Risk Assessment Data Directory

Report No. 434 – 1

March 2010

Process
release
frequencies
International Association of Oil & Gas Producers
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 RADD – Process release frequencies

contents
1.0 Scope and Definitions ........................................................... 1
1.1 Equipment ....................................................................................................... 1
1.2 Release types .................................................................................................. 2
2.0 Summary of Recommended Data ............................................ 2
3.0 Guidance on use of data ...................................................... 19
3.1 General validity ............................................................................................. 19
3.2 Uncertainties ................................................................................................. 20
3.3 Definition of release types ........................................................................... 20
3.3.1 Full releases.............................................................................................................. 20
3.3.2 Limited releases ....................................................................................................... 21
3.3.3 Zero pressure releases ............................................................................................ 21
3.4 Consequence modelling for the largest release size ................................ 21
3.5 Modification of frequencies for factors specific to plant conditions ....... 22
3.5.1 General considerations ........................................................................................... 22
3.5.2 API 581 Approach..................................................................................................... 22
3.5.3 Safety Management.................................................................................................. 24
3.5.4 Inter-unit piping ........................................................................................................ 25
3.5.5 Flanges...................................................................................................................... 26
4.0 Review of data sources ....................................................... 27
4.1 Basis of data presented ............................................................................... 27
4.1.1 Summary of release statistics................................................................................. 28
4.1.2 Methodology for obtaining release frequencies ................................................... 28
4.1.3 Uncertainties in release frequencies...................................................................... 29
4.1.4 Comparison with experience .................................................................................. 29
4.1.5 Conclusions.............................................................................................................. 30
4.2 Other data sources ....................................................................................... 30
5.0 Recommended data sources for further information ............ 31
6.0 References .......................................................................... 31
6.1 References for Sections 2.0 to 4.0 .............................................................. 31
6.2 References for other data sources examined ............................................ 32

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Abbreviations:
ANSI American National Standards Institute
API American Petroleum Institute
DNV Det Norske Veritas
ESD Emergency Shutdown
HC Hydrocarbon
HCRD Hydrocarbon Release Database
HSE (UK) Health and Safety Executive
LNG Liquefied Natural gas
OREDA Offshore Reliability Data
OSHA Occupational Safety and Health Administration
PSM Process Safety Management
QRA Quantitative Risk Assessment (sometimes Analysis)
UKCS United Kingdom Continental Shelf

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1.0 Scope and Definitions

1.1 Equipment
This datasheet presents (Section 2.0) frequencies of releases from the following
process equipment types. They are intended to be applied to process equipment on the
topsides of offshore installations and on onshore facilities handling hydrocarbons but
are not restricted to releases of hydrocarbons.
1. Steel process pipes 10. Compressors: Reciprocating
2. Flanges 11. Heat exchangers: Shell & Tube, shell
side HC
3. Manual valves
12. Heat exchangers: Shell & Tube, tube
4. Actuated valves
side HC
5. Instrument connections
13. Heat exchangers: Plate
6. Process (pressure) vessels
14. Heat exchangers: Air-cooled
7. Pumps: Centrifugal
15. Filters
8. Pumps: Reciprocating
16. Pig traps (launchers/receivers)
9. Compressors: Centrifugal
OREDA [1] gives frequencies of releases from subsea equipment. If these are used, it
should be noted that these are based on only a small number of incidents (a total of 13
from several different components) and so are subject to considerable statistical
uncertainty. It is suggested that use of onshore/topsides failure frequencies, i.e. the
frequencies for the corresponding equipment types from nos. 1 to 16 above, is
preferable.
The precise definition of each equipment type is given with the data in Section 2.0.
Besides the equipment defined in the above list, the equipment types listed in Table 1.1
are also covered by the data given in Section 2.0.

