529E‐03 6.099E‐03 4.320E‐04
1 ‐ 3 mm 4.204E‐03 4.044E‐03 1.566E‐04
3 ‐ 10 mm 1.575E‐03 1.432E‐03 1.073E‐04
10 ‐ 50 mm 7.497E‐04 6.242E‐04 1.681E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.529E‐03 6.099E‐03 4.320E‐04
1 ‐ 3 mm 4.204E‐03 4.044E‐03 1.566E‐04
3 ‐ 10 mm 1.575E‐03 1.432E‐03 1.073E‐04
10 ‐ 50 mm 5.846E‐04 4.973E‐04 8.119E‐05
2 in
50 ‐ 150 mm 1.652E‐04 1.269E‐04 8.688E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.529E‐03 6.099E‐03 4.320E‐04
1 ‐ 3 mm 4.204E‐03 4.044E‐03 1.566E‐04
3 ‐ 10 mm 1.575E‐03 1.432E‐03 1.073E‐04
10 ‐ 50 mm 5.846E‐04 4.973E‐04 8.119E‐05
4 in
50 ‐ 150 mm 1.652E‐04 1.269E‐04 8.688E‐05
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.529E‐03 6.099E‐03 4.320E‐04
1 ‐ 3 mm 4.204E‐03 4.044E‐03 1.566E‐04
3 ‐ 10 mm 1.575E‐03 1.432E‐03 1.073E‐04
10 ‐ 50 mm 5.846E‐04 4.973E‐04 8.119E‐05
6 in
50 ‐ 150 mm 1.063E‐04 8.411E‐05 3.151E‐05
> 150 mm 5.880E‐05 4.276E‐05 5.537E‐05
Total 6.529E‐03 6.099E‐03 4.320E‐04
30 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Reciprocating Pump
Definition:
Reciprocating pumps including single‐seal and double‐seal types. The scope includes the pump itself, but excludes
all attached valves, piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also
excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 2.848E‐03 2.331E‐03 2.347E‐04
3 ‐ 10 mm 1.644E‐03 1.457E‐03 1.625E‐04
10 ‐ 50 mm 1.708E‐03 1.812E‐03 2.627E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.200E‐03 5.600E‐03 6.600E‐04
1 ‐ 3 mm 2.848E‐03 2.331E‐03 2.347E‐04
3 ‐ 10 mm 1.644E‐03 1.457E‐03 1.625E‐04
10 ‐ 50 mm 1.708E‐03 1.812E‐03 2.627E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.200E‐03 5.600E‐03 6.600E‐04
1 ‐ 3 mm 2.848E‐03 2.331E‐03 2.347E‐04
3 ‐ 10 mm 1.644E‐03 1.457E‐03 1.625E‐04
10 ‐ 50 mm 1.014E‐03 9.886E‐04 1.247E‐04
2 in
50 ‐ 150 mm 6.934E‐04 8.236E‐04 1.380E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.200E‐03 5.600E‐03 6.600E‐04
1 ‐ 3 mm 2.848E‐03 2.331E‐03 2.347E‐04
3 ‐ 10 mm 1.644E‐03 1.457E‐03 1.625E‐04
10 ‐ 50 mm 1.014E‐03 9.886E‐04 1.247E‐04
4 in
50 ‐ 150 mm 6.934E‐04 8.236E‐04 1.380E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 6.200E‐03 5.600E‐03 6.600E‐04
1 ‐ 3 mm 2.848E‐03 2.331E‐03 2.347E‐04
3 ‐ 10 mm 1.644E‐03 1.457E‐03 1.625E‐04
10 ‐ 50 mm 1.014E‐03 9.886E‐04 1.247E‐04
6 in
50 ‐ 150 mm 3.186E‐04 3.428E‐04 4.908E‐05
> 150 mm 3.748E‐04 4.807E‐04 8.894E‐05
Total 6.200E‐03 5.600E‐03 6.600E‐04
I quantified risk assessment I PROCESS INDUSTRY I 31
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Small Bore Fittings
Definition:
Includes small‐bore connections for flow, pressure and temperature sensing. The scope includes the instrument
itself plus up to 2 valves, 4 flanges, 1 fitting and associated small‐bore piping, usually 25mm diameter or less.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 3.092E‐04 2.998E‐04 1.092E‐05
3 ‐ 10 mm 1.373E‐04 1.287E‐04 7.144E‐06
10 ‐ 50 mm 8.644E‐05 7.643E‐05 9.935E‐06
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 5.330E‐04 5.050E‐04 2.800E‐05
