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.     

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 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.     

基于马尔可夫的地面控制井下安全阀可靠性评估

为保障地面控制井下安全阀系统的安全运行，防止系统发生故障，建立了井下安全阀可修复系统的马尔可夫模型；针对系统设备构成复杂及共因故障等问题，基于β因子模型描述共因失效，同时将模型划分为3个独立模块，通过克罗内克积方法合并，评估系统可靠性；参照OREDA可靠性数据，定量求解井下安全阀系统可用度、可靠度以及稳态指标，研究模型中状态转移概率对系统稳态可用度的影响。研究结果表明:井下安全阀系统的可用度随时间增长而迅速到达稳态值；系统检修周期应小于2.5 a；根据可靠性分析结果，运营方应考虑系统经济与可靠性间的博弈关系，合理优化系统冗余结构与维修周期管理，防止井下安全阀系统失效。     

铁路信号PES安全性定量分析的研究

铁路信号中的可编程电子系统 (PES)是一种安全相关系统。这类系统更注重失效 -安全 ,而不仅仅是可靠性或可用性。基于系统的可靠性分析方法 ,给出了一种安全性定量分析方法。通过把失效率划分为一些独立的部分 ,据其各自失效率的影响 ,利用 Markov模型可同时分析系统的可靠性和安全性。笔者根据铁路信号 PES常用的 2 oo2 D(附加诊断的二取二 )容错结构给出了方法应用的实例     

安全系统的故障分析

以可靠性研究为基础,分析独立和冗余配置的安全系统的故障状态,给出独立配置和冗余配置时安全系统的显性故障率、隐性故障率以及系统可用度的定量模型。以该模型对以紧急停车系统(ESD)和生产监控系统(DCS)构成的组合安全系统进行了比较和分析。笔者认为:ESD单独设置时,应注意降低隐性故障率、提高其修复率;ESD与DCS冗余配置时,无论是并联冗余还是串联冗余,安全保护功能都是增加的,但同时显性故障率有所增加,隐形故障率大大减少。因此,用ESD补充DCS的安全保护功能而不是简单的重复其功能,对提高系统的整体安全水平将是十分明显的。     

基于Isograph的地铁车载ATP系统动态故障树分析

针对传统的可靠性分析方法在具有动态特性的地铁车载ATP系统可靠性分析中的不足,提出动态故障树分析法。在引用可用度、平均失效时间和平均修复时间等可靠性指标的基础上,结合Isograph软件改进动态故障树分析法,建立基于Isograph的动态故障树分析模型,并通过对车载ATP系统的结构与功能分析以及历史故障数据的统计分析确定车载ATP系统的关键部件,使用 Isograph软件预计关键部件的可靠性参数,对地铁车载ATP系统的可靠性进行评估。结果表明:采用该方法求解的系统可靠性指标均满足系统需求,并且精确度较高,运用此方法能够对具有顺序相关、资源共享、可修复以及冷、热备份等特性的系统进行可靠性建模,达到快速以及准确分析动态特性系统可靠性的目的。     

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。     

基于人因可靠性的间歇装置SIL分析与改进

IEC 61508和IEC 61511等标准针对连续工艺装置提出了安全仪表系统安全完整性等级评估方法。但对于间歇装置的SIL评估，受人因因素影响水平并未明确，且没有提出相应计算模型。以某六氟磷酸锂间歇生产装置典型SIS为例，采用HAZOP结合LOPA方法对其进行风险分析，在明确间歇生产装置存在人员中毒、窒息及燃烧爆炸风险的基础上，确定并验证其安全仪表系统的SIL，再依据间歇生产装置人工依赖性高，即部分安全仪表系统未接入自动联锁且需人工手动触发的特点，建立人因可靠性模型，来分析人因可靠性对安全仪表系统SIL的影响，并进行改进研究。研究结果表明:人因因素对安全仪表系统SIL有显著影响；可通过改变SIS元件冗余结构、测试策略并结合改进人因管理措施来提高SIL。     

煤矿安监系统数据通信可靠性的研究

煤矿安全生产监控系统的通信网络可归纳为单分站单设备、单分站双设备、双分站单设备和双分站双设备几种组网模式,通过对其任务可靠性和基本可靠性进行比较分析,综合考虑任务完成概率和维护成本两方面的要求,提出了双分站,局部(高故障点处)双设备的组网模式,以期有效提高通信网络的系统可靠性。     

可靠性理论在公共安全领域的应用研究

对公共安全体系从系统可靠性的视角,综合运用可靠性方面的知识,构建公共安全系统混联模型;进而将可靠性分配理论与故障树分析方法相结合,根据系统安全目标的要求,确定混联系统的第一层次各单元事件的可靠性目标值,对构成各单元的各个下属单元采取最小工作量可靠度分配方法,从而建立系统中各单元可靠度再分配量化模型。通过建筑物火灾引起人员伤亡事故实例,详述系统各单元可靠性分配的计算过程。研究表明,可靠性理论可以成功地应用到公共安全领域;使系统在给定的目标值条件下达到系统的安全性优化,实现了公共安全保障效能,减小灾害损失。     

