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.     

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.     

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.     

A capping technique for emergency response in offshore blowout accidents

Capping stack is an emergency shut-in technique that can effectively control offshore blowout accidents. This technique stemmed the spilled oil well (Macondo) in 2010 Deepwater Horizon blowout accident. However, few efforts have been devoted to studying the way to efficiently and safely conduct the operation of capping stack. In this paper, program evaluation and review technique (PERT) was employed to quantitatively design the operation procedure of capping stack. A mechanical model was established to determine the configuration scheme of capping stack. And a sensitivity analysis of operational factors of capping stack was conducted through orthogonal tests. Experimental results recommend to optimize the operation process by reducing the working time of diamond cutting tool down-pass, Lower Marine Riser Package (LMRP) upper riser incision, LMRP and original Blowout Preventer (BOP) separation, and LMRP recovery, in order to guarantee that the whole operation can be completed as scheduled. The results show that the number of ram BOPs has little effect on the equivalent stress of conductors. To improve system reliability, a five-ram capping stack is recommended to be applied in the defined accident scenario. The maximum equivalent stress of conductors rates the drilling vessel offset as the primary factor, followed by shut-in pressure, ocean current and top tension. The drilling vessel offset needs to be given the priority control and the shut-in pressure should be jointly monitored.     

钻井井喷失控因素分析及预防对策

井喷失控是钻井中的灾难性事故,有必要开展井喷失控研究,找到井喷失控发生的原因和提出防止井喷失控的对策。在统计分析1970年到2009年间中石油发生在钻进过程中的48例井喷失控事故的基础上,通过对防喷器、节流压井管汇、套管、井喷后爆炸起火等井喷失控因素分析,并利用MLS法对上述各种井喷失控因素危险值进行评估。最后,根据井喷失控因素分析和危险值评估结果,结合现有的钻井井控设计,提出了防止钻井井喷失控的对策。     

Integrated framework to optimize RAM and cost decisions in a process plant

The research implications of reliability, availability and maintainability (RAM) aspects of engineering systems in recent years have increased substantially due to rising operation and maintenance costs. To strike a balance between the two the paper presents a framework which makes use of both qualitative and quantitative techniques to optimize RAM and cost decisions in a process plant. In the quantitative analysis, the imprecise and vague information regarding the system failure behavior is quantified by using the principles of fuzzy mathematics in terms of fuzzy and crisp values. Further, to manage the system reliability for best economic performance a resource optimization model based on multi-stage decision making (MSDM) has been proposed. The model makes use of crisp output values of unit's reliability along with relevant system information (number of components, manpower, cost ranges). In the qualitative analysis the in-depth analysis of the system is carried out using Root Cause analysis (RCA) and Failure Mode & Effects Analysis (FMEA). The ambiguities associated with the traditional FMEA are handled using Fuzzy Decision Making System (FDMS) and Grey Relation Analysis (GRA). The suggested framework has been illustrated with the help of a case.     

基于系统动力学的井喷事故仿真研究

为动态预测井喷事故发展过程,在分析导致井喷事故主要因素的基础上,结合系统动力学的相关原理,构建井喷事故系统仿真流图,并运用系统动力学仿真软件Vensim对井喷事故的整体流程进行仿真,实现了对油气井安全水平的动态监测和预警。结果表明:井喷事故的发生是由人为因素、管理因素、环境因素、设备因素和法律法规因素四大子系统的交叉耦合作用而导致整个油气井系统的安全水平低于井喷事故的安全临界点所造成的。     

Modeling and optimizing efficiency gap between managers and operators in integrated resilient systems: The case of a petrochemical plant

The reliability issue in complex industrial systems such as oil, gas, petrochemical companies, nuclear and aviation industries has been of great importance. Resilience engineering (RE) is a new attitude toward the improvement of safety and reliability in the stated systems. One of the challenges a resilient system might face is the gap between work as imagined by managers and work as actually done by operators. This study will introduce a new framework named integrated resilience engineering (IRE) as a result of developing the concept of RE. The data used in this research have been obtained by means of questionnaire from a petrochemical company. Thereafter, the efficiency of operators and managers are calculated in RE and IRE frameworks through data envelopment analysis (DEA) approach. Then, the gaps between managers and operators are analyzed in two frameworks. The results are indicative of a significant growth in the number of efficient operators and managers in IRE framework compared to RE framework. Besides, the efficiency mean of managers and operators in IRE framework has experienced the growth of 1.8% and 5% compared to RE framework, respectively. The efficiency gap between managers and operators in IRE framework has also enjoyed the improvement of 88% compared to RE framework. Generally, it can be said that the suggested items of this research has led to the betterment of managers and operators’ efficiency and of the efficiency gap between them. Therefore, these items can improve the resilience and safety of complex systems. The results of Spearman test show that there is a strong direct correlation between the DEA results in two frameworks. This is the first study that examines the efficiency gap between operators and managers based on the RE principles and by means of DEA approach.     

