Reliability and availability modeling of Subsea Xmas tree system using Dynamic Bayesian network with different maintenance methods

Subsea Xmas tree is a vital equipment for offshore oil and gas development. Aiming at the fault mode of subsea Christmas tree system under production conditions, the fault tree of subsea tree system was established, which was transformed into Dynamic Bayesian network, and the reliability and availability of subsea tree system with different repair states are quantitatively analyzed. In this paper, the DBNs are partially verified by the method based on three axes. The results show that the reliability of subsea vertical tree system is slightly higher than that of subsea horizontal tree system. After repair and maintenance, the performance of subsea tree system has been significantly improved, and the improvement of the system performance by preventive maintenance is more obvious. Compared with the perfect repair, the performance of the system with imperfect repair is not significantly reduced. Compared with perfect repair & preventive maintenance, the performance of the system with imperfect repair & preventive maintenance is slightly reduced. In addition, the influence of failure rates and degradation probability on reliability and availability is analyzed. By comparing the influence of failure rates on the system performance of non-maintenance and maintenance, it is found that the change of failure rates has the greatest influence on the reliability and the least influence on the availability of perfect repair & preventive maintenance. By comparing the performance of each component in the subsea tree system, it is found that the failure rates has the most obvious influence on the chock module, and gate valve and tree cap have the most significant influence on the reliability of the system. In order to improve the reliability of subsea tree system, it is necessary to improve the reliability of chock module, gate valve and tree cap.     

基于马尔可夫方法的水下防喷器可靠性研究

水下防喷器是保障海上钻井安全的关键设备,对其可靠性进行定量评价对井控作业有重要的指导意义.为了弥补现有水下防喷器可靠性评价方法的不足,将水下防喷器的工作状态分为四种,包括无故障可用、关井、井控关键失效及关井时失效.利用Markov方法建立了水下防喷器的Markov模型.通过水下防喷器系统的状态转换图找出了各工作状态的转换关系.通过分析墨西哥湾83口深水井水下防喷器的失效数据,定义了影响水下防喷器可靠性的井控关键失效,并对深水钻井水下防喷器防喷功能的可靠性进行了定量计算.将计算结果与不考虑关井期间的井控关键失效相比较发现,防喷器的防喷失效概率增加了65％.因此传统的定量评价方法可能会得出相对乐观的结论,应在实际生产中给予重视.     

Reliability analysis of subsea blowout preventer control systems subjected to multiple error shocks

Two configurations of subsea blowout preventer (BOP) distributed control systems, which are triple modular redundancy (TMR) control system and double dual modular redundancy (DDMR) control system, are presented. With respect to common-cause failures, the performances of the two systems are evaluated by using Markov method with multiple error shock model. Due to the complexity, each system is split into three independent modules, and the corresponding Markov models are proposed subsequently. The probability of failure on demand, availability and reliability of the systems are evaluated by merging the independent Markov modules by Kronecker product approach. The results indicate that a same safety integrity level of SIL3 can be attained for the two configurations, which satisfies the requirement of subsea BOP control system, even though both of them have some advantages and shortcomings. In addition, for TMR control system, the effects of multiplicity distribution of multiple error shock and mean time to repair on reliability performances are studied.     

Subsea pipelines incidents prevention: A case study in Brazil

There are more than 4000 subsea pipelines in Brazil. These pipes include umbilicals, drilling risers, flexible risers, rigid risers, hybrid risers, flowlines, and export pipelines. Despite all standards, regulations, guides, and risk management tools designed to avoid events, subsea pipeline incidents still occur, revealing possible failures in companies' risk control. Identifying similarities between different subsea pipeline failure events is crucial to improving the design, risk management practices, and regulation requirements, besides promoting accident prevention. This paper proposes applying the life cycle and management practices combined to analyze subsea pipeline incidents from the RDI (Detailed Incident Report) and investigations reported to ANP (Brazilian National Agency of Petroleum, Gas, and Biofuels), the Brazilian safety regulatory agency. Furthermore, subsea pipeline incidents data were analyzed: correlated circumstances, consequences, and causes. The results show that most riser and flowlines causal factors are related to equipment failures, and recurrent root causes are design errors and integrity control. Based on the proposed approach, it was possible to identify gaps in most riser and flowlines accident investigations since there are few causal factors, root causes, and the absence of riser and flowlines failure mode and mechanisms. Therefore, the development of accident recommendations can be compromised. Thus, this paper proposes improvements to current Brazilian regulations to clarify the minimal subsea pipeline accident investigation requirements.     