Table 1.1 Other Equipm ent Types Covered

Equipment Type See Equipment Type See

Datasheet or Datasheet or
Section No. Section No.
Absorbers 6 Grayloc flanges Section 3.5.5
Clamp connections 2 Knock-out drums 6
Columns 6 Pipe connections 2
Distillation columns 6 Process reactors 6
ESD valves 4 Reactors 6
Fin-fan coolers 14 Scrubbers 6
Fittings (small-bore) 5 Separators 6
Gaskets Section 3.5.5 Small-bore fittings 5

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1.2 Release types

According to analysis of historic process release frequency data [2], releases can be
split into three different types:
• Full releases: consistent with flow through the defined hole, beginning at the
normal operating pressure, and continuing until controlled by emergency shut-down
and blowdown (if present and operable) or inventory exhaustion. This scenario is
invariably modelled in any QRA.
• Lim ited releases: cases where the pressure is not zero but the quantity released
is much less than from a full release. This may be because the release is isolated
locally by human intervention (e.g. closing an inadvertently opened valve), or by a
restriction in the flow from the system inventory (e.g. releases of fluid accumulated
between pump shaft seals). This scenario may be modelled, depending on the detail
of the QRA, but the consequences should reflect the limited release quantities.
• Zero pressure releases: cases where pressure inside the leaking equipment is
virtually zero (0.01 barg or less). This may be because the equipment has a normal
operating pressure of zero (e.g. open drains), or because the equipment has been
depressurised for maintenance. This scenario is typically excluded from QRA, and
is included mainly for consistency with the original HSE data (see Sections 3.3, 4.0).

Therefore, the release frequencies are tabulated for each of these release types, as well
as the overall frequencies for all release types taken together being tabulated1.

2.0 Summary of Recommended Data

A datasheet is given below for each of the equipment types listed in Section 1.1. The
definitions given of the equipment types are consistent with those used by the UK HSE.

1
Note that these overall frequencies are not the sum of the frequencies for each release type;
they are calculated by a separate mathematical function, as described in Section 4.1.2, fitted to
the release data.

2 ©OGP
 RADD – Process release frequencies

Equipment Type: (1) Steel process pipes

Definition:
Offshore: Includes pipes located on topsides (between well and riser) and subsea (between
well and pipeline).
Onshore: Includes pipes within process units, but not inter-unit pipes or cross-country
pipelines.
The scope includes welds but excludes all valves, flanges, and instruments.

(a) All piping release frequencies (per metre year) by pipe diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 9.0E-05 4.1E-05 3.7E-05 3.6E-05 3.6E-05 3.6E-05
3 to 10 3.8E-05 1.7E-05 1.6E-05 1.5E-05 1.5E-05 1.5E-05
10 to 50 2.7E-05 7.4E-06 6.7E-06 6.5E-06 6.5E-06 6.5E-06
50 to 150 0.0E+00 7.6E-06 1.4E-06 1.4E-06 1.4E-06 1.4E-06
>150 0.0E+00 0.0E+00 5.9E-06 5.9E-06 5.9E-06 5.9E-06
TOTAL 1.5E-04 7.4E-05 6.7E-05 6.5E-05 6.5E-05 6.5E-05

(b) Full piping release frequencies (per metre year) by pipe diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 5.5E-05 2.6E-05 2.3E-05 2.3E-05 2.3E-05 2.3E-05
3 to 10 1.8E-05 8.5E-06 7.6E-06 7.5E-06 7.4E-06 7.4E-06
10 to 50 7.0E-06 2.7E-06 2.4E-06 2.4E-06 2.4E-06 2.3E-06
50 to 150 0.0E+00 6.0E-07 3.7E-07 3.6E-07 3.6E-07 3.6E-07
>150 0.0E+00 0.0E+00 1.7E-07 1.7E-07 1.6E-07 1.6E-07
TOTAL 8.0E-05 3.8E-05 3.4E-05 3.3E-05 3.3E-05 3.3E-05

