final project reliability & process quality - lj (revi a. ; arfittariah ; arief b.)

8/13/2019 Final Project Reliability & Process Quality - LJ (Revi a. ; Arfittariah ; Arief B.)

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FI NAL PROJECT

RELI ABI L I TY AND PROCESS QUALI TY

Evaluation of Reli abil ity, Maintainabili ty, and Safety In H igh Pressure Separator V-101

Area Hydrofini shing Unit PT. AGIP

RELI ABIL I TY ENGINEER :

Revi Adikhari sma NRP. 2412105021

Ar fi ttariah NRP. 2412105020

Ar ief Budhiyono NRP. 2412105018

DEPARTMENT OF ENGINEERING PHYSICS

FACULTY OF INDUSTRIAL TECHNOLOGY

SEPULUH NOPEMBER INSTI TUTE OF TECHNOLOGY

SURABAYA

2013



I . PIPING AND INSTRUMENTATION DIAGRAM

I I . HIGH PRESSURE SEPARATOR V-101

2.1 Process Description

High Pressure Separator is a unit that served as a separator two phase or three phase

such as oil, water, and gas. In the area of 100 - hydrofinishing unit in the recycle section,

high pressure separator separates the gas phase and liquid phase which will be passed to

the next process. Inputs that go into the high pressure separator comes from refining

reactor. Gas phase will be forwarded to the washing water receiver, while the liquid phaseis passed to the stripper.

At high pressure separator where the control loop there is a controlled flow and level. For there is a level loop LT1008 and an electrical signal is passed to LIC1008. Of LIC1008,

will be forwarded to FIC1002 where the system is a cascade system. For the inputs that go

into FIC1008 also obtained from FE1002 and FT1002 that sense of flow in the pipe. Signal

indicating that the controller has entered into will be continued to the I / P ie FY1002 in the

form of electrical signals and converted to pneumatic signal to command flow control valve.

Here is a flow control valve normally open or fail close.

In the unit there is also a protection system with sensors LSLL1010. Where the signal

of LSLL1010 which will be forwarded to an alarm LALL1010 from the system. Unsafe level

readings are also accepted by XY1010 solenoid valve to shut - off valve on XV1010 order

flow from high pressure liquid phase separator does not continue to flow and keep the level so it is not in a state of low - low.



2.2 I /O Equipment L ist

NO TAG SYMBOL DESCRIPTION

1 LG 1008 LEVEL GLASS

2 LT 1008 LEVEL TRANSMITTER

3 LIC 1008 LEVEL INDICATING CONTROLLER

4 FIC 1002 FLOW INDICATING CONTROLLER

5 FT 1002 FLOW TRANSMITTER

6 FE 1002 FLOW ELEMENT

7 FY 1002 I/P

8 FCV 1002 FLOW CONTROL VALVE



9 LSLL 1010 LEVEL SWITCH LOW LOW

10 LALL 1010 LEVEL ALARM LOW LOW

11 XY 1010 SOLENOID VALVE

12 XV 1010 ON-OFF VALVE



I I I . MAI NTENANCE DATA AND RELI ABIL I TY DISTRIBUTION

3.1 Maintenance Data of HP Separator V-101

LT – 1008

Occurence

Date

Occurence

Time

Completion

Date

Completion

Time

TTF

(Day) TTF (Hours)

TTR

(Hours)

3-Oct-06 7:00:00 3-Oct-06 7:00:00 0 0 0

5-Nov-06 3:00:00 9-Nov-06 11:00:00 33 792 104

7-Jan-07 16:00:00 11-Jan-07 15:00:00 59 1416 95

2-Mar-07 9:00 8-Mar-07 20:00 50 1200 155

17-May-07 15:00 20-May-07 16:00 70 1680 73

10-Jul-07 11:00:00 13-Jul-07 21:00:00 51 1224 82

20-Jul-07 21:00:00 25-Jul-07 15:00:00 7 168 114

9-Aug-07 16:00:00 10-Aug-07 14:00:00 15 360 22

13-Aug-07 20:00:00 16-Aug-07 21:00:00 3 72 73 12-Oct-07 9:00 16-Oct-07 15:00 57 1368 102