南海某深水高温高压气井SS-15型井口头系统薄弱点安全评价*

为应对深水高温高压气井生产过程中井口系统复杂性、井口抬升等对整个井口系统完整性的破坏情况,研究环空压力、上顶力、温度、产量对井口头系统薄弱点的影响。基于数值模拟方法建立井口系统有限元力学模型,分析在不同环空压力与上顶力条件下,井口系统各部件的应力大小变化情况,为井口系统薄弱点位置的确定提供理论依据,进而提出深水高温高压井井口系统完整性的管控图版及方法。研究结果表明:环空密封本体与套管挂、锁环与限位槽的接触部位是薄弱点;同一环空压力下,上顶力越大,套管挂等效应力与锁环变形量越大;当上顶力超过700 t时,不论环空压力是否存在,均达到井口系统薄弱点屈服强度。因此,深水高温高压油气井应制定合理生产制度或管理措施,研究结果对保障井口系统完整性,降低深水高温高压井生产阶段风险具有一定参考意义。     

Dynamic Bayesian network modeling of reliability of subsea blowout preventer stack in presence of common cause failures

A subsea blowout preventer (BOP) stack is used to seal, control and monitor oil and gas wells. It can be regarded as a series–parallel system consisting of several subsystems. This paper develops the dynamic Bayesian network (DBN) of a parallel system with n components, taking account of common cause failures and imperfect coverage. Multiple error shock model is used to model common cause failures. Based on the proposed generic model, DBNs of the two commonly used stack types, namely the conventional BOP and modern BOP are developed. In order to evaluate the effects of the failure rates and coverage factor on the reliability and availability of the stacks, sensitivity analysis is performed.     

基于时变可靠度分析的桥梁使用寿命预测

为分析一座桥梁结构寿命,在现有混凝土桥梁抗力和荷载的时变性研究的基础上,建立桥梁时变可靠度计算模型。将结构抗力等效转换为车辆荷载作用下结构所产生的竖向位移限值,预测远景交通量,反映荷载的时变性;运用非线性有限单元增量分析方法,以递增特定荷载的方式,采用响应面法计算时变可靠度指标及累计失效概率。结果表明:桥梁结构初始阶段具有足够大的可靠性,但其会随时间推移迅速衰减,利用韦伯分布函数和最小二乘法计算桥梁累计失效概率,进而推算桥梁使用寿命。根据桥梁寿命可靠度计算结果,制定出桥梁最佳维修养护策略。     

埋地管道腐蚀剩余寿命预测概率模型

为考察腐蚀参数的不确定性对埋地管道失效和剩余寿命的影响,建立以Shell—92确定性模型为基础的管道腐蚀剩余寿命预测概率模型。采用Monte-Carlo方法计算管道剩余寿命及其累积分布函数,并进行参数敏感性分析,详细研讨影响埋地管道腐蚀剩余寿命的主要参数及其随服役时间的变化规律。计算结果表明,提出的管道腐蚀剩余寿命预测模型能有效预测实际中受多因素影响的管道失效和剩余寿命问题。     

Applications of fuzzy faulty tree analysis and expert elicitation for evaluation of risks in LPG refuelling station