基于AMESim的带压作业防喷器关闭性能仿真

针对带压作业防喷器关闭时易发生井涌、管柱失稳和闸板胶芯磨损等问题，基于AMESim软件分析了防喷器闸板关闭过程中的位移和速度特性，揭示了防喷器操作压力和井筒压力2个因素对于闸板动作响应的影响规律；利用Abaqus软件分析了防喷器关闭时闸板胶芯与管柱的接触应力及其分布；结合防喷器闸板关闭过程中的位移、速度特性，得到了不同井筒压力时防喷器闸板操作压力的推荐值。研究结果表明:根据不同的井筒压力精确控制防喷器闸板的操作压力，既能迅速关闭闸板有效密封井筒，又能防止防喷器闸板关闭后胶芯与管柱间的接触力过大，从而减小胶芯的磨损和起下管柱阻力。以此方法确定的防喷器闸板操作压力推荐值，可为PLC引入带压作业装置控制系统，实现防喷器操作的精确控制提供依据。     

自动抢接止回阀装置液压系统设计及仿真分析

利用井口自动化装置进行石油钻井过程中溢流、井喷时的关井作业是目前井控作业的热点。为了有效减少工作人员操作时间,保证装置的可靠性。提出了1种自动抢接止回阀装置,并将装置的控制系统设计成全液压系统。基于AMEsim对设计的液压系统进行建模以及模拟仿真分析,得到了执行元件（3个液压马达和1个伸缩液压缸）的输出特性曲线,然后与理论计算、设计及选型的执行元件的参数进行对比。研究结果表明:设计的液压回路可以确保自动抢接止回阀装置的整个工作过程正常、稳定的进行。设计的自动抢接止回阀装置的性能基本满足使用要求,具有一定的实用价值。     

Qualitative risk assessment of a Dual Fuel (LNG-Diesel) system for heavy-duty trucks

A Dual Fuel (LNG-Diesel) system can be applied to heavy-duty diesel trucks for achieving environmental benefits in comparison to existing diesel vehicles. Because of lack of reports about risk assessment of this technology, we performed a qualitative assessment based on a framework of some literature techniques for risk identification, analysis and evaluation. After constructing a Reliability Block Diagram (RBD) to establish the context, we conducted bow-tie analysis, Fault Tree Analysis (FTA), Failure Mode and Effects Analysis (FMEA), likelihood and consequence analysis, and used a risk matrix. We applied these methods and techniques qualitatively to identify causes (e.g. collisions), critical events (e.g. releases of natural gas), related consequences (e.g. fires and explosions), and different possible pathways from a specific cause to its consequence, and to assess some negative accident scenarios related to use and parking of the vehicle. The bow-tie analysis also allowed to make explicit barriers and controls that prevent critical events and/or mitigate consequences. Therefore, we identified a set of safety measures, including design, technical, management, and emergency actions, which shall be implemented in each step of the system's life cycle.Our risk assessment showed that the risk level of the Dual Fuel (LNG-Diesel) system is similar to the risk level of a traditional diesel system. Future research will overcome current lack of data and, therefore, permit a quantitative rating of the risk of the Dual Fuel (LNG-Diesel) system.     

油气井井筒系统可靠性评价方法与应用

为了保障油气井尤其是高温高压含腐蚀性流体油气井的安全长效生产，针对油气井井筒结构设计的可靠性开展研究。利用可靠性原理，通过分类分析典型油气井井筒部件构成，开展井筒可靠性定量分析方法设计，建立了油气井井筒系统可靠性框图和井筒部件、系统可靠性定量分析数学模型；采用该分析方法对Y油田进行井筒系统可靠性定量估评，估评结果表明:如果采用针对性的措施工艺设计，该油田井筒系统可靠度在投产十年后为0.794 8，与常规设计相比可靠度提高165.64%；评估结果可为Y油田井筒系统设计提供参考；从应用情况来看，与预计情况相符。     

影响大型复杂机械钢结构系统可靠性的因素分析

以结构力学为理论依据,以有限单元法为基础,借助和参考有关有限元程序设计方法,按照结构系统可靠性失效模式分析的要求,采用编程语言研制成功基于有限元的可靠性分析软件RAPS(Reliability Analysis Program of Structure based on FEM),运用该软件对立体车库钢结构的可靠性进行具体的分析;对判定结构系统失效与否的失效准则进行讨论和分析,并针对立体车库钢结构,得出合理的失效准则和系统可靠度的计算方法;通过实例说明约界参数CAP、失效路径长度和系统复杂程度对失效准则和系统可靠度结果的影响。     

油气管道腐蚀可靠性的贝叶斯评价法

对油气管道腐蚀危害因素进行分析,建立其失效故障树。根据故障树分析原理,找出导致管道腐蚀穿孔破坏的23个因素。通过对故障树的定性分析,采用下行法求出油气管道腐蚀失效故障树的96个全部最小割集,并确定失效的主要影响因素。结合最小割集不相交化法和贝叶斯可靠性评定法对管道腐蚀失效进行定量分析,通过某油气管道事故统计数据,利用贝叶斯可靠性评定方法求出油气管道腐蚀可靠性的一阶矩和二阶矩。对一阶矩和二阶矩进行拟合,求出油气管道腐蚀可靠性的第一近似下限和第二近似下限。结果表明:得出的油气腐蚀管道贝叶斯可靠性评价结果可以指导管道系统的维护和维修,降低管道运行的风险。     

