FINAL PROJECT

RELIABILITY AND PROCESS QUALITY

Evaluation of Reliability, Maintainability, and Safety In High Pressure Separator V-101

Area Hydrofinishing Unit PT. AGIP

RELIABILITY ENGINEER :

Revi Adikharisma

NRP. 2412105021

Arfittariah

NRP. 2412105020

Arief Budhiyono

NRP. 2412105018

DEPARTMENT OF ENGINEERING PHYSICS

FACULTY OF INDUSTRIAL TECHNOLOGY
SEPULUH NOPEMBER INSTITUTE OF TECHNOLOGY
SURABAYA
2013

I. PIPING AND INSTRUMENTATION DIAGRAM

II. HIGH PRESSURE SEPARATOR V-101

2.1

Process Description
High Pressure Separator is a unit that served as a separator two phase or three phase
such as oil, water, and gas. In the area of 100 - hydrofinishing unit in the recycle section,
high pressure separator separates the gas phase and liquid phase which will be passed to
the next process. Inputs that go into the high pressure separator comes from refining
reactor. Gas phase will be forwarded to the washing water receiver, while the liquid phase
is passed to the stripper.
At high pressure separator where the control loop there is a controlled flow and level.
For there is a level loop LT1008 and an electrical signal is passed to LIC1008. Of LIC1008,
will be forwarded to FIC1002 where the system is a cascade system. For the inputs that go
into FIC1008 also obtained from FE1002 and FT1002 that sense of flow in the pipe. Signal
indicating that the controller has entered into will be continued to the I / P ie FY1002 in the
form of electrical signals and converted to pneumatic signal to command flow control valve.
Here is a flow control valve normally open or fail close.
In the unit there is also a protection system with sensors LSLL1010. Where the signal
of LSLL1010 which will be forwarded to an alarm LALL1010 from the system. Unsafe level
readings are also accepted by XY1010 solenoid valve to shut - off valve on XV1010 order
flow from high pressure liquid phase separator does not continue to flow and keep the level
so it is not in a state of low - low.

2.2

I/O Equipment List

NO

TAG

SYMBOL

DESCRIPTION

1 LG 1008

LEVEL GLASS

2 LT 1008

LEVEL TRANSMITTER

3 LIC 1008

LEVEL INDICATING CONTROLLER

4 FIC 1002

FLOW INDICATING CONTROLLER

5 FT 1002

FLOW TRANSMITTER

6 FE 1002

FLOW ELEMENT

7 FY 1002

I/P

8 FCV 1002

FLOW CONTROL VALVE

9 LSLL 1010

LEVEL SWITCH LOW LOW

10 LALL 1010

LEVEL ALARM LOW LOW

11 XY 1010

SOLENOID VALVE

12 XV 1010

ON-OFF VALVE

III. MAINTENANCE DATA AND RELIABILITY DISTRIBUTION

3.1 Maintenance Data of HP Separator V-101
LT 1008
Occurence
Date
3-Oct-06
5-Nov-06
7-Jan-07
2-Mar-07
17-May-07
10-Jul-07
20-Jul-07
9-Aug-07
13-Aug-07
12-Oct-07

Occurence
Time
7:00:00
3:00:00
16:00:00
9:00
15:00
11:00:00
21:00:00
16:00:00
20:00:00
9:00

Completion
Date
3-Oct-06
9-Nov-06
11-Jan-07
8-Mar-07
20-May-07
13-Jul-07
25-Jul-07
10-Aug-07
16-Aug-07
16-Oct-07

Completion
Time
7:00:00
11:00:00
15:00:00
20:00
16:00
21:00:00
15:00:00
14:00:00
21:00:00
15:00

TTF
(Day)
0
33
59
50
70
51
7
15
3
57
MTTF

TTF (Hours)
0
792
1416
1200
1680
1224
168
360
72
1368
828

Probability Density Function

0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

200

400

600

800

1000

1200

1400

1600

x
Histogram

Weibull

Parameter Weibull : = 1.4539 ; = 1003.2 ; = 0

TTR
(Hours)
0
104
95
155
73
82
114
22
73
102

Probability Density Function

0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

200

400

600

800

1000

1200

1400

1600

x
Histogram

Normal

Parameter Normal : = 629.95 ; = 828

Probability Density Function

f (1000) =

= 0,00039

LIC 1008

Occurence
Date
4-Feb-06
18-May-06
28-Oct-06
10-Jan-07
16-May-07
5-Jun-07
13-Jul-07
13-Oct-07
26-Feb-08
19-Mar-08

