“FMEA Data Base for Process and Oil & Gas Industry”

(Platforms, Subsea, Refineries, chemical and petrochemical plants)

2020
 TABLE OF CONTENTS
CONTENTS ............................................................................................................... 2
ABBREVIATIONS...................................................................................................... 3
1. INTRODUCTION................................................................................................. 4
1.1 PURPOSE OF THIS DOCUMENT......................................................................... 4
1.2 METHODOLOGY .................................................................................................. 4
1.3 DATABASE STRUCTURE .................................................................................... 4
2. ONSHORE EQUIPMENT .................................................................................... 7
2.1 ROTATING EQUIPMENT ...................................................................................... 7
2.1.1 Pumps (Components: seal, bearing, shaft, impeller, O-ring, casing, packing, shaft,
coupling, nozzle) ............................................................................................................................ 7
2.1.2 Motors (Components: shunt, brushes, wires, armature, magnetic frame, packing, shaft,
stator magnets, bearing and widing)............................................................................................. 16
2.1.3 Centrifugal Compressors (Components: seal, bearing, rotor shaft, impeller, casing,
packing, coupling, rotor, gasket, labyrinth, inlet guide vane) ...................................................... 21
2.1.4 Screw Compressor (Components: seal, bearing, Screw rotor, gear, casing, packing,
coupling and gasket)..................................................................................................................... 28
2.1.5 Reciprocating Compressor (Components: seal, bearing, inlet valve, outlet valve,
crankshaft, packing, casing, connection rod, coupling, piston, piston rod, cylinder and frame) . 35
2.1.6 Compressor Auxiliaries (Equipment: sensors, controller, Inlet valve, outlet valve, relief
valve, gas filter, gear box, piping and cooler) .............................................................................. 42
2.1.7 Lubrication Unit (Equipment: oil tank, pump, motor, oil filter, check valve, cooler and
piping) 49
2.1.8 Gas turbine (Components: seal, bearing, gear, casing, fuel nozzle, rotor shaft, rotor
blades) 52
2.1.9 Turboexpander (Equipment: bearing, gear, casing, shaft, controller, actuator, lines,
primary sealing, secondary sealing, generator, reductor, valves)................................................. 60
2.2 STATIC EQUIPMENT ......................................................................................... 67
2.2.1 Vessel (Components: cylinder, head, flange, support feed, manhole flange) ................. 67
2.2.2 Tank (Components: tank structure, joint, gasket, nozzle) ............................................... 70
2.2.3 Pipes (Components: pipe structure, joint, gasket, flange) ............................................... 74
2.2.4 Towers/columns: (Components: demister, trays, liquid distributor, liquid re-distributor,
bad limiter, packing, manhole) ..................................................................................................... 77
2.2.5 Reactors: (Components: Feed diffuser, trays, support grid, mix chamber, collection tray,
outlet collector, center pipe, scallops, outer basket, SSR flow, header)....................................... 80
2.2.6 Furnace (Components: burner, firebox, radiant tubes, conventional tubes, refractory,
damper, stack, pre-heater, air blower) .......................................................................................... 83
2.2.7 Air coolers (Components: shell, tube, motor, speed reducer, fan, fixed header, floating
header, support) ............................................................................................................................ 87
2.2.8 Heat Exchangers (Components: shell, tube, tie rod & spacer, baffles, tube Sheet) ........ 90
2.2.9 Oil Filters (Components: Internal filter elements, external filter body).......................... 93
 2.2.10 Gas Filters (Components: Internal filter elements, external filter body)......................... 96
2.3 SAFETY AND CONTROL ................................................................................... 99
2.3.1 Safety and Control (Equipment: control valve, relief valve, safety valve, emergency
shutdown valve, controller, valve actuator, sensor, alarm and instruments) ................................ 99
2.4 UTILITY SYSTEM ............................................................................................. 103
2.4.1 Boiler System (Equipment: burner, combustion chamber, drum, boiler support, fan, fire
tube, heat exchanger, supply line, return lines, dearator, condenser) ......................................... 103
2.4.2 Electric System (Equipment: generator, electric panel, substation, disjunctor, cables,
power connection, barr, switch board) ....................................................................................... 107
2.4.3 Water System (Equipment: water reservoir, water tower, pump, motor, fan, valve,
cooler, filter, valves, piping, chillers)......................................................................................... 110
2.4.4 Air System (Equipment: compressor, air receiver vessel, air dryer vessel, air dryer pre-
filter, air dryer filter, relief valve, control valve, controller, alarms and instruments, lines) ..... 113
APPENDIX A ...................................................................................................... 116
REFERENCES ....................................................................................................... 118