(c) Limited piping release frequencies (per metre year) by pipe diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 3.1E-05 9.9E-06 8.1E-06 7.8E-06 7.7E-06 7.6E-06
3 to 10 1.5E-05 4.9E-06 4.0E-06 3.8E-06 3.8E-06 3.7E-06
10 to 50 1.3E-05 2.5E-06 2.0E-06 1.9E-06 1.9E-06 1.9E-06
50 to 150 0.0E+00 3.2E-06 5.2E-07 5.0E-07 4.9E-07 4.9E-07
>150 0.0E+00 0.0E+00 2.4E-06 2.4E-06 2.4E-06 2.4E-06
TOTAL 5.9E-05 2.0E-05 1.7E-05 1.6E-05 1.6E-05 1.6E-05

(d) Zero pressure piping release frequencies (per metre year) by pipe diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 3.7E-06 3.2E-06 3.1E-06 3.1E-06 3.1E-06 3.1E-06
3 to 10 2.7E-06 2.3E-06 2.3E-06 2.3E-06 2.3E-06 2.3E-06
10 to 50 6.0E-06 1.9E-06 1.8E-06 1.8E-06 1.8E-06 1.8E-06
50 to 150 0.0E+00 3.4E-06 7.7E-07 7.6E-07 7.6E-07 7.6E-07
>150 0.0E+00 0.0E+00 2.6E-06 2.6E-06 2.6E-06 2.6E-06
TOTAL 1.24E-05 1.07E-05 1.06E-05 1.05E-05 1.05E-05 1.05E-05

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Equipment Type: (2) Flanges

Definition:
The following frequencies refer to a flanged joint, comprising two flange faces, a gasket
(where fitted), and two welds to the pipe. Flange types include ring type joint, spiral wound,
clamp (Grayloc) and hammer union (Chicksan).

(a) All flange release frequencies (per flanged joint year) by flange diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 4.4E-05 6.5E-05 9.6E-05 1.2E-04 1.5E-04 2.1E-04
3 to 10 1.8E-05 2.6E-05 3.9E-05 5.1E-05 6.2E-05 8.5E-05
10 to 50 1.5E-05 1.1E-05 1.6E-05 2.1E-05 2.5E-05 3.4E-05
50 to 150 0.0E+00 8.5E-06 3.2E-06 4.1E-06 5.1E-06 6.9E-06
>150 0.0E+00 0.0E+00 7.0E-06 7.6E-06 8.2E-06 9.3E-06
TOTAL 7.6E-05 1.1E-04 1.6E-04 2.1E-04 2.5E-04 3.4E-04

(b) Full flange release frequencies (per flanged joint year) by flange diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 2.6E-05 3.7E-05 5.9E-05 8.3E-05 1.1E-04 1.7E-04
3 to 10 7.6E-06 1.1E-05 1.7E-05 2.4E-05 3.2E-05 4.9E-05
10 to 50 4.0E-06 3.0E-06 4.7E-06 6.6E-06 8.8E-06 1.4E-05
50 to 150 0.0E+00 2.0E-06 6.1E-07 8.7E-07 1.1E-06 1.8E-06
>150 0.0E+00 0.0E+00 1.7E-06 1.8E-06 1.9E-06 2.2E-06
TOTAL 3.8E-05 5.3E-05 8.3E-05 1.2E-04 1.5E-04 2.4E-04

(c) Limited flange release frequencies (per flanged joint year) by flange diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 1.5E-05 2.3E-05 3.1E-05 3.8E-05 4.4E-05 5.4E-05
3 to 10 7.9E-06 1.2E-05 1.6E-05 2.0E-05 2.3E-05 2.8E-05
10 to 50 8.6E-06 6.4E-06 8.7E-06 1.1E-05 1.2E-05 1.5E-05
50 to 150 0.0E+00 5.4E-06 2.4E-06 2.9E-06 3.4E-06 4.1E-06
>150 0.0E+00 0.0E+00 4.3E-06 4.8E-06 5.2E-06 5.9E-06
TOTAL 3.2E-05 4.7E-05 6.2E-05 7.5E-05 8.7E-05 1.1E-04