Occurence
Time
13:00:00
2:00:00
7:00:00
17:00:00
13:00
8:00
14:00
18:00:00
17:00:00
17:00:00

Completion
Date
4-Feb-06
21-May-06
29-Oct-06
12-Jan-07
23-May-07
12-Jun-07
18-Jul-07
16-Oct-07
2-Mar-08
22-Mar-08

Completion
Time
13:00:00
16:00:00
2:00:00
17:00:00
15:00
6:00
19:00
16:00:00
15:00:00
8:00:00

TTF
(Day)
0
103
160
73
124
13
31
87
133
17
MTTF

TTF
(Hours)
0
2472
3840
1752
2976
312
744
2088
3192
408
1778.4

TTR
(Hours)
0
86
19
48
170
166
125
70
142
63

Probability Density Function

0.4
0.36
0.32
0.28

f(x)

0.24
0.2
0.16
0.12
0.08
0.04
0
0

400

800

1200

1600

2000

2400

2800

3200

3600

x
Histogram

Weibull

Parameter Weibull : = 1.5794 ; = 2190.5 ; = 0

Probability Density Function
0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

400

800

1200

1600

2000

2400

2800

3200

x
Histogram

Normal

Parameter Normal : = 1354.9 ; = 1778.4

Probability Density Function

3600

f (1000) =

= 0,00017

FIC 1002
Occurence
Date
9-Sep-06
18-Dec-06
24-Feb-07
10-Apr-07
16-Jul-07
5-Sep-07
13-Dec-07
13-Feb-08
26-Jul-08
1-Sep-08

Occurence
Time
21:00:00
5:00:00
4:00:00
21:00:00
13:00
9:00
14:00
15:00:00
17:00:00
16:00:00

Completion
Date
9-Sep-06
21-Dec-06
26-Feb-07
12-Apr-07
23-Jul-07
12-Sep-07
18-Dec-07
16-Feb-08
28-Jul-08
12-Sep-08

Completion
Time
21:00:00
20:00:00
8:00:00
19:00:00
15:00
6:00
16:00
16:00:00
19:00:00
6:00:00

TTF
(Day)
0
100
65
43
95
44
92
57
161
35
MTTF

TTF
(Hours)
0
2400
1560
1032
2280
1056
2208
1368
3864
840
1660.8

Probability Density Function

0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

2000

2500

3000

3500

x
Histogram

Weibull

Parameter Weibull : = 2.1984 ; = 2094.8 ; = 0

TTR
(Hours)
0
87
52
46
170
165
122
73
50
254

Probability Density Function

0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

2000

2500

3000

3500

x
Histogram

Normal

Parameter Normal : = 1073.5 ; = 1660.8

Probability Density Function

f (1000) =

= 0,00021

FT 1002
Occurence
Date
7-Nov-06
3-Dec-06
3-Feb-07
4-Apr-07
21-Jun-07
8-Aug-07
25-Aug-07
6-Sep-07
18-Sep-07
2-Nov-07

Occurence
Time
7:00:00
8:00:00
13:00:00
5:00
21:00
1:00:00
18:00:00
18:00:00
15:00:00
1:00

Completion
Date
7-Nov-06
12-Dec-06
11-Feb-07
6-Apr-07
24-Jun-07
13-Aug-07
27-Aug-07
10-Sep-07
24-Sep-07
16-Nov-07

Completion
Time
7:00:00
11:00:00
21:00:00
14:00
17:00
14:00:00
15:00:00
14:00:00
21:00:00
15:00

TTF
(Day)
0
26
53
52
76
45
12
10
8
39
MTTF

TTF
(Hours)
0
624
1272
1248
1824
1080
288
240
192
936
770.4

TTR
(Hours)
0
219
200
57
68
133
45
92
150
350

Probability Density Function

0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

x
Histogram

Weibull

Parameter Weibull : = 1.6314 ; = 956.71 ; = 0

Probability Density Function
0.44
0.4
0.36
0.32

f(x)