ABBREVIATIONS
2P Two Parameters

ETF Expected Time to Failure

PDF Probability Density Function

RAM Reliability Availability and Maintainability

 1. INTRODUCTION

1.1 PURPOSE OF THIS DOCUMENT

The ECC FMEA database aims to provide the information of equipment failure modes, cause
and effects of oil and gas and petrochemical industries. The FMEA database provides a
guideline for support projects and assessment of physical asset during operational phase.
Based on the equipment / component list defined the FMEA is described by using a general
risk matrix. In order to update the FMEA database by using the different risk matrix, a re-
assessment must to take place.

1.2 METHODOLOGY
The FMEA database is based on the Reliability Engineer Expert Dr. Eduardo Calixto past
experience in hundreds of Reliability Engineering analysis including FMEA.
However, this FMEA database is defined in for equipment and component level. Because of
different equipment configuration, it was considered the most critical component that affect
the equipment reliability performance.
The FMEA data base is presented in level 1 (equipment) and level 2(component).
The main equipment of Oil and gas industry of downstream and upstream are divided in
different types of equipment and system such as:

 Rotating;
 Static;
 Safety and Control;
 Utilities.

1.3 DATABASE STRUCTURE

The FMEA database is structured in a template divided in:

 Equipment List
 Equipment / Component Functions
 Failure Mode
 Cause
 Detection
 Risk
 Mitigation Action/Recommendation
The “Equipment Description” describes the type of equipment, supplier, operation conditions
and design specification.
The “Equipment Configuration” describes the number of equipment components in order to
clarify if there is redundancy or not.
The “Equipment Function” describes the equipment objective.
The “Component” describes the type of components of the equipment.
The “Component Function” describes the objective of the components.
The “Failure Modes” describes the way that such components lose their function.
The “Failure Mode Causes” describes why failure mode happens.
The “Phase” describes each phase of an asset when the failure mode happens, based on its
cause. The asset phases are described in the FMEA sheet as: De (design), Mo (Montage), Tra
(Transportation), Ins (Installation), Prec (Pre-Commissioning), Op (Operation).
The “Risk Assessment” on the FMEA analysis, the risk is the combination of the likelihood of
failure mode with the consequence of failure mode effect. In order to analyze the risk, the
qualitative risk assessment was carried out based on specialist opinion, regarding a risk matrix
with the likelihood and consequence criteria established.
The “Likelihood Assessment” is the frequency of the failure modes occurring for each system
is analyzed.
There are different configurations of risk matrix and such configuration must reflect the law
and companies risk policy. The figure 2 shows an example of risk matrix with four severity
categories and six frequency categories.

Figure 2 – Risk Matrix

In addition, severity classification must describe all parties affected in the case of an accident
like employees, community and environment as well as company installations cost. The figure
3 shows an example of severity category.
Figure 3 – Severity classification

Description and caracteristic

PERSONAL ENVIROMENT AND

INSTALATION SOCIAL
SAFETY IMAGE

Economics effects in local

Loss of ecosystem activities, healh cost in local
Cathastrofic injures Losses in equipment
Catastofic

with bad nacional populatio, economics losses in

with death, its and plant with high
and international turism, ecosystem local losses
IV

possible to effect cost to buy the new

company image and quality of life losses.
people outside one
reputation (Betwen R$ 101.000.000,00
and R$ 336.000.000,00)

