Shell Global Solutions

Usual Fail ure rvtoqes

d [or T vt,tcat KeTtnerv
M R f¡ Equtrrmen
I E Update: April 2000
Data is confidential and should be used for the sole purpose of S-RCM analysis.
AII values are indicative. Site/Company conditions and experience of own personnel should be primary source of failure data.
Careful evaluation should be made before usinq this data for a particular application as the same failure scenarios mav not aoolv.
Estimation of MTBF w/o PM Usual MTBF With PM ETBC (examples)
(No attention to the equipment) (Full attention to the equipment) (Estimated Between Time
Consequences, as per OP99-
0517; Average from previous S-
Pr/\f\/l cfr r¡liac\
ROTATING EQUIPMENT
Blowers lcombustíon Ah/Flue oas)
FD Fañ rotor daFage (ro :9q --_ ---- 5 !o 1 O _
y.fs
-:-- --'r0 to-30yrl yrs-
.Brúpm
lD Fan rotor damage (rotor change-out) 5 to 0 yrs >20 to 30 yrs >25'5O
to >50 yrs
rF5tls--,--@
1

(ball)
Bearing f¿ilurc _ _0.5to4yls 5to'10yrs >20 yrs _
go_gglllElgi!!1(greased) 2to4yts ___>15yrs >25 yrÉ (not eñough data)
__,
> 15 yrs ___
_q9_!pl¡9_fa¡turo,1!9!g9e!9!.rn9!ÉE !1,-_
tQll]lg qemeCe 1oto1syrs ' 15 yls '15
yrs
:?s-y.l!ot g".!Sh qgt ).._.,
__ _Gp p"lLq-ali s.p.s-g[ g) * -,
'20y8
9n - -->1:.3!-Yrs
Belt failure lto5yrs to 5 yrs

Rotor failure (rotorchange-out) 5 to 20 yrs >25 yrs (not enough data)

Fouling (appl ication specific) 2 to 12 yrs 2 to 20 yrs >30 yrs
9ee[!gle!!]Ie (qleeve bearinss) '10 ylq >30 >50 yrs
,99-!rp!ru&!{rslsrgeiqql - ,19_tp*?9- r-s __ 10 to 25 >25
>25 vrs (not enough data)
9e_uilltglellglgOon:gFei,e_Q."ln9nqr"?rc1qrgph.) *---_,]_l_!q_?l itlqz9vF
Seal failure
Guide Vanes failure
l to5yrs , * 1_-19_13vr: ___.ll€lvn je]g)-
:?9yt_(n9l9!9ss! --_
Comp ressors - rgci p rocatjl¡q
qlo_sgq
Valve failure __ o
0.5to4yB
0.5 to 3
l to8yrs 'l !q ?!Jrs
-q9!p$l!l9u!!9 !9fl!!S9!jl9* __ _ >5 to 100yrs
yrs
Rod packing failure __ 0.5 to 2 yrs 2 io 4 yrs _ >0.25 to 20 ,.___

,q$gAqUS_y9l!9:_Ejlg9_ _ o.5to2yr1__ 0 s_tgl}Is __ >10yrs__

Lubrlcatiglryglglllailure stoJgtF _,_ 10to20yrs >10yrs (nol enough data)
> 20 yrs , ___,,'-:?SJIL >25 yrs {not enoush data) _
.lisl9!-E9!_ejlg9_
Cylinder Lining failure _ _,--,__ 0 5 q1JE _?9 yIL_ >25 yrs (flot snough dala) ,--
Cooling System failure (app!g¡!iLsps9{a_ 0.51o 10 yrs _j?qIE__ >25 yrs (Lot enough data) __

