Design Optimization of New Plants by Reliability Engineering Methodologies: Application to a Subsea Pumping Station

Summary

Reliability Engineering methodologies may be successfully applied to the analysis of new plants for which no direct experiences exist. For these plants the risk analysis represents the only possibility to optimize the design in alternative to the “a posteriori” experience.

In this context the conventional methods for the risk analysis have to be calibrated on the particular needs of the case to be analyzed.

The paper shows the main results of an application carried on in SNAMPROGETTI in the framework of SBS (Subsea Booster System) project involving the design of a remotely controlled pumping station to be installed in deep sea (up to –1000 m) for oil/gas reservoirs development. The installation and maintenance costs of the system require to ensure the system reliability; the design solutions will therefore be defined on the basis of a reliability analysis.

The procedure that has been applied starts from the reliability data calibration to enable, by FMEA, HAZOP and Fault. Tree methods, the system availability evaluation and the identification of critical components.

On the basis of the reliability model, indications are provided about the expected reliability level for each sub-system and the optimum design configuration in order to achieve the economical feasibility targets.

A sensitivity analysis is also applied to evaluate the influence of the parameters’ estimation on the final results and the benefits due to increased component quality level, different functional solutions or component redundancies.