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Contents. Oil Refinery System Consider a simplified reliability block diagram (RBD) of an oil refinery, as shown next. The RBD consists of a block representing the crude oil supply (Crude Oil Supply block) and two pumps (Pump 1 and Pump 2 blocks) used to feed the crude oil to the furnace (Furnace block). The crude oil from the furnace is sent to the fractional distillation column (Distillation Unit block) to separate out different fractions. For simplicity it is assumed that gasoline is the only main fraction under consideration. Some gasoline is also obtained from cracking of higher fractions (Cracking Unit block).
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All units processing gasoline after the fractional distillation and cracking are represented by a single block (Gasoline Unit block). Gasoline and the other fractions (Other Fractions block), after going through their respective refining processes, are sent for storage. Storage units for the whole refinery are again represented by a single block (Storage block). RBD for oil refinery The purpose of the Crude Oil Supply block in the diagram is to represent the time-varying throughput as the oil refinery goes through its three operational phases of Start Up, Normal Production and Shut Down. This block is therefore not assigned any failure properties and is set to ignore backlog. The two pump blocks are used to represent two supply lines of crude oil (along with their respective components such as pumps and valves) to the refinery furnace.
One of the lines is assumed to supply 70% of crude oil while the other line supplies the remaining 30%. This is achieved by selecting the Weighted allocation across paths option for the throughput simulation settings for the Crude Oil Supply block and assigning throughput values of 70 and 30 units per day respectively for the Pump 1 and Pump 2 blocks. It is assumed that gasoline is obtained as 45% of the crude oil supply. Thus a throughput of 45 units per day is assigned to the Gasoline Unit block.
The remaining 55% throughput is assigned to the Other Fractions block. The unequal division of throughput across the two paths is achieved using the Weighted allocation across paths option for the Cracking Unit block. Both the Gasoline Unit block and the Other Fractions block are required to remain operational for the refinery to function. Thus a 2-out-of-2 node is used to represent this series configuration. The Storage block is assumed to have no failure or repair properties. Phases and Throughput The phase diagram is shown next.
Shut Down phase properties The major annual overhaul is represented by a maintenance phase, which is the fourth and last phase of the phase diagram. In this phase, all components are preventively maintained and failed components, if any, are subjected to repairs. Except for the two pump blocks, it is assumed that no blocks can be repaired during the operational phases. Any system failure of the refinery during any of the operational phases is considered to lead to an immediate overhaul of the refinery. Thus the failure path for all the operational phases leads to the Maintenance phase. Simulation Objective A phase diagram simulation is run to estimate availability and percentage of gasoline throughput obtained from the refinery for a one-year period.
(The percentage of gasoline obtained from crude oil over the one-year period may be determined by dividing the total throughput of the Gasoline Unit block to the total throughput of the Crude Oil Supply block. Ideally this percentage should be 45%, but due to failures of the refinery the actual throughput percentage obtained would be less.) The following failure and repair properties (in days) are assumed for the different blocks used in the RBD.
ReliaSoft BlockSim provides a comprehensive platform for system reliability, availability, maintainability and related analyses. The software offers a sophisticated graphical interface that allows you to model the simplest or most complex systems and processes using reliability block diagrams (RBDs) or fault tree analysis (FTA) — or a combination of both approaches.
Markov diagrams are also available. Using exact computations or discrete event simulation, BlockSim facilitates a wide variety of analyses for both repairable and non-repairable systems that will be of use to both product designers and asset managers.
This includes reliability analysis, maintainability analysis, availability analysis, reliability optimization, throughput calculation, resource allocation, life cycle cost estimation and other system analyses. Identify critical components (or failure modes). Determine the most effective ways to improve system performance through design improvements and/or maintenance planning. Use simulation to obtain estimated performance metrics that can facilitate decision-making in a variety of areas, such as:. Scheduling planned maintenance. Planning for spares. Identifying bottlenecks in production throughput.
Estimating life cycle costs. Model any configuration to analyze its reliability, maintainability and availability using load sharing, standby redundancy, phases and duty cycles to represent the system. BlockSim provides intelligent integration between reliability program activities and tools, while simultaneously facilitating effective information sharing and cooperation between engineering teams of any size. Use analyses performed in other ReliaSoft applications to set the properties for blocks in a BlockSim RBD or fault tree. Build RBDs or fault trees in BlockSim from system configuration and failure mode data in //, or from failure rate predictions in. Use BlockSim simulation diagrams to generate response data for experiment designs in.
