Fault Tree Analysis

Failures in Process Industries

Single Component Failure
Data for failure rates are compiled by industry Single component or single action

Multiple Component Failure

Failures resulting from several failures and/or actions Failure rates determined using FTA

Failure Rates Data

Instrument
Controller Control valve Flow measurements (fluids) Flow measurements (solids) Flow switch Gas liquid chromatograph Hand valve Indicator lamp Level measurements (liquids)

Faults/year
0.29 0.60 1.14 3.75 1.12 30.6 0.13 0.044 1.70

Level measurements (solids)

6.86

Failure Rates Data

Instrument Oxygen analyser Faults/year 5.65

pH meter Pressure measurement Pressure relief valve Pressure switch Solenoid valve Stepper motor Strip chart recorder Thermocouple temperature meas. Thermometer temperature meas. Valve positioner

5.88 1.41 0.022 0.14 0.42 0.044 0.22 0.52 0.027 0.44

Failure Rates Data

Some data are per hour
Failure Frequency Component Gasket Failure (leak) Gasket Failure (total) Pipe Rupture (> 3 in) Pipe Rupture (< 3 in) (hr-1) 1.00 x 10-06 1.00 x 10-07 1.00 x 10-10 1.00 x 10-09 Component Pump Seal Failure Alarm Failure Operator Error Hose Rupture Failure Frequency (hr-1) 8.00 x 10-07 1.00 x 10-05 2.00 x 10-05 2.00 x 10-05

Valve Rupture

1.00 x 10-08

Frequency, Reliability and Probability

Component Failure Rate m (faults/year)
0.6 0.29 1.41

Reliability R=e(-mt)
0.55 0.75 0.24

Control Valve Controller DP Cell

Failure Probability P=1-R 0.45 0.25 0.76

p = 1-

-mt e

where p is the annual probability of occurrence, m is the annual frequency and t is time period (i.e., 1 year).
Conversion is important in OR gate (dimensional homogeneity)

Frequency and Probability - Example

taking the case of gasket failure and assuming that we have 10 gaskets, the annual probability of occurrence is:
1 x 10 -7 8760 hr 10 8.72 x 10 3 year 1 p 1 exp hr year

What is Fault Tree Analysis

Fault Tree is a method by which a particular undesired system failure mode can be expressed in terms of component failure modes and operator actions. The system failure mode to be considered is termed the top event and fault tree is developed in branches below this event showing it causes.

Fault Tree Analysis

Fault tree analysis is typically carried out by a group or people or an individual. These individuals must have knowledge on the process so that causes of undesirable events can be understood The following information is important
process and equipment description and specification process flow diagram, process instrumentation diagram and design information plant operation, human factors and environmental factors

Two basic Element

The two mostly used gate symbol are and & or gates.
And gate is used to indicate that output event occurs if all input event occurs simultaneously. Or gate is used when output event occurs if any one of the input event occurs.

Event symbol mostly used is Rectangle to show any event. Signify the TOP EVENT by a double box.

FTA Procedure
1. Define top event 2. Choose events identified by hazard identification method (i.e HAZOP) which can lead to this top event. 3. Decide on the hierarchical construction of fault tree 4. Construct fault tree. All inputs to a particular gate should be completely defined before further analysis of one of them is undertaken. 5. Quantify the base events 6. Quantify the top event

FTA Procedure
7. Analyze results to determine the significance of particular base events or combination events 8. Carry out sensitivity analysis to test the following factors:
uncertainty of basic data effect of improving reliability of plant and control systems effect of varying method of operation on the plant effect of plant modernization effect of improved training of operators

Underlying Principles
Causes of undesirable events can only be understood with knowledge on how the system functions through:
chemical/physical processes in the plant specific information on the whole process data on hazardous properties of materials process flow diagram and process instrumentation diagram equipment specification plant operation human factors and environmental factors

Example: Pump
A system to pump acetic acid from the supply tank to the process is illustrated in figure. The system function automatically. When the regulator is energized, one of the pumps is started and acid passes through the feed pipes; if no acid is detected in the feed pipe the second pump is started. Construct a fault tree with the top event no flow to the process. To make your life easier, consider failure modes listed here. Is there any other notable failures not listed should be considered?