_g*Eqgerepellqlleillrte ,1lo 8-vr9- --_81o ?9_vr9- -_-_ _- >25 yrs

Bearing lailure to 4
1 yrs 8 to 10 yrs >25 yls (not enough data)
Belt failure 0.5 to 4 yrs
Pii¿h ¿tñtroi mechañsm 9lq_?s vrg-
Gear Boxes (soecial purpose)
B-_earing failure o g,ts l-q vr.s,
Gear failure
-___ ---
!]e-19,yjl_ -
_-_. . _ *l2to_?9_yrg_. >20 yrs
Oil seal failure 9lo-J-5 vl! --* - -319-1q vr9*,- "-"-- '9Js-CI-9!erl9!slt-9e1el --
Centrifuoal DumDs
Beari¡g failuré __,
-q!1g?jrs 'qyl,s >2 to 0O yr 1

8eafing fáilu¡e (sleeve b€arings) __,_____ llosyrs 15 qlqyjg_ >2to100yrs

Se_el-Eilulg lbulflg !C9¡lf!9 ___.___ 0.5to3yrs o.stolyrs __.- >0.5b15yrs _,
Sealfailure (advanceq deslltljpg!) _ _ o.q!o9Jl_ 3 to g yrs __- >0.5 to 15 yrs
Packing Fáilglg ,___ >0.5 to 6 yrs
'_____-__qqlS?_yrs -
__ >15yrs
.

.gSu¡rlg 1a]!I9_ _, 2to15yrs >8io'lsyrs _-_

l4pglgflllqe __ _._jgqq_yrs 3 to 25 yrs >0.5 to 25 yrs {not enough data)
Fouling 0.2 to 25 yrs 0.2 to 25 yrs >0.5 to 25 yrs (not enough data)
q99tg_9y!!9ll|Btl!rlg_ __ 0.5 to 10 yrs ,__-___l.99jF_ >5 to 2s yrs (not enoush dáta)
.9S?Llyllgqjg]Crq _ 0.!,!q8 yrs _ > 30 yrs >25 y¡s (not enouqh dala)
Gearbox failure SEEABOVE SEEABOVE SEEAVOaE
Lu-oricatrorrsystern raiture 0.5 lo 8 yrs > 15 yrs
s,,to 19 yts
'rlyFf not enougñTtil-
Oil seal failure _ __!lql9.yfs=__ __-__ *- '_9 yrs .CIglelgtrgh data) -- -
"__ _ .

Turbines (soecial ouroose)

Beglllg failure (bearing change only) ,_-,___ 4to12yrs _,4!9?9-yrs _ >2to100yrs _
12 yfs >15 to 30 yrs
Steam sealfailure
Nózzte fai¡ure
__!¡9
4t"roy" --------- 5 to 15 yrs
,._. _
trs yr" (note-nousúrdata)
--_.
Gove¡nor failu.e (mechanic€D-- _ 1 !o 8 yrs a to m y's >5 to 25 vrs
Cooling System failure (applicaton specif:c) 0.5!o10yrs __- >30yrs >5 to 25 yrsl!!r!¡9gg!,q¡lgL
Lubricatioñ Syste! failure 0.5 to 4 yrs __ > 30 yrs ,_ >10 yrs _
-
STATIC EQUIPMENT

Burners
Tip burned off _*l tp_
_¿_yr¡ _ .- req_vre
Page 1 of 4
 Shell Global Solutions

U sual F
Fallure
¡t Moqes
M d Tor TI yplcal R
fo KeTlnery
f¡ trqu
E pment Update: April 2000
Data is confidential and should be used for the sole purpose of S-RCM analysis.
All values are indicative. Site/Company conditions and experience of own personnel should be primary source of failure data.
Careful evaluation should be made before using th¡s data for a particular appl¡cation as the same fa¡lure scenarios may not applY.
Estimation of MTBF w/o PM Usual MTBF With PM ETBC (examples)
(No attention to the equipment) (Full attention to the equipment) (Estimated Time Betweer
Consequences, as per OP99.
0517; Average from previous S.
Ol"fi/l clr r¡iac\