Work with BlockSim diagrams and flowcharts together in the same analysis project, and use diagram results in flowcharts if desired. Publish selected analyses and reports for easy access via the. Easy drag-and-drop techniques allow you to build reliability block diagrams (RBDs) for the simplest to the most complex systems. Simple Series and Parallel: Simple series configuration assumes that the failure of any one component causes the system to fail, while simple parallel configuration assumes full redundancy in the system. Complex: Require a more advanced analytical treatment than a simple combination of series and parallel blocks. Such configurations may be required for analyzing network systems, competing failure modes, etc.
Free optical flares. k-out-of-n: Node blocks can be used to define k-out-of-n redundancy, where a specified number of paths leading to the node must succeed in order for the system to succeed. Load Sharing: Each block supports a percentage of the total load.
BlockSim supports stress-independent distributions for load sharing blocks. Standby Redundancy: Standby blocks are available to become active under specified circumstances. BlockSim can model hot, warm or cold standby configurations. Mirrored Blocks: Allow you to put the exact same component in more than one location within the diagram. These blocks can be used, for example, to simulate bi-directional paths in a communications network. BlockSim offers increased modeling flexibility by supporting mirrors across different diagrams.
Multi Blocks: Help you to save time (and space in the diagram) by using a single block to represent multiple identical components configured in series or parallel. Subdiagrams: BlockSim offers a virtually unlimited capability to link diagrams as components in other diagrams, which provides a variety of opportunities to encapsulate one analysis into another. BlockSim's fault tree analysis interface supports all of the traditional gates and event symbols that are applicable to system reliability and related analyses. In addition, only BlockSim allows you to expand the modeling capabilities with additional logic gates that represent load sharing and standby redundancy configurations. The available event symbols include Basic, Undeveloped, Trigger, Resultant and Conditional, while the supported fault tree diagram gates include:. AND and OR gates. NOT, NAND and NOR gates. Voting gates.
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Inhibit gates. Priority AND and Sequence Enforcing gates. Load Sharing and Standby gates Fault tree diagrams can be configured to display intermediate results at each individual gate. Your BlockSim projects can contain both fault trees and reliability block diagrams together in the same analysis workspace. You can also integrate your fault trees and RBDs by linking a fault tree as a subdiagram to an RBD or vice versa, copying events from a fault tree diagram and pasting them as blocks in an RBD, and automatically converting any fault tree to an RBD.
System reliability metrics and plots: You can use the convenient Quick Calculation Pad (QCP) and plot sheets to calculate and visualize key system reliability metrics such as:. Reliability and probability of failure.
Reliable life (i.e., time for a given reliability). BX% life (i.e., time for a given unreliability). Mean life. Failure rate Minimal cut sets: For each analytical diagram, BlockSim identifies the unique combinations of component failure that can cause system failure. These minimal cut sets can be used to understand the structural vulnerability of a system. Identify critical components: FRED Reports (Failure Reporting, Evaluation and Display) provide an intuitive graphical presentation of key metrics, with color-coding to identify the ones that may be critical for system improvement.
FRED reports are available for analytical and simulation diagrams. Reliability importance plots: BlockSim provides a set of Reliability Importance plots designed to show the relative importance of each component with respect to the overall reliability of a system. BlockSim's simulation capability for reliability, availability, maintainability and supportability analysis of repairable systems is more flexible and realistic than ever. For a new system, you can use simulation results to optimize the design and make projections about how the system may perform in the field. For existing equipment, use the results for maintenance planning, throughput estimates, life cycle cost estimation and more. When you utilize simulation, the analysis can consider:.
Task scheduling logistics, which includes a 'Virtual Age' option for situations in which the scheduled maintenance task will be performed even if the item has failed. Restoration factor that captures the impact of repairs on the future reliability of the component. Duty cycles for components (or assemblies) that experience a different stress load than the rest of the system. Expected downtime associated with corrective or scheduled maintenance.