A method is presented for analysis of reliability of complex engineering systems using information from fault tree analysis and uncertainty/imprecision of data. Fuzzy logic is a mathematical tool to model inaccuracy and uncertainty of the real world and human thinking. The method can address subjective, qualitative, and quantitative uncertainties involving risk analysis. Risk analysis with all the inherent uncertainties is a prime candidate for Fuzzy Logic application. Fuzzy logic combined with expert elicitation is employed in order to deal with vagueness of the data, to effectively generate basic event failure probabilities without reliance on quantitative historical failure data through qualitative data processing.The proposed model is able to quantify the fault tree of LPG refuelling facility in the absence or existence of data. This paper also illustrates the use of importance measures in sensitivity analysis. The result demonstrates that the approach is an apposite for the probabilistic reliability approach when quantitative historical failure data are unavailable. The research results can help professionals to decide whether and where to take preventive or corrective actions and help informed decision-making in the risk management process.     

Dynamic risk assessment using failure assessment and Bayesian theory

To ensure the safety of a process system, engineers use different methods to identify the potential hazards that may cause severe consequences. One of the most popular methods used is quantitative risk assessment (QRA) which quantifies the risk associated with a particular process activity. One of QRA's major disadvantages is its inability to update risk during the life of a process. As the process operates, abnormal events will result in incidents and near misses. These events are often called accident precursors. A conventional QRA process is unable to use the accident precursor information to revise the risk profile. To overcome this, a methodology has been proposed based on the work of Meel and Seider (2006). Similar to Meel and Seider (2006) work, this methodology uses Bayesian theory to update the likelihood of the event occurrence and also failure probability of the safety system. In this paper the proposed methodology is outlined and its application is demonstrated using a simple case study. First, potential accident scenarios are identified and represented in terms of an event tree, next, using the event tree and available failure data end-state probabilities are estimated. Subsequently, using the available accident precursor data, safety system failure likelihood and event tree end-state probabilities are revised. The methodology has been simulated using deterministic (point value) as well as probabilistic approach. This Methodology is applied to a case study demonstrating a storage tank containing highly hazardous chemicals. The comparison between conventional QRA and the results from dynamic failure assessment approach shows the significant deviation in system failure frequency throughout the life time of the process unit.     

机车双司机驾驶行为可靠性研究

在人机系统可靠性理论与机车驾驶行为链的基础上,结合双司机作业特点,构建了基于感知、判断、操作元件及模块组的单司机及双司机驾驶行为模型。基于该模型,在确定单项器官元件可靠度测试与计算方法后,运用可靠性理论给出了功能模块可靠度、单司机驾驶行为可靠度、双司机驾驶行为可靠度模型,并对信息感知差系数、正副司机主次差系数等参数进行了分析和讨论,从而构建了一套较为完善的驾驶行为可靠性测试分析方法。最后对4组16名机车司机按事故与非事故组进行分时段连续测试与可靠度计算,其结果表明,双司机驾驶行为可靠性不仅决定于单司机驾驶行为可靠性,并且正副司机间的协调性密切相关,同时与作业时间呈凹函数分布。     

基于贝叶斯网络的气井井筒完整性风险评价

井筒完整性失效是气井生产中的主要风险,为有效评价井筒完整性风险,应用贝叶斯网络的推理与学习能力,建立了基于贝叶斯网络和Noisy-OR gate模型的井筒完整性失效概率计算方法和风险评价模型。由故障树分析将井筒分为管柱、水泥环密封性、井口装置、水力屏障和其他部件5个评价单元,确定了各单元的主要风险因素,建立了井筒完整性失效的贝叶斯网络拓扑结构;由Noisy-OR gate模型和历史数据,确定了贝叶斯网络的条件概率参数;将基于贝叶斯网络的失效概率与层次分析法相结合,确定了风险评价指标和等级划分标准;建立了气井井筒完整性风险评价方法。结果表明,该方法实现了井筒完整性失效概率的定量计算、风险的定量评价和主要风险因素的反向推理,可为预防和控制井筒完整性失效提供决策依据,有助于降低井筒完整性失效风险。     

Effects of environment, vehicle and driver characteristics on risky driving behavior at work zones