A safety culture maturity model for petrochemical companies in Brazil

A framework to measure safety culture maturity in the Brazilian oil and gas companies was formulated based on the model of Hudson (2001). Following a review of the safety culture literature, a questionnaire was designed to measure five aspects of organisational safety indicative of five levels of cultural maturity. The questionnaire was completed by the safety managers of 23 petrochemical companies based in Camacari, Bahia, Brazil and they were interviewed one month later. The reliability of the questionnaire was tested by asking the same questions in an interview and comparing the results (alternate forms reliability). The correlation coefficients between the questionnaire and interview scores on each dimension ranged from r = 0.7 to 0.9, demonstrating good reliability of the measures used. The research findings demonstrated that the 23 companies studied showed characteristics of different levels of safety culture maturity. Most scores were at the level of proactive. The model of Hudson (2001) and the revised framework and questionnaire were found to be practical to use, making it possible to identify levels of safety culture maturity in the context of the Brazilian petrochemical industry.     

A safety barrier-based accident model for offshore drilling blowouts

Blowout is one of the most serious accidents in the offshore oil and gas industry. Accident records show that most of the offshore blowouts have occurred in the drilling phase. Efficient measures to prevent, mitigate, and control offshore drilling blowouts are important for the entire offshore oil and gas industry. This article proposes a new barrier-based accident model for drilling blowouts. The model is based on the three-level well control theory, and primary and secondary well control barriers and an extra well monitoring barrier are established between the reservoir and the blowout event. The three barriers are illustrated in a graphical model that is similar to the well-known Swiss cheese model. Five additional barriers are established to mitigate and control the blowout accident, and event tree analysis is used to analyze the possible consequence chains. Based on statistical data and literature reviews, failures of each barrier are presented. These failures can be used as guidance for offshore drilling operators to become aware of the vulnerabilities of the safety barrier system, and to assess the risk related to these barriers. The Macondo accident is used as a case study to show how the new model can be used to understand the development of the events leading to the accident. The model can also be used as an aid to prevent future blowouts or to stop the escalation of events.     

安全苛求系统的交叉验收框架

交叉验收是一个涉及技术和法律的工作,其目的是在新项目中能够尽快地应用类似的产品、系统和方法(PSP)。交叉验收的PSP首先要求在原始的应用中能够满足可靠性、安全性和环境要求。PSP目标和原始的应用应具有很好的相似性,因此,不需要很大的改动,在技术上和经济上可行性会很强。当然,交叉验收从根本上来说和PSP的安全性和适用性有关。目前交叉验收缺乏系统的指导和专门的标准,笔者阐述的一个基于风险分析的结构化PSP交叉验收框架包括7个主要原则。该框架基于笔者多年在安全苛求系统和铁路领域开发应用控制风险和安全确信系统框架的经验,采用通行的原则,对于目前还未建立交叉验收系统框架的安全苛求系统尤其适用。     

HAZOP、LOPA和SIL方法的应用分析

通过概括介绍危险与可操作性分析(HAZOP)、保护层分析(LOPA)和安全完整性等级分析(SIL)三种方法的特点,总结三种分析方法之间的关系.LOPA分析是HAZOP分析的继续,可以解决HAZOP分析中残余风险不能定量化的不足,是对HAZOP分析结果的丰富和补充;SIL分析则在LOPA分析的基础上,进一步对需要增加的安全仪表系统(SIS)进行设计,并对LOPA分析结果进行验证,即HAZOP、LOPA分析是SIL分析的前期准备工作.因此,在详细介绍SIS的组成、安全生命周期阶段、SIL的选择确定方法以及SIL分析流程之前,也简要介绍了HAZOP、LOPA分析方法,梳理了两种方法的分析流程.最后通过引入示例来展示三种分析方法之间的关系.     

基于DEMATEL/ISM的深水井喷风险影响因素研究*

为提高深水井喷事故风险管理水平，提出研究深水井喷风险影响因素的分析方法。从技术、人员、环境和管理4个方面，识别深水井喷事故风险致因因素，建立深水井喷事故风险评价指标体系；运用矩阵决策实验室分析法（DEMATEL），研究风险因素之间的相互影响关系，计算不同风险因素的中心度和原因度，确定关键风险因素；进一步基于解释结构模型（ISM）划分不同影响因素的层次结构，分析风险因素之间的综合影响关系，建立深水井喷事故风险影响因素模型。结果表明:层级1为近邻致因，可直接导致井喷事故的发生；层级2~7为过渡致因，在风险传递过程中起到桥梁作用，对井喷事故的直接影响较小；而层级8则为本质致因，重视本质致因的改善有利于从根源上降低井喷事故的风险。研究结果可为深水井喷事故风险的预防和控制提供理论依据。