1 ‐ 3 mm 3.092E‐04 2.998E‐04 1.092E‐05
3 ‐ 10 mm 1.373E‐04 1.287E‐04 7.144E‐06
10 ‐ 50 mm 8.644E‐05 7.643E‐05 9.935E‐06
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 5.330E‐04 5.050E‐04 2.800E‐05
1 ‐ 3 mm 3.092E‐04 2.998E‐04 1.092E‐05
3 ‐ 10 mm 1.373E‐04 1.287E‐04 7.144E‐06
10 ‐ 50 mm 6.220E‐05 5.601E‐05 5.119E‐06
2 in
50 ‐ 150 mm 2.424E‐05 2.042E‐05 4.815E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 5.330E‐04 5.050E‐04 2.800E‐05
32 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Actuated Valves
Definition:
Includes all types of actuated valves (block, blowdown, choke, control, ESDV and relief), but not actuated pipeline
valves (pipeline ESDV and SSIV). Valve types include gate, ball, plug, globe and needle. The scope includes the valve
body, stem and packer, but excludes flanges, controls and instrumentation.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 5.587E‐04 5.421E‐04 6.077E‐06
3 ‐ 10 mm 1.767E‐04 1.681E‐04 4.209E‐06
10 ‐ 50 mm 7.507E‐05 7.023E‐05 7.804E‐06
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 8.105E‐04 7.804E‐04 1.809E‐05
1 ‐ 3 mm 5.594E‐04 5.427E‐04 7.710E‐06
3 ‐ 10 mm 1.769E‐04 1.683E‐04 5.340E‐06
10 ‐ 50 mm 7.515E‐05 7.030E‐05 9.633E‐06
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 8.114E‐04 7.813E‐04 2.268E‐05
1 ‐ 3 mm 5.611E‐04 5.444E‐04 9.926E‐06
3 ‐ 10 mm 1.774E‐04 1.688E‐04 6.875E‐06
10 ‐ 50 mm 5.404E‐05 5.030E‐05 5.276E‐06
2 in
50 ‐ 150 mm 2.131E‐05 2.018E‐05 6.838E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 8.138E‐04 7.837E‐04 2.891E‐05
1 ‐ 3 mm 5.656E‐04 5.487E‐04 1.293E‐05
3 ‐ 10 mm 1.788E‐04 1.702E‐04 8.957E‐06
10 ‐ 50 mm 5.447E‐05 5.070E‐05 6.873E‐06
4 in
50 ‐ 150 mm 2.140E‐05 2.026E‐05 8.606E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 8.202E‐04 7.898E‐04 3.737E‐05
1 ‐ 3 mm 5.711E‐04 5.540E‐04 1.517E‐05
3 ‐ 10 mm 1.805E‐04 1.718E‐04 1.050E‐05
10 ‐ 50 mm 5.500E‐05 5.119E‐05 8.060E‐06
6 in
50 ‐ 150 mm 8.033E‐06 7.292E‐06 3.172E‐06
> 150 mm 1.347E‐05 1.307E‐05 6.748E‐06
Total 8.281E‐04 7.974E‐04 4.365E‐05
I quantified risk assessment I PROCESS INDUSTRY I 33
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Actuated Valves
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 5.843E‐04 5.669E‐04 1.861E‐05
3 ‐ 10 mm 1.847E‐04 1.758E‐04 1.289E‐05
10 ‐ 50 mm 5.628E‐05 5.238E‐05 9.891E‐06
10 in
50 ‐ 150 mm 8.220E‐06 7.462E‐06 3.892E‐06
> 150 mm 1.356E‐05 1.314E‐05 8.053E‐06
Total 8.471E‐04 8.157E‐04 5.334E‐05
1 ‐ 3 mm 6.000E‐04 5.821E‐04 2.134E‐05
3 ‐ 10 mm 1.897E‐04 1.805E‐04 1.478E‐05
10 ‐ 50 mm 5.778E‐05 5.378E‐05 1.134E‐05
14 in
50 ‐ 150 mm 8.440E‐06 7.661E‐06 4.463E‐06
> 150 mm 1.365E‐05 1.323E‐05 9.088E‐06
Total 8.695E‐04 8.373E‐04 6.102E‐05
1 ‐ 3 mm 6.269E‐04 6.082E‐04 2.471E‐05
3 ‐ 10 mm 1.982E‐04 1.886E‐04 1.712E‐05
10 ‐ 50 mm 6.038E‐05 5.620E‐05 1.313E‐05
20 in
50 ‐ 150 mm 8.819E‐06 8.005E‐06 5.169E‐06
> 150 mm 1.381E‐05 1.337E‐05 1.037E‐05
Total 9.081E‐04 8.745E‐04 7.050E‐05
34 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Manual Valves