MTTF 828

Parameter Weibull : α = 1.4539 ; β = 1003.2 ; γ = 0

Probability Density Function

Histogram Weibull

x16001400120010008006004002000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0



Parameter Normal : σ = 629.95 ; μ = 828

Probabil ity Density Function

f (1000) =

( ) = 0,00039

LIC – 1008

Occurence

Date

Occurence

Time

Completion

Date

Completion

Time

TTF

(Day)

TTF

(Hours)

TTR

(Hours)

4-Feb-06 13:00:00 4-Feb-06 13:00:00 0 0 0

18-May-06 2:00:00 21-May-06 16:00:00 103 2472 86

28-Oct-06 7:00:00 29-Oct-06 2:00:00 160 3840 19

10-Jan-07 17:00:00 12-Jan-07 17:00:00 73 1752 48

16-May-07 13:00 23-May-07 15:00 124 2976 170

5-Jun-07 8:00 12-Jun-07 6:00 13 312 166

13-Jul-07 14:00 18-Jul-07 19:00 31 744 125

13-Oct-07 18:00:00 16-Oct-07 16:00:00 87 2088 70

26-Feb-08 17:00:00 2-Mar-08 15:00:00 133 3192 142 19-Mar-08 17:00:00 22-Mar-08 8:00:00 17 408 63

MTTF 1778.4


Histogram Normal

x

16001400120010008006004002000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0




Parameter Normal : σ = 1354.9 ; μ = 1778.4



Histogram Weibull

x

36003200280024002000160012008004000

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0


Histogram Normal

x

36003200280024002000160012008004000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0



f (1000) =

( ) = 0,00017

FIC – 1002

Occurence

Date

Occurence

Time

Completion

Date

Completion

Time

TTF

(Day)

TTF

(Hours)

TTR

(Hours)

9-Sep-06 21:00:00 9-Sep-06 21:00:00 0 0 0

18-Dec-06 5:00:00 21-Dec-06 20:00:00 100 2400 87

24-Feb-07 4:00:00 26-Feb-07 8:00:00 65 1560 52

10-Apr-07 21:00:00 12-Apr-07 19:00:00 43 1032 46 16-Jul-07 13:00 23-Jul-07 15:00 95 2280 170

5-Sep-07 9:00 12-Sep-07 6:00 44 1056 165

13-Dec-07 14:00 18-Dec-07 16:00 92 2208 122

13-Feb-08 15:00:00 16-Feb-08 16:00:00 57 1368 73

26-Jul-08 17:00:00 28-Jul-08 19:00:00 161 3864 50

1-Sep-08 16:00:00 12-Sep-08 6:00:00 35 840 254

MTTF 1660.8



Histogram Weibull

x

3500300025002000150010005000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0





f (1000) =

( ) = 0,00021

FT – 1002

Occurence

Date

Occurence

Time

Completion

Date

Completion

Time

TTF

(Day)

TTF

(Hours)

TTR

(Hours)

7-Nov-06 7:00:00 7-Nov-06 7:00:00 0 0 0

3-Dec-06 8:00:00 12-Dec-06 11:00:00 26 624 219

3-Feb-07 13:00:00 11-Feb-07 21:00:00 53 1272 200

4-Apr-07 5:00 6-Apr-07 14:00 52 1248 57

21-Jun-07 21:00 24-Jun-07 17:00 76 1824 68

8-Aug-07 1:00:00 13-Aug-07 14:00:00 45 1080 133

25-Aug-07 18:00:00 27-Aug-07 15:00:00 12 288 45

6-Sep-07 18:00:00 10-Sep-07 14:00:00 10 240 92

18-Sep-07 15:00:00 24-Sep-07 21:00:00 8 192 150

2-Nov-07 1:00 16-Nov-07 15:00 39 936 350

MTTF 770.4


Histogram Normal

x

3500300025002000150010005000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0







Histogram Weibull

x

150010005000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0


Histogram Normal

x

150010005000

0.44

0.4

0.36

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0



f (1000) =

( ) = 0,0004

FCV – 1002

Occurence

Date

Occurence

Time

Completion

Date

Completion

Time

TTF

(Day)