0.28
0.24
0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

x
Histogram

Normal

Parameter Normal : = 594.1 ; = 770.4

Probability Density Function

f (1000) =

= 0,0004

FCV 1002
Occurence
Date
7-May-06
14-Sep-06
30-Nov-06
11-Jan-07
7-Feb-07
8-Apr-07
19-Apr-07
9-Jun-07
11-Sep-07
2-Dec-07

Occurence
Time
2:00:00
21:00:00
20:00:00
14:00:00
20:00:00
16:00
14:00
21:00
20:00:00
3:00

Completion
Date
7-May-06
15-Sep-06
30-Nov-06
19-Jan-07
9-Feb-07
13-Apr-07
19-Apr-07
12-Jun-07
13-Sep-07
7-Dec-07

Completion
Time
2:00:00
21:00:00
16:00:00
1:00:00
5:00:00
15:00
18:00
16:00
10:00:00
21:00

TTF
(Day)
0
130
76
42
19
58
6
51
91
80
MTTF

TTF
(Hours)
0
3120
1824
1008
456
1392
144
1224
2184
1920
1327.2

TTR
(Hours)
0
24
20
179
33
119
28
67
38
138

2500

3000

Probability Density Function

0.32
0.28
0.24

f(x)

0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

2000

x
Histogram

Weibull

Parameter Weibull : = 1.6616 ; = 1637.0 ; = 0

Probability Density Function

0.32
0.28
0.24

f(x)

0.2
0.16
0.12
0.08
0.04
0
0

500

1000

1500

2000

2500

3000

x
Histogram

Normal

Parameter Normal : = 976.59 ; = 1327.2

Probability Density Function

f (1000) =

= 0,00025

3.2 System Reliability of HP Separator V-101

LT

LIC
FCV

FT

FIC

In the picture above can be seen that the system is a serial (LT - LIC and FT - FIC)
which both can be considered parallel and then forwarded to the FCV to be serial. We
conclude if that system is serial systems.

Cumulative Distribution Function

LT 1008

F (1000) =

= 0,57

R(1000) = 1 F(t)
= 1 - 0,57 = 0,43

LIC 1008

F (1000) =

= 0,36

R(1000) = 1 F(t)
= 1 - 0,36 = 0,64

FIC 1002

F (1000) =

= 0,35

R(1000) = 1 F(t)
= 1 - 0,35 = 0,65

FT 1002

F (1000) =
R(1000) = 1 F(t)
= 1 - 0,59 = 0,41

= 0,59

FCV 1002

F (1000) =

= 0,42

R(1000) = 1 F(t)
= 1 - 0,42 = 0,58

Total System Reliability for 1000 hours

R (t)

= ( R (LT) . R (LIC)) + (R(FT) . R(FIC)) . R(FCV)

= (0,43 . 0,64) + (0,41 . 0,65) . 0,58

R(1000)

= 0, 31

Reliability for 720 Hours, 4320 Hours, and 8640 Hours

LT 1008

F (720) =

= 0,46

R(720) = 1 F(t)
= 1 - 0,46 = 0,54

F (4320) =
R(4320) = 1 F(t)
= 1 - 0,99 = 0,01

= 0,99

F (8640) =

= 0,99

R(8640) = 1 F(t)
= 1 - 0,99 = 0,01

LIC 1008

F (720) =

= 0,31

R(720) = 1 F(t)
= 1 - 0,31 = 0,69

F (4320) =

= 0,86

R(4320) = 1 F(t)
= 1 - 0,86 = 0,14

F (8640) =

= 0,99

R(8640) = 1 F(t)
= 1 - 0,99 = 0,0,01
FIC 1002

F (720) =

= 0,29

R(720) = 1 F(t)
= 1 - 0,57 = 0,71

F (4320) =

= 0,92

R(4320) = 1 F(t)
= 1 - 0,92 = 0,08

F (8640) =

= 0,99

R(8640) = 1 F(t)
= 1 - 0,99 = 0,01

FT 1002

F (720) =

= 0,48

R(720) = 1 F(t)
= 1 - 0,48 = 0,52

F (4320) =
R(4320) = 1 F(t)
= 1 - 0,99 = 0,01

= 0,99

F (8640) =

= 0,99

R(8640) = 1 F(t)
= 1 - 0,99 = 0,01
FCV 1002

F (720) =

= 0,34

R(720) = 1 F(t)
= 1 - 0,34 = 0,66

F (4320) =

= 0,96

R(4320) = 1 F(t)
= 1 - 0,96 = 0,04

F (8640) =

= 0,99

R(8640) = 1 F(t)
= 1 - 0,99 = 0,01

From the simulation results by taking the example of 720 hours, 4320 hours and 8640 hours
can be seen that the reliability of each equipment will decrease. it can be seen from the value of
R at the time of 720 hours to 4320 hours to 8640 hours onwards decreased. so the longer it is
used, the level of reliability of the equipment will decrease and result in damage.