This study aims to analyze the effects of environment, vehicle and driver characteristics on the risky driving behavior at work zones. A decision tree is developed using the classification and regression tree (CART) algorithm to graphically display the relationship between the risky driving behavior and its influencing factors. This approach could avoid the inherent problems occurred in the conventional logistic regression models and further improve the model prediction accuracy. Based on the Michigan M-94/I-94/I-94BL/I-94BR highway work zone driving behavior data, the decision tree comprising 33 leaf nodes is built. Bad weather, poor road and light conditions, partial/no access control, no traffic control devices, turning left/right and driving in an old vehicle are found to be associated with the risky driving behavior at work zones. The middle-aged drivers, who are going straight ahead in their vehicles with medium service time and equipped with an airbag system, are more likely to take risky behavior at lower work zone speed limits. Further, the middle-aged male drivers engage in risky driving behavior more frequently than the middle-aged female drivers. The number of lanes exhibits opposing effects on risky behavior under different traveling conditions. More specifically, the risky driving behavior is associated with the single-lane road under bad light or weather conditions while drivers are more likely to engage in risky behavior on the multi-lane road under good light conditions.     

深水水下测试树球阀剪切连续油管性能分析

为研究不同工况、不同结构参数对于深水水下测试树球阀剪切连续油管性能的影响,采用有限元分析软件建立剪切分析模型,对不同工况下剪切过程进行数值模拟,并与试验对比验证分析模型的准确性;结果显示,有限元模型结果与试验结果相对偏差小于5%;油管剪切过程中会出现2个剪切力矩峰值,通过分析不同工况下2个峰值变化规律,发现油管承受拉力越大、球阀剪切速度越小、球阀外径越小剪切过程所需剪切力越小,剪切性能越好。研究结果表明:得到的剪切模型及不同工况下剪切力变化规律,可为水下测试树的设计选型及现场应用提供指导及参考意义。     

改进广义灰色关联故障树的危化品LSSC可靠性诊断

为了探究影响危化品物流整体运作的关键事故因素,提出一种改进广义关联故障树的危化品LSSC可靠性诊断方法。结合实例构建危化品LSSC系统失效故障树,运用灰色关联技术对以最小割集构造的标准故障模式向量和底事件概率重要度组成的待检模式向量进行相关性分析,得到系统失效概率等级与失效故障模式可能性排序,确定系统关键薄弱环节。研究结果表明:该方法能够快速识别危化品物流运作系统关键事故因素,为危化品LSSC风险等级控制和分级防范措施制定提供参考和借鉴。     

基于BDD考虑共因失效的接触网系统可靠性分析

为分析共因失效对高速铁路接触网系统的影响，将二元决策图(Binary Decision Diagram，BDD)与共因失效理论引入到接触网系统可靠性分析中。利用逻辑相邻优先组合法(Logic Neighbor Priority Connect，LNPC)将高速铁路接触网系统的故障树模型转化为BDD模型并求取其可靠度表达式，利用隐式方法对考虑了共因失效的接触网系统可靠度进行计算，利用MATLAB绘制考虑共因失效和不考虑共因失效情况下接触网系统可靠度变化曲线。研究结果表明:提出的分析方法适用于接触网系统的可靠性分析，为接触网系统的可靠性分析提供了一定的理论依据。     

Reliability analysis of subsea blowout preventers with condition-based maintenance using stochastic Petri nets

Blowout Preventer (BOP) has maintained its function as a safety barrier and the last line of defence against oil and gas spills since its development in the early 1900s. However, as drilling and exploration activities move further offshore, challenges pertaining to reliable operation of the subsea BOP systems continue to be a source of concern for stakeholders in the industry. In spite of recent advancements in reliability analysis of safety instrumented systems (SISs), the research on reliability assessment of BOP is still lacking in some regards. There are gaps in the literature with respect to the incorporation of preventive maintenance (PM) strategies as well as dynamic operating conditions into BOP reliability analysis. To address these gaps, this paper develops an advanced analysis method using stochastic Petri nets (SPN) to estimate the reliability of subsea BOP systems subject to condition-based maintenance (CBM) with different failure modes. The BOP system is divided into five subsystems which are connected in series with each other and categorised into degrading and binary units. The performance of the BOP system in terms of availability, reliability and mean-time-between failures (MTBF) is obtained and analysed. A sensitivity analysis is also performed to evaluate the effect of fault coverage factor and redundancy design on system performance. The results show that both the fault coverage factor and redundancy have significant impact on the BOP's reliability, availability and MTBF.     