flggs,ed tips (apptication s ,l*_Qeyle l lyeeilglq yl1 >25 vrs

tnroat tailure tro]{!Q--* ._ - . |!9 1O-ffs¿l i-yq(-G" AS) . - >25 yrs (not enough data)
-aurner
Aurnei ihroat failure (erosion) 6 lglq y5 -* a?!*¿rs__09!elous! gqlel- --
Exchanqels
€ñiitzffi;"r p rl""k _ - rtr!9*!9!g¡-9eta)
Tü¡es¡raeunole
/ H""d", i
teal --- (appúcatio¡ "p*, ")
spe<inc) -,- >?: vrs (¡g!!!g!g!jg!4
@ ¡Bl
-("pp!,t*!"" - -,-- >?! Yrs
lnotenoush
qáta)

ffiplcá&;ap4ld --_
---=!
:4v_ g¡e!e!re!s4e1e)

Fi"*-rr!g r"!ll1st"*t"I*( -"1!999!9"L--- - Ilo'lov" -- ,i4]tr1ll9te!o!C!!qqEl ..

-
RBI
ltlleg$v:qqF.qje!!{e!
Furnaces/Heáters
T"be fo"lins (int"m"D

: SFEABOVE _
Damper FailuÉ --- 20 to 30vrs ^_- >25 vl!- >2! vrs (not enough datA.,--
>?: vrs-Inot enous¡ deta)
Fraúé reakase i Header teakase ----- l1s ylg

@-- t t9,6vrs . -='--- i?!-vEl!9!!!19!s.¡!alel

--_

Expaqsion Joint Failure (application specific) >25 yrs

jetq)
l-,pe-Q!elr_
Fianoe Leak
-Qp.plis3!91*speeiliE
(application specific) - iaryE*0919n9!s¡
>25 to 100 yrs
> 75 to 100 Yrs
lgsggs*__
Structural/__support _ ___ _(up-p]L$!on:ggg!|iQ_ _---
¡qsliqs19-oirls ep-p-!igg!9n-lp,e-cilQ--* , '25 vrs inoi eno"gh dátaj
>25 y1s (19! e!o!t-s_¡_.{119)
failure (application specific)
lnsulation
N RVFa$¡ ns
- * "-_ __:__
-- __-____:_-ilp_p199!ion9régi9¡-- >25 yrs (not enough data)
,V.alve Passins ___-Fpdl93!919P99{9I__ i?! rre 0gl e_rqssl !s]4
-Yelvq.sl9.np-rykils lgek?99-------,- - -(agPLqeti-qll9P-99{E _'_21{9 09! e!gsg¡gq!3l_ _

Ve!ve,!As!-e-9]l-o!! eI- i,2_5__y_rc11g1*q!9_qs!3e14-

_Eie9!g¡I9_z¿19 r!g!'ot gPd'c11ie¡-9_p"99if¡cl >25 yrs (not enough data)
__ _"

I üee¡E_rq!g!e{ Ei l, tg s RBI

Vessels
-.-{gpp¡""t.gn tpgofo)
: ---- '4_!9, 109yJ,s
(¡ot enough data)
- ----: >4
!o 100 yrs, (no,!enoug! dgtq)
Liner/lnternal Protection Failure (application specific) _ l-ll9 l_gqJ9 Ogt erys$tqala)
lnternals Corrosion / Erosion - (application specific) _- ',4 1o_1q0_ [s_(nql.9n9.9g¡ dq]q)
ú!9l!_gl1[3'Lll¡gtegltry_¡ ggrnrster cycigré.91_",1 , (áflEfütr"gl .p"9.'¡9¡- >4 to 'l 00 yrs (not enough data)
l$VlAligúelgctgrylq'k{e. _ _ _ __ __ _(gpplication speciflc)
>4 to 1 00 yrs (not enough data)

-__ a?5 yF 0919[q9g[!ata)

I ntegrity related failures
-RBt - --

ELECTRICAL EQUIPMENT
Starters / Breakqrs / Switch Gear
Low Vo ta g sl:-1"-0_0 ! _vo t)
I I >50 yrs
Medium Voltage (1000 - 6600 Volt) >10 to 50 yrs __Ylvrq -
-ltL_s-llYel_tagp*e
iqqt [o_19_ _- _ l!g?qrr_ '_3_9 vis_, >75 yrs