Research and application of risk and condition based maintenance task optimization technology in an oil transfer station

Oil transfer stations of PetroChina mostly scatter in Gobi, mountain areas or other sparsely populated areas, inconvenient transportation and absent professional engineers often delay the best time to repair the machines. Time-or interval-based maintenance (TBM) accounts for almost 100%, while, On-condition maintenance and other proactive maintenance are seldom adopted. TBM not only can't prevent happens of equipment fault but also cause the waste of the maintenance resource. In order to allocate maintenance resources reasonably, ascertain the minimum preventive maintenance requirement, ensure the reliability, availability and safety, this paper carries out a research on Risk and Condition Based Maintenance (RCBM) task optimization technology. Utilizing the internet of things (IOT), real-time database, signal-processing, Gray Neural Network, probability statistical analysis and service oriented architecture (SOA) technology, a Risk and Condition Based Indicator Decision-making System (RCBIDS) is built. RCBIDS integrates RCM, condition monitoring system (CMS), key performance management module, file management module, fault and defect management module, maintenance management module together, which aims to realize remote condition monitoring, maintenance technical support services (TSS), quantitative maintenance decision-making, and to ensure the Reliability, Availability, Maintainability and Safety (RAMS). The Predictive Maintenance Indicator model, reliability prediction model and Key Performance Indicator (KPI) model, which are embedded in the RCBIDS, are constructed separately. An engineering case shows that the risk and condition based maintenance task optimization technology can be used to optimize maintenance content and maintenance period, to minimize maintenance deficiencies and maintenance surplus, and to prolong the lifespan of equipment.     

基于JSA-BN的水上提管维修作业风险分析

为保障海底油气管道维修作业安全,提出1种基于JSA-BN的作业风险分析方法。采用JSA方法辨识分析水上提管维修作业过程中潜在的风险因素,得出不同作业步骤的风险等级;建立水上提管维修作业贝叶斯网络模型,计算出各作业环节的成功概率;依托贝叶斯网络的逆向推理及敏感性分析能力,实现水上提管维修作业风险薄弱点的定量预测和评估。研究结果表明:提出的基于JSA-BN的作业风险分析方法可应用于近岸海底管道应急维修作业风险分析;在整个水上提管维修作业活动中,提管作业和切割破损管道作业为关键作业环节,提升过程中碰撞、掉落事件为薄弱风险因素。     

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。     

基于危险工艺装置设置安全联锁系统的研究

针对危险工艺装置设置安全联锁系统(SIS)问题进行分析和研究,提出在装置建设和改造中,应合理设置独立的SIS,并根据生产装置的安全度等级选择合适的联锁回路,并具有一定的冗余能力,以避免由于硬件随机失效或系统故障时造成联锁功能无法执行;指出SIS在设计时应遵循独立原则、故障安全型原则、共享原则、可靠性原则等。研究结果表明:SIS可提高化工装置的本质安全度,保障生产过程的安全、稳定运行,最大限度地减少由于过程失控造成的人身伤害和设备损坏。     

Model selection and fault detection approach based on Bayes decision theory: Application to changes detection problem in a distillation column

The fault detection of industrial processes is very important for increasing the safety, reliability and availability of the different components involved in the production scheme. In this paper, a fault detection (FD) method is developed for nonlinear systems. The main contribution consists in the design of this FD scheme through a combination of the Bayes theorem and a neural adaptive black-box identification for such systems. The performance of the proposed fault detection system has been tested on a real plant as a distillation column. The simplicity of the developed neural model of normal condition operation, under all regimes (i.e. steady-state and unsteady state), used in this case is realised by means of a NARX (Nonlinear Auto-Regressive with eXogenous input) model and by an experimental design. To show the effectiveness of proposed fault detection method, it was tested on a realistic fault of a distillation plant of laboratory scale.     

可靠性分配理论在系统安全目标实现中的应用

在系统安全理论中,确定各基本事件的可靠度以实现所给定的系统安全目标值问题一直没有得到很好解决。笔者将可靠性分配理论与故障树分析方法相结合,提出了2个层次可靠度分配法:最小割集之间采取可靠度再分配法,对构成最小割集的各个基本事件之间采取等分配法。从而建立系统中各单元可靠度再分配量化模型。为便于应用,通过实例,详述系统各单元可靠性分配的计算过程。研究表明,运用该模型可准确、简便地计算出各单元的可靠度,使系统在给定的目标值条件下达到系统的安全性优化。     

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.