Critical effects to
enviroment being
hard to improve Economics effects in local
Critical injuries. eosystem condition activities, healh cost in local
Equipment serius
Critical

Employees stay a even with human populatio, economics losses in

damaged with high
III

period oftime out of actions. Bad turism, ecosystem local losses

cost to repair
workplace nacional and (Betwen R$ 2.500.000,00 and
SEVERITY CATEGORY

international R$ 101.000.000,00)
company image
reputation

Not serius
enviroment effect but Economics effects in local
its necessary human activities, healh cost in local
Marginal

Moderate injuries Low equipment

intervention and population, economics losses in
with firt aid damaged with low
II

actions to improve turism, fishing and the others

assistence repair cost
enviroment.Bad (Form R$ 0,00 to R$
nacional company 2.500.000,00)
image reputation

Insignificant
NOT EFFECT

enviroment effect.
Theres no injuries There is not There is not economics effects
There is not
and health damaged to in local activities, healh cost in
I

necessity to human
damaged equipment and plant local population
action to ecosystem
improvment. There
is not nacional
company image
reputation bad effect
.
 2. ONSHORE EQUIPMENT

2.1 Rotating Equipment

2.1.1 Pumps (Components: seal, bearing, shaft, impeller, O-ring, casing,

packing, shaft, coupling, nozzle)

The centrifugal pump is one of the most used pumps in gas and oil industry, therefore, such
FMEA will describe the main components failure modes. The first step in FMEA analysis is to
define the equipment and components list. The main component of centrifugal pump can be
described on equipment hierarchy as follows:

 Seal;
 Bearing;
 Shaft;
 Impeller;
 O-ring;
 Casing;
 Packing;
 Shaft;
 Coupling;
 Nozzle.

The next step is to define the equipment and component function, which is described on table
1 below.
Page 7 of 118
 Table 1 – Equipment and component function (FMEA)

Failure Mode and Effect analysis (FMEA)

FMEA Leader: Document:
Date:xx-xxx-xxxx
Dr. Eduardo Calixto DE-xxxx-001 Rev01
Subsystem:
System: xxxxxxx Equipment: P-01 A/B
xxxxxxx
N0 Equipment Equipment Equipment Function Component Component
Number Description Function
Avoid fluid
1 O-ring
turbulence
Protect the
impeller and
2 Casing create a chamber
for the fluid be
pumped through.
Transmit torque
to impeller

3 Coupling

This pump is used to increase the Spin the fluid

Centrifugal pressure flow in Train 1. It transfers inside the pump
P-101 A/B fluids, enough to deliver to the main
Pump chamber
export pumps.
4 Impeller

Transmit
5 Shaft mechanical
energy
Prevent external
6 Seal
leakage
Ensure shaft
7 Bearing
alignment
8 Packing Control leakage
Avoid fluid
9 Nozzle
turbulence

The next step is to perform the different component FMEA Analysis as shows the tables 2
below

Page 8 of 118
 Table 2 – FMEA Pump O-ring, Casing, and Coupling)

Failure Mode and Effect analysis (FMEA)

Document:
FMEA Leader:
DE-xxxxxx-001 Date:XX-XX-2020
Dr. Eduardo Calixto
Rev01
Component:
Subsystem:
System: XXXXXXX Equipment: P-01 A/B O-ring, Casing
XXXX
and Coupling
N0 Component Failure mode Phase Cause O Consequence S Risk Mitigate O S Risk
(Pri) Action (Post)
1 Op Normal wear E EI N/A D EI
Excessive solids
To control
2 Op in fluid causing E EI D DI
fluid quality
premature wear

Worn out
Low flow ( To verify
Impeller Pumps less
3 Ins E EI impeller D DI
misaligned than the alignment
required
O-ring I I
flow rate of
'X' or
Overheat due
pressure of
lack of cooling To control
4 Brittle Op E 'Y'.) EI D DI
or adequate fluid quality
liquid flow
Excessive
To control
temperature,
5 Deformation OP E EI fluid D DI
pressure or
temperature
chemical attack

6
Casing
7

8 Coupling

Page 9 of 118