IV . FAILURE MODE AND EFFECT ANALYSIS (FMEA)

No

Item

Level
Degradation
Transmitter
of range
LT-1008
reading

Level
Indicating
Controller
LIC-1008
Flow
Indicating
Controller
FIC-1002

Flow
Transmitter
FT-1002

Flow
Control
Valve
FCV-1002

Potential
failure
mode

Manufacting
defect

Wrong
signal

Failed to
flow sensing
Positioner
stuck/ failed
open
(premature
open)

Potential
effect of the
failure
Level tank
over high
and allow
explosion
Cannot
transmit
signal to
FIC
normally
Cannot give
command to
FCV
Cannot
transmit
process
variable
present
value
Over
pressure
and allow
explosion

Severity

Probability Critical
(occurence)
rank

Recommended
Action

II

2/B

Check and
calibration
transmitter

III

4/D

Check signal
cable

II

3/C

Check signal
cable

Check and
calibration
transmitter

Check
postioner or
diaphragma
valve

III

1/A

5/E

Notes :
High Risk
Medium Risk
Low Risk

Can be seen from the the above table that the level transmitter failed degradation of
range reading which will cause the tank level will be high and could explode. For the severity
level is II, occurence probability 2/B, critically rank 1. Recommended action is to check and
calibration transmitter.
Level indicating controller failed manufacturing defect which will cause cannot transmit
signal to flow indicating controller. For the severity level is III, occurence probability 4/D,
critically rank 3. Recommended action is to check signal cable
Flow indicating controller failed wrong signal which will cause cannot give command to
flow control valve. For the severity level is II, occurence probability 3/C, critically rank 4.
Recommended action is to check signal cable.
Flow transmitter failed to flow sensing which will cause cannot transmit process variable
present value. For the severity level is III, occurence probability 1/A, critically rank 4.
Recommended action is to check and calibration transmitter.
Flow Control Valve failed positioned stuck or failed open which will cause over pressure
and allow explosion. For the severity level is I, occurence probability 5/E, critically rank 1.
Recommended action is to check positioned or diaphragma valve.

V . FAULT TREE ANALYSIS (FTA)

In the picture above can be seen that the top event is the state failed to separated which is
caused by over-pressure, gas dehydrator trip, and flow turbulence. Three are the logical choice
for the top event. After that is below the over-pressure basic events such as pump impeller was
broken and the control valve to fail closed with OR logic. For gas dehydrator is caused by overtemperature, fluid viscosity, and safety devices not work with OR logic. Different with flow
turbulence events caused by three causes the friction on the pipe, shear induced structure, and
pipe leakage where the three cause have an AND logic.

VI . RELIABILITY UNDER PREVENTIVE MAINTENANCE (MAINTAINABILITY)

With T =30 days ; n = 1

FT 1002
No

1
2
3
4
5

0 hours
720
hours
1000
hours
4320
hours
8640
hours

R(t)

R(t-nT)

Rm(t)

No PM

PM

Cumulative PM

0, 99

0,52

1384,6

0, 85

0,41

2439

0, 82

0,01

432000

0, 77

0,01

864000

0, 60

R(t)

R(t-nT)

Rm(t)

No PM

PM

Cumulative PM

0, 99

0,66

1090,9

0, 92

0,58

1724,1

0, 88

0,04

108000

0, 86

0,01

864000

0, 80

1,63

957

1,63

957

1,63

957

1,63

957

1,63

957

FCV 1002
No

1
2
3
4
5

0 hours
720
hours
1000
hours
4320
hours
8640
hours

1,66 1637
1,66 1637
1,66 1637
1,66 1637
1,66 1637

VII. ISHIKAWA DIAGRAM