Costs and logistical constraints associated with allocating the personnel ( repair crews) and materials ( spare parts) required to perform maintenance. Maintenance groups that identify components that will receive maintenance based on what happens to other components. State change triggers that activate or deactivate a block under certain conditions during the simulation. This provides increased modeling flexibility for highly complex dependency scenarios, such as standby configurations and other situations when you may need to divert the simulation onto an alternate path when a particular event occurs.
BlockSim’s simulations generate a wide variety of results at the system and/or component level (such as Uptime/Downtime, Mean Time to First Failure (MTTFF), Availability, Reliability, Number of Failures, Number of PMs/Inspections, Costs, etc.). You can use these results for many different applications, including:. Choosing the most effective maintenance strategy based on considerations of safety, cost and/or availability. Using the optimum replacement tool to calculate both the optimum preventive maintenance (PM) and/or optimum inspection intervals. Managing the spare parts inventory based on considerations of cost, utilization rate, supply bottlenecks, etc.
Identifying the components that have the biggest impact on availability (downtime). The software’s Log of Simulations feature provides the information you need to evaluate the variability in specific simulation results of interest.
BlockSim allows you to specify both the direct and indirect costs associated with the maintenance strategies that you have defined, including costs related to downtime, maintenance crews, spares, etc. This yields a wide array of simulation results that are instrumental in performing realistic LCC assessments. With BlockSim's modeling flexibility, you can:.
Specify what kinds of crew delays are included in cost calculations and what delays should be ignored. Specify costs associated with system failure, including cost per incident and downtime rate. Specify system uptime revenue and revenue due to throughput so the simulation is able to calculate opportunity costs. View new cost-related simulation results, including system-level costs, the contributions of different kinds of wait times to block costs and the contribution (criticality) of a block's cost to the total system costs. You can use reliability phase diagrams (RPDs) to model systems that go through different phases during the course of their operation.
For example, some aircraft components operate only during the take-off and landing phases of a mission. Other components may experience a higher failure rate during certain phases due to higher stress. In addition, the software uses Maintenance Phases to model scenarios in which a system goes directly to maintenance under specified conditions. For example, if a failure during the taxi phase sends an aircraft in for maintenance, it will start over from the beginning of the mission once repaired — not from the middle of the taxi phase where it was when the failure occurred, as other RBD analyses have been forced to assume. This flexibility provides a tremendous leap forward in the ability to simulate system operation more realistically. BlockSim includes success/failure paths, for situations where a system proceeds to one operational phase upon success and a different operational phase upon failure. Node blocks and stop blocks are included as well.
BlockSim’s throughput analysis capabilities can be used to identify bottlenecks, optimize resource allocation and otherwise improve the processing efficiency of the system. The software allows you to determine how the simulation will allocate the processed output across the paths defined in the diagram.
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The software also allows you to specify how the backlog will be processed. When the throughput varies over time, BlockSim's phase diagrams can be combined with models to describe the time-dependent variability (linear, exponential or power). The Simulation Worksheets feature allows you to vary values that are used in BlockSim RBD or flowchart simulations. This enables you to investigate the effect of one or more variables on the simulation results. Two of the most useful applications are the ability to:. Design an experiment in — simulate the experiment in BlockSim or RENO — then return to Weibull and analyze the simulated 'response' data.
Perform batch simulation of an RBD, using different input values for each simulation. For example, this tool makes it easy to run a set of simulations that compare a variety of possible scenarios by altering specific inputs (e.g., cost, maintenance interval, etc.) for each simulation. Plots and charts to visualize your analysis results:. Plot setup allows you to completely customize the 'look and feel' of plot graphics while the RS Draw metafile graphics editor provides the option to insert text, draw objects or mark particular points on plot graphics.
You can save your plots in a variety of graphic file formats for use in other documents. Overlay plots allow you to plot multiple results together in the same plot. This can be an effective visual tool for many different purposes, such as comparing different analyses (e.g., Design A vs.
Design B) or demonstrating the effects of a design change (e.g., Before vs. Customizable reports: The Synthesis Workbook is a custom reporting tool that is built into BlockSim. It seamlessly integrates spreadsheet and word processing capabilities while enabling you to include calculated results and plots from your analysis.
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