基于MTBF的光电感烟探测器可靠性研究

针对火灾探测报警系统重要组成模块—光电感烟探测器-报警控制器,根据其在实际使用过程中的不完全故障数据,改良了前人对该问题的传统研究方法,并提出了分段定时截尾可靠性参数模型。该模型主要考虑火灾探测报警系统控制器工作时序性和故障处理时间的影响,采用自主提出的原始故障数据筛选统计方法,分别求得光电感烟模块的首次使用寿命与平均故障间隔时间的参数估计。该方法能够减少火灾探测报警系统初始使用寿命过长而产生的平均故障间隔时间的估计偏差,对于火灾探测报警系统整体使用寿命的估计和维修管理有着重要意义。同时基于序贯思想的动态截尾也克服了定时截尾模型无法准确判断试验停止时间的不足,在保证参数较为精确的前提下最大限度地节省时间和资源。     

Model-based information fusion investigation on fault isolation of subsea systems considering the interaction among subsystems and sensors

The offshore oil industry has expanded to deep water and Arctic. The harsh operating conditions (e.g., ice and strong wind) and increasing complicated system raise the occurrence likelihood of system faults. This requires timely fault isolation and management in the subsea system. However, the offshore oil industry mainly relies on humans to isolate faults based on alarms. With harsh operating conditions and increasing complicated system, this industry urgently needs research on more efficient fault isolation and cause diagnosis methods. Unfortunately, limited research is conducted on fault isolation method in the offshore oil industry. Furthermore, in industry 4.0 era, large amounts of information are obtained. This provides precondition for the application of information fusion technique which aims to improve diagnosis results. However, to the authors’ knowledge, information fusion has not been much studied in the fault isolation of the offshore oil industry. Moreover, the interaction of different subsystems contains valuable information. How the interaction of different subsystems can influence the fault diagnosis has not been explored. This paper proposes a Bayesian network (BN) based method for timely fault isolation and cause diagnosis for the offshore oil industry. The work fuses different information, and it also includes the dependency among different subsystems in the fault diagnosis. As an important alarm source, false alarms are also taken into account in the model. A case study on the subject of the subsea wellhead and chemical injection systems is conducted to demonstrate the functions and merits of the proposed method.     

System failure probability evaluation using fault tree analysis and expert opinions in intuitionistic fuzzy environment

In quantitative fault tree analysis of a system, exact failure probability values of components are utilized to calculate the failure probability of the system. However, in many real world problems, it is problematic to get precise and sufficient failure data of system components due to insufficient or imprecise information about components, changing environment or new components. A methodology has already been developed by employing fuzzy set theory for the system reliability evaluation by utilizing qualitative failure data of system components when quantitative failure data of components are inaccessible or insufficient. This paper extends the concept of fuzzy set to intuitionistic fuzzy set and proposes a novel approach to evaluate system failure probability using intuitionistic fuzzy fault tree analysis with qualitative failure data of system components. The qualitative failure data such as expert opinions are collected as linguistic terms. These linguistic terms are then quantified by triangular intuitionistic fuzzy numbers in form of membership function and non-membership function. Additionally, a method is developed for combining the different opinions of experts. To illustrate the applicability of proposed approach, a case study of the crude oil tank fire and explosion accident is performed. The obtained results are very close to the results from pre-existing approaches which confirm that the proposed approach is a more realistic alternative for the study of system reliability in intuitionistic fuzzy environment when quantitative failure data of system components are not known. To help decision makers for improving the security execution of the crude oil tank system, importance measures including Fussell-Vesely importance and cut sets importance are also executed.