Heatifiq Tracinq,-
tel!I9l19t.lgltl3ilure _ :l vr9_ __l lq ? yrs_
>5 yrs

Motors
M oto r C o m p a rtrye n t_la-i g tq : QpglQf sqlgf !. Vo-lt gs q
yrs
I

Motor Compartment failure - Circuitbreaker H. Voltage 5 to 20 10 to 20 yrs >50 yrs

Motor Compartment failure - Auxillary contacts 5 to 20 yrs 10 to 20 yrs >50 yrs
Cable Cinsulation) tgilqiq >50 y¡s _ __
Mo_tor earth i ng fa i u rel¡qslLqlgl.s)
I

q9?fiqstsj!!q(s9?!eq &r!ife) 9 t! lSfÉ 5 to 20 yq >s0 yrs

>50 yrs
Bearing failure (roller-bearing) 0.5 to 2 yrs B to 10 yrs
-'1sle-qqJE-*-.,

Page 2 of 4
 Shell Global Solutions

ooes Tor TI yptcat Keftnerv

Usual Failure Mod R f¡ Equ
E nt
nent Uodate:Aorit2oOo
Dataisconfidentialandshouldbeusedforthesotepu
All values are indicative. Site/Company conditions and experience of own personnel should be primary source of failure data.
Care{ul evaluation should be made before using this data for a particular application as the same failure scenarios may not apply
Est¡mat¡on of MTBF w/o PM Usual MTBF With PM ETBC (examples)
(No attention to the equipment) (Full attention to the equipment) (Estimated Betweer Time
Consequences, as per OP99.
0517; Average from previous S-
Rfll\il cir r.liae\
!!e!et !-Utt9-us -{F"y lq!!-or BrLu r
!!Y oT tait*e Gss-ouqry
[o-!u !ar!!:r! kj.Lrggg otr, Ea¡r!'s ¡anurer _ __:,_ -_,_,
u 5Io 4 v¡s
\:si1r!!,v Ée,tres-é-["-n-pffrllsGlq'g_-_:__!..s_l9 __ , 8-i9
tqloI:___,,
Coor¡ng Fan failure (design and c€difcátion Eex)
___,_'-9 10,y, E
:rn vÉ
_ __ __ __
-.crg¡s-ey@ a d e -- ___
Vl"q!91 9t!i9$¡_eJe.tvl9 lQglg! ! C rt i f i ca t i o n E ex)

Transformers (hiqh power)_

Iransror.rBr win¿¡n_q failure (quality ofu,in¿ing) - ----O yrs_ yrs -- vrs
Loose cable connection >25 yrs - '75
, m-- -----=E yr"--- ---_
varue) vrs tsúia
--'7s _
glqqgE!$!9q¿q9ylpp¡9yrq >1s
Oilleakage-d,ue to conosion (tank coolers) yrs yfs -- '7s
r?S trs
i1O 'S0 -- ---
UPS
Co.verter fa¡lure F--- - t3oy,=
lnverter failure 1 !ozyrs >20yrs l?s yfs, ,
Staic slitch Fallya-
Batiery failure (19p9!ding on pe ofqqLery)_ 'loyÁ
.1yrs ______q
_':si'. >5oyrs
-*-;tdyrs -
-
INSTRUMENTATION
Controllers
Pneumatic controller
Lq!e!{
based)
5 to 10 yrs . -,1?-9J,re
>7
q
t"qt'e¡lCjoúelelgg1¡ l'LC_
_El99ll9ry_c_t_qlq9!91CI9! __ 1o_tgl!:Q*_*
_ -*__ :> ruJLS*_ .- *.":29-vr,*
Sil$g-lgo_q qo_ülder _
_ _-