Example: Pump
S C1 F1
P1

E C2

M
R

F2 P2
E : ELECTRICITY F1,F2 : FEED PIPES M : MANIFOLD
C1, C2 : CABLES

P1,P2 : PUMPS R : REGULATOR S : SUPPLY TANK

Failure Modes to Consider

Component Symbol Failure Mode

Cables Electricity supply Feed pipes Manifold Pumps Regulator tank

C1 + C2 E F1 + F2 M P1 + P2 R S

short-circuit power cut rupture of pipe rupture fail to start fail to open on Supply level too low

Fault Tree
NO FLOW TO PROCESS

PROBLEMS WITH PUMPS GENERAL PROBLEMS

PUMP P1 PROBLEMS

PUMP P2 PROBLEMS

Tanks level too low Regulator fails

Manifold M fails Power cut

Pump P1 fails to start

Pipe P2 ruptures

Cable C2 short circuits

Pipe P1 ruptures

PROBLEM 1 - SIMPLIFIED SYSTEM

Cable C1 short circuits

Pumps P2 fails to start

Unit on Fault Tree and Rules

Frequency (failure/year) = probability of failure per operation number of operation per year AND GATE rules : can multiply P and P = unit of probability can multiply P and F = unit of F cannot multiply F and F = unit F2 (for example failure/yr2) OR GATE rules : can add P and P = unit of P can add F and F = unit F cannot add F and P =different unit RULES for AND GATES P(A.B) = PA.PB F(AB) = FA.PB

Boolean Algebra and Minimal Cut Set

Boolean Rules Differences to numerical manipulation Indempotent A+A=A A.A=A Absorption A+A.B=A A.(A+B)=A For example : (M+W) . (M+Z) = M.M + M.Z +W.M +W.Z = M + M.Z +W.M +W.Z = (M + M.Z +M.W) + W.Z = M+ W.Z
A CUT SET = combination of basic events which will produce TOP EVENT In the example : M, M.Z, W.M, W.Z are all cut set But Minimal CUT SET is a CUT SET if any basic event is removed the TOP EVENT will not occur Therefore MINIMAL CUT SET is M and W.Z can redraw the FAULT TREE..

Example Minimal Cut Set

PUMP FAIL

PUMP A FAILS

PUMP B FAILS

Failure of Power Supply M

Pump A Mechanic al Failure W

PROBLEM 1 - SIMPLIFIED SYSTEM

Failure of Power Supply M

Pump B Mechanic al Failure Z

Unit on FTA
Quantify Fault Tree Electrical supply failure, P = 0.1 Single pump failure, P = 0.25 Referring to Fault Tree :
Before minimal cut set, Probability of pump fail = 0.1225 After minimal cut set, Probability of pump fail = 0.1625

Example -Minimum Cut Set

PUMP FAIL

FAILURE OF POWER SUPPLY M

MECHANICAL FAILURE OF PUMPS

PROBLEM 1 - SIMPLIFIED SYSTEM

Pump A Mechanical Failure W

Pump B Mechanical Failure Z

Boolean Algebra-Minimum Cut Set

TOP EVENT

D D E C

Boolean Algebra-Minimum Cut Set

(A + B) . [ (C + D) . (E + C) + (D.E) ]

= (A + B) . (C.E + D.E + C.C + D.C + D.E )

= (A + B) . (C.E + D.E + C + D.C + D.E ) = (A + B) . (C + C.E + D.E + D.C + D.E )

= (A + B) . (C + C.D + C.E + D.E + D.E )

INDEMPOTENT LAW = (A + B) . (C + C.D + C.E + D.E)

ABSORPTION LAW
= (A + B) . (C + D.E )

Boolean Algebra-Minimum Cut Set

TOP EVENT