(d) Zero pressure flange release frequencies (per flanged joint year) by flange diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 1.5E-06 1.7E-06 2.6E-06 4.2E-06 6.7E-06 1.4E-05
3 to 10 1.1E-06 1.2E-06 1.9E-06 3.1E-06 4.9E-06 1.1E-05
10 to 50 2.0E-06 1.0E-06 1.5E-06 2.5E-06 4.0E-06 8.6E-06
50 to 150 0.0E+00 1.3E-06 6.4E-07 1.1E-06 1.7E-06 3.6E-06
>150 0.0E+00 0.0E+00 1.4E-06 2.2E-06 3.5E-06 7.6E-06
TOTAL 4.6E-06 5.3E-06 7.9E-06 1.3E-05 2.1E-05 4.5E-05

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 RADD – Process release frequencies

Equipment Type: (3) Manual valves

Definition:
Includes all types of manual valves (block, bleed, check and choke); valve types gate, ball,
plug, globe, needle and butterfly. The scope includes the valve body, stem and packer, but
excludes flanges, controls and instrumentation.

(a) All manual valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 4.4E-05 6.6E-05 8.4E-05 9.8E-05 1.1E-04 1.3E-04
3 to 10 2.3E-05 3.4E-05 4.3E-05 5.0E-05 5.6E-05 6.4E-05
10 to 50 2.1E-05 1.8E-05 2.3E-05 2.7E-05 3.0E-05 3.4E-05
50 to 150 0.0E+00 1.1E-05 6.3E-06 7.3E-06 8.0E-06 9.3E-06
>150 0.0E+00 0.0E+00 7.8E-06 8.7E-06 9.5E-06 1.1E-05
TOTAL 8.8E-05 1.3E-04 1.7E-04 1.9E-04 2.1E-04 2.4E-04

(b) Full manual valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 2.0E-05 3.1E-05 4.3E-05 5.3E-05 6.2E-05 7.8E-05
3 to 10 7.7E-06 1.2E-05 1.7E-05 2.1E-05 2.4E-05 3.0E-05
10 to 50 4.9E-06 4.7E-06 6.5E-06 8.0E-06 9.4E-06 1.2E-05
50 to 150 0.0E+00 2.4E-06 1.2E-06 1.5E-06 1.8E-06 2.2E-06
>150 0.0E+00 0.0E+00 1.7E-06 1.9E-06 2.1E-06 2.3E-06
TOTAL 3.2E-05 5.0E-05 6.9E-05 8.5E-05 1.0E-04 1.2E-04

(c) Limited manual valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 2.4E-05 2.7E-05 3.2E-05 3.7E-05 4.3E-05 5.4E-05
3 to 10 1.4E-05 1.5E-05 1.8E-05 2.1E-05 2.5E-05 3.1E-05
10 to 50 1.4E-05 9.5E-06 1.1E-05 1.3E-05 1.5E-05 1.9E-05
50 to 150 0.0E+00 6.4E-06 3.5E-06 4.1E-06 4.7E-06 6.0E-06
>150 0.0E+00 0.0E+00 4.1E-06 4.8E-06 5.5E-06 7.0E-06
TOTAL 5.1E-05 5.8E-05 6.9E-05 8.1E-05 9.3E-05 1.2E-04

(d) Zero pressure manual valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 3.6E-07 7.1E-07 1.1E-06 1.4E-06 1.7E-06 2.2E-06
3 to 10 3.5E-07 6.9E-07 1.1E-06 1.4E-06 1.7E-06 2.1E-06
10 to 50 2.4E-06 7.8E-07 1.2E-06 1.6E-06 1.9E-06 2.4E-06
50 to 150 0.0E+00 4.0E-06 7.1E-07 9.2E-07 1.1E-06 1.4E-06
>150 0.0E+00 0.0E+00 5.4E-06 7.0E-06 8.5E-06 1.1E-05
TOTAL 3.1E-06 6.2E-06 9.5E-06 1.2E-05 1.5E-05 1.9E-05