Note that pnetmaü_c

-**_pl9?qJrs_
controllers are nowadays hardly_gsgg.*rnglead a DCS and Electronig
__ 50 yrs >20
glryglg lg_op gg!t!rg!!_eF glg!!s,94:

PgS_c9n!ro!_!eep __ -- _-?!le_1_o_yn
> 50 yrs >25 yrs (not enough data)

Flame Controls
Flame detector failure 'l to5
-- : ?9-,Y-!'x
Flame detector failure f PF

rlows (iiqn¡ficánt on-fr. b¡aa. correóE;il;AóE-

E;;t;;;ñ;lñ;ta¡lurel. --
see serv¡ce
ErY."n",9P,Er
Ebc-rrolic (¡nclsr.rart) gP ge¡l(appllEl[on sp€cifc) 15to20yÉ Random withit¡.tii]F period. _>25 yrs h hdata)-
v9% ,-9!9?qyq _-_! noom wifrin t a¡ 1c3¡¡99. --- tr/l

!S llo\arneter (application speciñc) _ 2oto2syrs Random wir¡in IVTBF iiriod

Pd Metd 5 to o yrs .t

Tur¡ine ltletei- t0 to t5 vrs > 25 vrs

uono[s Merer (apprrcá¡on spec¡f¡c) _ 15 to 20 yrs Random within tt4TBF penod. _
y.g¡91¡,c-119ry-I1+! l?pplic¿tio¡ ip-eI¡¡g1 19!9?gyts - - nan¿om wit¡;n n¡rsF perioa -----
B-ol3m+r (application
qrifce ?late Failurg ,-
specif c) - _ 10 to 15 yÉ Éa¡qo¡ wi!!]in-,MTBF periit. .-
_,_(?!p!!9!io'1,!p!9{9) _. ___._______l:gyE1""G"",sñ¡L
,lqSged l!p!Lqe,Lj¡91lqp!l!9l._ . _ _, {gpplr9g!i9¡-!p994c) _ >25 yrs (nor enoush data) _,_
-!9e!!gD!sl4r9! r.rllrje ,_,,- ___-_.,-, __,_ E!v"tna!*ughd"to _
tn S_alq!app¡"et¡_ñq_l____ -

Level (siqnificant drift. ,bias. freeze. complete failure). See service correction factors
>7
*eFeqerc (upl-Que(L-9?-qet-(app!gc!o! _****Be!geo!iqritI4ÍBFlq¡qq. >20 yrs
!jp_r"*i@l!4[ _
9p--e_eir!e)
- - --__?9 !g*?-9 v_p_--__
=*__*___----'-_*5_tei_qy" ___: i"?órrs_ *:3furs_(ng!9!9ys! lelel
prspracer hrectron¡
Electroni yrs t iS tis -
_Arsplacer _ _._ _ _ _$g
5 to 10
i q-yIt _:é y{lelglessh {q!e) ---- *
Level switch (no moving parts) (application specific) 20 to 25 yrs Random within MTBF perioO. >25 yrs (noi engugh data)
I,evelSwitch (no_yinS_!gÉq* s_tgl!1lx,_ -___ > 20 yrs-_
Sgrvg Gsqge __* > 25 yrs
Igqe$augq _
P!ugged mpglse Line/Tappings/Chamber/Cell
to 15
10 ls 1l _
(appl ication specific)
yE __ _-_ t ?qyF
>25 yrs (not enough data)
!

.Llsq!rcllr!,letier_telse _
- ._ _?-9yr:091_9r-queh_g.qld _ _

ll_-s-elqJv-epplie4prl_-_* __ __.,._-_
-,-::___i¡* "--_,_

_ l_? sJIg_( n o_L-ggo Lr g_! !etQ-__

Heating/l nsulation fai lure >25 yrs (not enouoh data)

ll$e|SU epplicatiqns

Page 3 of 4
 Shell Global Solutions

U sual Failure Mooes

F ¡t M d tor
fo T yplcal KeTlnery
R f¡ trqu¡pmen
I E Update: April 2000
Data is confldential and should be used for the sole purpose of S-RCM analysis.
All values are indicative. Site/Company conditions and experience of own personnel should be primary source of failure data.
Careful evaluation should be made before usinq this data for a particular application as the same failure scenarios may not apply
Estimation of MTBF w/o PM Usual MTBF With PM ETBC (examples)
(No attention to the equipment) (Full attention to the equipment) (Estimated Time Betweer
Consequences, as per OP99.
0517, Average from previous S.
Dl'f\/l c+¡ ¡Aiac\