Definition:
Includes all types of manual valves (block, bleed, check and choke). Valve types gate, ball, plug, globe, needle and
butterfly. The scope includes the valve body, stem and packer, but excludes flanges, controls and instrumentation.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 5.166E‐05 5.247E‐05 3.030E‐07
3 ‐ 10 mm 2.401E‐05 2.278E‐05 2.222E‐07
10 ‐ 50 mm 1.837E‐05 1.479E‐05 4.241E‐07
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.404E‐05 9.004E‐05 9.494E‐07
1 ‐ 3 mm 5.180E‐05 5.260E‐05 5.840E‐07
3 ‐ 10 mm 2.407E‐05 2.284E‐05 4.283E‐07
10 ‐ 50 mm 1.841E‐05 1.483E‐05 8.172E‐07
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.428E‐05 9.027E‐05 1.829E‐06
1 ‐ 3 mm 5.262E‐05 5.344E‐05 1.146E‐06
3 ‐ 10 mm 2.446E‐05 2.320E‐05 8.403E‐07
10 ‐ 50 mm 1.169E‐05 1.023E‐05 6.906E‐07
2 in
50 ‐ 150 mm 6.986E‐06 4.814E‐06 9.129E‐07
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 9.575E‐05 9.169E‐05 3.590E‐06
1 ‐ 3 mm 5.760E‐05 5.850E‐05 2.269E‐06
3 ‐ 10 mm 2.677E‐05 2.540E‐05 1.664E‐06
10 ‐ 50 mm 1.279E‐05 1.120E‐05 1.368E‐06
4 in
50 ‐ 150 mm 7.459E‐06 5.176E‐06 1.808E‐06
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 1.046E‐04 1.003E‐04 7.110E‐06
1 ‐ 3 mm 6.876E‐05 6.984E‐05 3.393E‐06
3 ‐ 10 mm 3.196E‐05 3.032E‐05 2.489E‐06
10 ‐ 50 mm 1.527E‐05 1.337E‐05 2.045E‐06
6 in
50 ‐ 150 mm 3.658E‐06 2.938E‐06 8.630E‐07
> 150 mm 4.859E‐06 3.047E‐06 1.840E‐06
Total 1.245E‐04 1.195E‐04 1.063E‐05
I quantified risk assessment I PROCESS INDUSTRY I 35
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Manual Valves
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 1.163E‐04 1.181E‐04 5.640E‐06
3 ‐ 10 mm 5.405E‐05 5.128E‐05 4.137E‐06
10 ‐ 50 mm 2.583E‐05 2.261E‐05 3.400E‐06
10 in
50 ‐ 150 mm 6.185E‐06 4.968E‐06 1.435E‐06
> 150 mm 6.834E‐06 4.462E‐06 3.059E‐06
Total 2.092E‐04 2.014E‐04 1.767E‐05
1 ‐ 3 mm 2.067E‐04 2.099E‐04 7.888E‐06
3 ‐ 10 mm 9.607E‐05 9.114E‐05 5.785E‐06
10 ‐ 50 mm 4.591E‐05 4.020E‐05 4.754E‐06
14 in
50 ‐ 150 mm 1.099E‐05 8.830E‐06 2.006E‐06
> 150 mm 1.059E‐05 7.154E‐06 4.278E‐06
Total 3.703E‐04 3.573E‐04 2.471E‐05
1 ‐ 3 mm 4.436E‐04 4.506E‐04 1.126E‐05
3 ‐ 10 mm 2.062E‐04 1.956E‐04 8.257E‐06
10 ‐ 50 mm 9.852E‐05 8.627E‐05 6.786E‐06
20 in
50 ‐ 150 mm 2.360E‐05 1.895E‐05 2.864E‐06
> 150 mm 2.044E‐05 1.421E‐05 6.107E‐06
Total 7.924E‐04 7.656E‐04 3.527E‐05
36 I PROCESS INDUSTRY I quantified risk assessment I
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Process Vessel
Definition:
Includes all types of pressure vessel (horizontal/vertical absorber, knock‐out drum, reboiler, scrubber, stabiliser,
separator and stabiliser), but not the HCRD category “other”, which are mainly hydrocyclones. The scope includes
the vessel itself and any nozzles or inspection openings, but excludes all attached valves, piping, flanges,
instruments and fittings beyond the first flange. The first flange itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 8.884E‐04 7.859E‐04 1.600E‐04