TTF

(Hours)

TTR

(Hours)

7-May-06 2:00:00 7-May-06 2:00:00 0 0 0

14-Sep-06 21:00:00 15-Sep-06 21:00:00 130 3120 24

30-Nov-06 20:00:00 30-Nov-06 16:00:00 76 1824 20

11-Jan-07 14:00:00 19-Jan-07 1:00:00 42 1008 179

7-Feb-07 20:00:00 9-Feb-07 5:00:00 19 456 33

8-Apr-07 16:00 13-Apr-07 15:00 58 1392 119

19-Apr-07 14:00 19-Apr-07 18:00 6 144 28 9-Jun-07 21:00 12-Jun-07 16:00 51 1224 67

11-Sep-07 20:00:00 13-Sep-07 10:00:00 91 2184 38

2-Dec-07 3:00 7-Dec-07 21:00 80 1920 138

MTTF 1327.2



Histogram Weibull

x

300025002000150010005000

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0





f (1000) =

( ) = 0,00025

3.2 System Reliabil ity of HP Separator V-101

In the picture above can be seen that the system is a serial (LT - LIC and FT - FIC)

which both can be considered parallel and then forwarded to the FCV to be serial. Weconclude if that system is serial systems.


Histogram Normal

x

300025002000150010005000

0.32

0.28

0.24

0.2

0.16

0.12

0.08

0.04

0

FCV

LIC

FIC

LT

FT



Cumulative Distribution Function

LT – 1008

F (1000) =

= 0,57

R(1000) = 1 – F(t)

= 1 - 0,57 = 0,43

LIC – 1008

F (1000) =

= 0,36

R(1000) = 1 – F(t)

= 1 - 0,36 = 0,64

FIC – 1002

F (1000) =

= 0,35

R(1000) = 1 – F(t)

= 1 - 0,35 = 0,65

FT – 1002

F (1000) =

= 0,59

R(1000) = 1 – F(t)

= 1 - 0,59 = 0,41



FCV – 1002

F (1000) = = 0,42

R(1000) = 1 – F(t)

= 1 - 0,42 = 0,58

Total System Reli abil ity for 1000 hours

R (t) = ( R (LT) . R (LIC)) + (R(FT) . R(FIC)) . R(FCV)

= (0,43 . 0,64) + (0,41 . 0,65) . 0,58 R(1000) = 0, 31

Reli abili ty for 720 Hours, 4320 Hours, and 8640 Hours

LT – 1008

F (720) =

= 0,46

R(720) = 1 – F(t)

= 1 - 0,46 = 0,54

F (4320) =

= 0,99

R(4320) = 1 – F(t)

= 1 - 0,99 = 0,01



F (8640) =

= 0,99

R(8640) = 1 – F(t)

= 1 - 0,99 = 0,01

LIC – 1008

F (720) =

= 0,31

R(720) = 1 – F(t)

= 1 - 0,31 = 0,69

F (4320) =

= 0,86

R(4320) = 1 – F(t)

= 1 - 0,86 = 0,14

F (8640) =

= 0,99

R(8640) = 1 – F(t)

= 1 - 0,99 = 0,0,01

FIC – 1002

F (720) = = 0,29



R(720) = 1 – F(t)

= 1 - 0,57 = 0,71

F (4320) =

= 0,92

R(4320) = 1 – F(t)

= 1 - 0,92 = 0,08

F (8640) =

= 0,99

R(8640) = 1 – F(t)

= 1 - 0,99 = 0,01

FT – 1002

F (720) =

= 0,48

R(720) = 1 – F(t)

= 1 - 0,48 = 0,52

F (4320) =

= 0,99

R(4320) = 1 – F(t)

= 1 - 0,99 = 0,01



F (8640) =

= 0,99

R(8640) = 1 – F(t)

= 1 - 0,99 = 0,01

FCV – 1002

F (720) = = 0,34

R(720) = 1 – F(t)

= 1 - 0,34 = 0,66

F (4320) = = 0,96

R(4320) = 1 – F(t)

= 1 - 0,96 = 0,04

F (8640) =

= 0,99

R(8640) = 1 – F(t)

= 1 - 0,99 = 0,01

From the simulation results by taking the example of 720 hours, 4320 hours and 8640 hours

can be seen that the reliability of each equipment will decrease. it can be seen from the value of

R at the time of 720 hours to 4320 hours to 8640 hours onwards decreased. so the longer it is

used, the level of reliability of the equipment will decrease and result in damage.