Temperature lslqn¡ficant d rift. b¡as. freeze, comtlete failure), See servlce corection factors
f9ms'!e!!q49r {!pplr93!s!-!¿?4c) __ 15to20-yrs
5loloYrs
,,_ Randolrry!!4 U]gllgljgd. ____j3qyl9_
rempiiátue s-¡lcn {applicálionrpe!!&) - Rando'n within I¡TBF period
rhermoco¡¡plqglLy _-- ___!q!91gyll,-.. lei.lly-qgins .,- >1ovrstosovrs --
iñ-s"!q!19ppftg¡1-9.¡¡¡

k**_
On/Off Valve > 20 vrs
-
-=* - Yrs
yrs_
controa\7bhre > 3-0
19 !q :lp.yls _
Solenoid Valve 5 to 10 > 20 yrs >1 5Yrs
Positioner ráilure >12 yrs
>_20_
Pneumatic Actuator Failure Yr_9

lxssrír g_( E ros ion)

V_a.!yg _ (qpp]lgqtto-t -sggg!¡ql_
(application speciflc)
__ :,?,Q vl: (not enough da!1)
>25 yrs (not enough data)
Valve Fouling/Sticking
yt: Oelg¡eyg! dgtg)
_V_e!ye 91e¡{f"!l{s '29,
a_?q y!]¡o_!gtougn
Valve Packing failure g9!O
Limit switch failure >6 yrs

,l! _Qelety,a p,p |_qg 91]!_ e, s

(
lj

iusl4un-e_n;rnzo¡ senúCe eaouF_ - _ EIy1!+ES ETBF Factor

_
pg-vlqe_¡as lLryg_relpyClS_e*lq !!g_lg!ufe pgtte!!_-e_:9. Ijrryit slyit9@t9, temp. elements 1

c/ea¿
oas- l,lgtuE!C9t,l!9L98 !z¿!!,Hc aases, oxwen, hvclrogen _ 1,2
- pa¡t¡cteslConos¡*
"e"" Gas
Sor. Gas. tvei a,7
Sfe¿m '....'......''_ LP, MP ¿na uP Stean -- -b.8
Water Cooling, Domestic Water
Ligtnt tiqiid UC;s tpc. Mogás, Gasor¿ Kerosinte, luboil So/uenls 1

_95
S/udge Sludge, Mud, Brine, SulPhur 0,5
9,yos9uc _ .______-. L¡qu¡d LNG, N2, Prcpane -..-_''_,!9-
sords __ !9!!pnp9E!9_!&t_9991yst _ o.a

QMI INSTRUMENTATION
Analvzer (Wpical checkinq frequencies)
Moisture 2 to 4 months Very application dependent >'l 0 yrs (not enough data)
PH
GC
óxyse.n
SamplS_S:lefg
Combustible 1 to 3 months Very application dependenl >10 yrs (not enough data)
pecl!g,q[cy'E 2 to 4 months Very application dependent >'l 0 yrs (not enough data)
Conductivity 2 to ¿ rnontns - ::__ Very app_lication dependen, ;'tO yrs lnot qlory|, qetq)

lnstrumentation: OGRM, Cees van Greel

Electrical: OGBEl3, Rene Ouendag
Rotating: OGBE/1 , Walter Schnabel
Static: ETBF values previous analysis;
General values: OGCP/I, Richard Gort; OGCR, Julio Torino
Average ETBC values and compagination: OGCR, Julio Torino
lssuing update: OGCR, Julio Torino

Page 4 of 4