3 ‐ 10 mm 5.946E‐04 4.093E‐04 1.393E‐04
10 ‐ 50 mm 8.768E‐04 3.448E‐04 5.117E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 2.360E‐03 1.540E‐03 8.110E‐04
1 ‐ 3 mm 8.884E‐04 7.859E‐04 1.600E‐04
3 ‐ 10 mm 5.946E‐04 4.093E‐04 1.393E‐04
10 ‐ 50 mm 8.768E‐04 3.448E‐04 5.117E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 2.360E‐03 1.540E‐03 8.110E‐04
1 ‐ 3 mm 8.884E‐04 7.859E‐04 1.600E‐04
3 ‐ 10 mm 5.946E‐04 4.093E‐04 1.393E‐04
10 ‐ 50 mm 4.379E‐04 2.236E‐04 1.408E‐04
2 in
50 ‐ 150 mm 4.389E‐04 1.211E‐04 3.709E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 2.360E‐03 1.540E‐03 8.110E‐04
1 ‐ 3 mm 8.884E‐04 7.859E‐04 1.600E‐04
3 ‐ 10 mm 5.946E‐04 4.093E‐04 1.393E‐04
10 ‐ 50 mm 4.379E‐04 2.236E‐04 1.408E‐04
4 in
50 ‐ 150 mm 4.389E‐04 1.211E‐04 3.709E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 2.360E‐03 1.540E‐03 8.110E‐04
1 ‐ 3 mm 8.884E‐04 7.859E‐04 1.600E‐04
3 ‐ 10 mm 5.946E‐04 4.093E‐04 1.393E‐04
10 ‐ 50 mm 4.379E‐04 2.236E‐04 1.408E‐04
6 in 50 ‐ 150 mm 1.652E‐04 6.181E‐05 7.316E‐05
> 150 mm 2.736E‐04 5.930E‐05 2.977E‐04
Total 2.360E‐03 1.540E‐03 8.110E‐04
I quantified risk assessment I PROCESS INDUSTRY I 37
Rev.: 1
Process Equipment Leak Frequencies
Date: 26/9/2012
Source: HCRD 10/92 – 03/10
Equipment Type: Atmospheric Storage Vessel
Definition:
This datasheet applies to offshore atmospheric tanks. Includes types of vessel at atmospheric pressure (oil storage
tanks). The scope includes the vessel itself and any nozzles or inspection openings, but excludes all attached valves,
piping, flanges, instruments and fittings beyond the first flange. The first flange itself is also excluded.
Frequency Data:
Equipment Size Category Total Full Pressure Zero Pressure
1 ‐ 3 mm 1.462E‐03 1.177E‐03 3.081E‐04
3 ‐ 10 mm 1.084E‐03 8.152E‐04 2.593E‐04
10 ‐ 50 mm 2.144E‐03 1.318E‐03 8.126E‐04
0.5 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 4.690E‐03 3.310E‐03 1.380E‐03
1 ‐ 3 mm 1.462E‐03 1.177E‐03 3.081E‐04
3 ‐ 10 mm 1.084E‐03 8.152E‐04 2.593E‐04
10 ‐ 50 mm 2.144E‐03 1.318E‐03 8.126E‐04
1 in
50 ‐ 150 mm 0.000E+00 0.000E+00 0.000E+00
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 4.690E‐03 3.310E‐03 1.380E‐03
1 ‐ 3 mm 1.462E‐03 1.177E‐03 3.081E‐04
3 ‐ 10 mm 1.084E‐03 8.152E‐04 2.593E‐04
10 ‐ 50 mm 9.034E‐04 6.255E‐04 2.514E‐04
2in
50 ‐ 150 mm 1.240E‐03 6.922E‐04 5.612E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 4.690E‐03 3.310E‐03 1.380E‐03
1 ‐ 3 mm 1.462E‐03 1.177E‐03 3.081E‐04
3 ‐ 10 mm 1.084E‐03 8.152E‐04 2.593E‐04
10 ‐ 50 mm 9.034E‐04 6.255E‐04 2.514E‐04
4in 50 ‐ 150 mm 1.240E‐03 6.922E‐04 5.612E‐04
> 150 mm 0.000E+00 0.000E+00 0.000E+00
Total 4.690E‐03 3.310E‐03 1.380E‐03
1 ‐ 3 mm 1.462E‐03 1.177E‐03 3.081E‐04
3 ‐ 10 mm 1.084E‐03 8.152E‐04 2.593E‐04
10 ‐ 50 mm 9.034E‐04 6.255E‐04 2.514E‐04
6 in
50 ‐ 150 mm 3.866E‐04 2.462E‐04 1.253E‐04
> 150 mm 8.537E‐04 4.461E‐04 4.359E‐04
Total 4.690E‐03 3.310E‐03 1.380E‐03
38 I PROCESS INDUSTRY I quantified risk assessment I
7. REFERENCES
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