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Equipment Type: (4) Actuated valves

Definition:
Includes all types of actuated valves (block, blowdown, choke, control, ESDV and relief), but not actuated pipeline valves
(pipeline ESDV and SSIV). Valve types include gate, ball, plug, globe and needle. The scope includes the valve body, stem
and packer, but excludes flanges, controls and instrumentation.

(a) All actuated valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 4.2E-04 3.6E-04 3.3E-04 3.1E-04 3.0E-04 2.8E-04
3 to 10 1.8E-04 1.5E-04 1.4E-04 1.3E-04 1.3E-04 1.2E-04
10 to 50 1.1E-04 6.6E-05 6.0E-05 5.6E-05 5.4E-05 5.0E-05
50 to 150 0.0E+00 3.3E-05 1.3E-05 1.2E-05 1.1E-05 1.1E-05
>150 0.0E+00 0.0E+00 1.8E-05 1.8E-05 1.8E-05 1.7E-05
TOTAL 7.1E-04 6.2E-04 5.6E-04 5.3E-04 5.0E-04 4.7E-04

(b) Full actuated valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 2.4E-04 2.2E-04 2.1E-04 2.0E-04 2.0E-04 1.9E-04
3 to 10 7.3E-05 6.6E-05 6.3E-05 6.0E-05 5.9E-05 5.6E-05
10 to 50 3.0E-05 1.9E-05 1.8E-05 1.7E-05 1.7E-05 1.6E-05
50 to 150 0.0E+00 8.6E-06 2.4E-06 2.3E-06 2.2E-06 2.2E-06
>150 0.0E+00 0.0E+00 6.0E-06 5.9E-06 5.9E-06 5.9E-06
TOTAL 3.5E-04 3.2E-04 3.0E-04 2.9E-04 2.8E-04 2.7E-04

(c) Limited actuated valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 1.7E-04 1.3E-04 1.1E-04 9.7E-05 8.9E-05 7.7E-05
3 to 10 8.8E-05 6.9E-05 5.7E-05 5.1E-05 4.7E-05 4.1E-05
10 to 50 7.8E-05 3.8E-05 3.2E-05 2.8E-05 2.6E-05 2.3E-05
50 to 150 0.0E+00 2.3E-05 9.0E-06 8.0E-06 7.3E-06 6.4E-06
>150 0.0E+00 0.0E+00 1.1E-05 9.8E-06 9.2E-06 8.3E-06
TOTAL 3.3E-04 2.6E-04 2.2E-04 1.9E-04 1.8E-04 1.6E-04

(d) Zero pressure actuated valve release frequencies (per valve year) by valve diameter

6" DIA 12" DIA 18" DIA 24" DIA 36" DIA
HOLE DIA 2" DIA (150 (300 (450 (600 (900
RANGE (mm) (50 mm) mm) mm) mm) mm) mm)
1 to 3 1.1E-05 1.8E-05 2.5E-05 3.0E-05 3.4E-05 4.1E-05
3 to 10 7.8E-06 1.3E-05 1.7E-05 2.1E-05 2.3E-05 2.8E-05
10 to 50 1.3E-05 9.6E-06 1.3E-05 1.6E-05 1.8E-05 2.2E-05
50 to 150 0.0E+00 1.1E-05 5.2E-06 6.2E-06 7.1E-06 8.5E-06
>150 0.0E+00 0.0E+00 9.3E-06 1.1E-05 1.3E-05 1.5E-05
TOTAL 3.2E-05 5.1E-05 6.9E-05 8.3E-05 9.5E-05 1.1E-04

6 ©OGP