Morris screening for FMECA of valve failure modes on offshore gas reinjection

FMECA is commonly used as a tool for assessing the consequences of different failure modes of a component and the criticality of the consequences. Traditionally failure modes are generated using a one-factor-at-a-time method. In this study, we propose extensions to the FMECA procedure in which failure modes are sampled using statistical sampling techniques, and their effects are evaluated under a wide range of operating conditions. Morris’s efficient sampling technique is used for generating failure mode effect analysis scenarios. The scenarios are evaluated in a KSpice simulator with a model of an offshore gas reinjection system in the Danish North Sea. The impact of the failure modes on the process performance and process safety is evaluated under varying process conditions. The extended methodology enables fast screening of the effects of the failure mode under different realistic process conditions. This provides a more comprehensive and global assessment of the consequences for process safety and reliability in the chemical industry.