IV . FAI LURE MODE AND EFFECT ANALYSIS (FMEA)

No I tem

Potential

failure

mode

Potential

effect of the

failure Severity Probability

(occurence) Critical

rank Recommended

Action

1

LevelTransmitter LT-1008

Degradationof rangereading

Level tank

over highand allowexplosion II 2 / B 1

Check andcalibrationtransmitter

2

Level Indicating

Controller LIC-1008

Manufactingdefect

Cannottransmit

signal to

FICnormally III 4 / D 3

Check signalcable

3

Flow IndicatingController FIC-1002

Wrong signal

Cannot givecommand to

FCV II 3 / C 4 Check signal

cable

4

FlowTransmitter

FT-1002 Failed to

flow sensing

Cannottransmit processvariable present

value III 1 / A 4

Check andcalibration

transmitter

5

FlowControlValve

FCV-1002

Positioner stuck/ failed

open(premature

open)

Over pressureand allowexplosion I 5 / E 1

Check postioner ordiaphragma

valve

Notes :

High Risk

Medium Risk

Low Risk

Can be seen from the the above table that the level transmitter failed degradation of

range reading which will cause the tank level will be high and could explode. For the severity

level is II, occurence probability 2/B, critically rank 1. Recommended action is to check and

calibration transmitter. Level indicating controller failed manufacturing defect which will cause cannot transmit

signal to flow indicating controller. For the severity level is III, occurence probability 4/D,

critically rank 3. Recommended action is to check signal cable

Flow indicating controller failed wrong signal which will cause cannot give command to

flow control valve. For the severity level is II, occurence probability 3/C, critically rank 4.

Recommended action is to check signal cable.

Flow transmitter failed to flow sensing which will cause cannot transmit process variable

present value. For the severity level is III, occurence probability 1/A, critically rank 4.

Recommended action is to check and calibration transmitter.

Flow Control Valve failed positioned stuck or failed open which will cause over pressure

and allow explosion. For the severity level is I, occurence probability 5/E, critically rank 1. Recommended action is to check positioned or diaphragma valve.



V . FAULT TREE ANALYSIS (FTA)

In the picture above can be seen that the top event is the state failed to separated which is

caused by over-pressure, gas dehydrator trip, and flow turbulence. Three are the logical choice for the top event. After that is below the over-pressure basic events such as pump impeller was

broken and the control valve to fail closed with OR logic. For gas dehydrator is caused by over-

temperature, fluid viscosity, and safety devices not work with OR logic. Different with flow

turbulence events caused by three causes the friction on the pipe, shear induced structure, and

pipe leakage where the three cause have an AND logic.



VI . RELI ABIL ITY UNDER PREVENTIVE MAINTENANCE (MAI NTAINABIL ITY)

With T =30 days ; n = 1

FT 1002

No T R(t) R(t-nT) Rm(t)

β θ No PM PM Cumulative PM

1 0 hours 1 0 0, 991,63 957

2

720

hours 0,52 1384,6 0, 851,63 957

3

1000

hours 0,41 2439 0, 821,63 957

4

4320

hours 0,01 432000 0, 77

1,63 957

5

8640

hours 0,01 864000 0, 601,63 957

FCV 1002

No T R(t) R(t-nT) Rm(t)

β θ No PM PM Cumulative PM

1 0 hours 1 0 0, 991,66 1637

2

720

hours 0,66 1090,9 0, 921,66 1637

3

1000

hours 0,58 1724,1 0, 881,66 1637

4

4320

hours 0,04 108000 0, 861,66 1637

5

8640

hours 0,01 864000 0, 801,66 1637



VII . ISHI KAWA DIAGRAM

final project reliability & process quality - lj (revi a. ; arfittariah ; arief b.)

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