Pipefitt er Struck by Pressurized Pipe and Killed

 On March 6, 2018, a 49-year-old pipefitter was hit in the chest by a pressurized 12-inch diameter polyvinyl chloride (PVC) pipe during a hydrostatic pressure test of a fire suppression system. The sudden pipe movement was attributed to a pipe joint connection failure in a buried section of the pipeline. The failure was due to torque shear bolts at the joint connection that were not tightened, which was missed during the utility installation process and the work inspection prior to the incident.

Read the incident in this link

EXPANSION BELLOW INCIDENT

"In this study, the explosion failure of a bellows expansion joint made of Type 304 stainless steel (UNS S30400) in a pipeline conducting methane (CH₄) gas at 400 °C is analyzed. Using the simulation mechanical software, the behavior of the pipeline during the working condition was investigated.

Observations of the metallographic sections indicated that corrosion was involved in the cracking of the bellows that led to the explosion. After investigating the fracture surface, it was noted that the cracks occurred at dimples in the bellows. The presence of hydrogen sulfide (H₂S) in the gas stream resulted in stress corrosion cracking". 

Read the incident in this link

INADEQUATE REPAIR OF AN AMMONIA VESSEL KILLS 3

The 109D-C was one of three identical vessels at the facility that removed moisture and carbon monoxide from a synthesis gas used in the manufacture of ammonia. The 109D-C, which had been taken off line to replace its desiccant material, had been online for approximately 11 1/2 hours when the vessel exploded into flame. One employee was killed instantly in the explosion and 6 more suffered severe burns. Another employee, a crane operator, suffered from severe burns and was hospitalized for several weeks before he died. An ammonia operator, was standing on the catwalk above the 109D-C when it exploded. He also suffered severe burns and died several weeks later. Subsequent inspection of the vessel revealed a cracked weld. Apparently, an inadequate repair job had been made to the weld two days before the accident. 

Source:osha.gov 

ARE YOU INSPECTING YOUR PILOT OPERATED VALVES CORRECTLY?

A Pilot operated relief valve failed to lift during planned recertification in the workshop. The cause of failure to lift identified as a plug fitted in the pilot exhaust port. Plug was removed from pilot exhaust port and RV functioned as intended.  On inspection of three remaining RV’s on compressor discharge, it was
found that another RV also had a plug fitted in the pilot exhaust port.

ARE YOU INPECTING SMALL BORE TUBING?

 An ammonia leak occurred at a commercial-industrial facility. Approximately 10 lbs ammonia entrained in approximately 200 litres of compressor oil was released when a suction side 3/8-inch pressure sensing line failed. The suction side oil pressure pushed approximately 200 litres of oil from the reservoir onto the floor where the entrained ammonia then escaped to atmosphere. The 3/8-inch stainless steel tubing within the compression fitting failed when a circumferential crack completely fractured. The crack within the
3/8-inch stainless steel compression fitting did not show up on external inspection. Metal fatigue appeared to be a factor, along with unit vibration and initial metal stress within this type of compression joint.
 

The refrigeration contractor identified the main cause and factors leading to the failure as a severe vibration condition of the compressor. This severe vibration condition only occurs when only happens when the control slide valve is at, or at near its minimum position. The vibration was so intense that the contractor immediately shut the compressor down. Also, the contractor’s investigation discovered the ‘PHD’ vibration monitoring system was inactive. When the monitoring system was activated, the compressor in fact shut down on ‘high vibration.’ 

Source: British Columbia Safety Authority

ARE YOUR SAFETY DEVICES WORKING?

Ammonia was released at a recreational facility. A high pressure cut out switch failed to shut down a compressor when the compressor experienced a high pressure condition. Pressure continued to build until a safety relief device operated releasing ammonia gas to atmosphere via the relief stack,
which triggered the ammonia alarm.
The water supply line to the condenser had no protection and was subject to freezing during cold weather. The high limit switch was old (1986) and is mounted on the compressor base subjecting it to vibration. The safety relief operated as designed, venting gas to atmosphere, preventing a possible
catastrophic failure.
Source: British Columbia Safety Authority

LOOSE BOLTS - CAUSES

 Www.smartbolts.com/insights/loose-bolts-causes-ways-prevent/

A pressurized bolted flange joint assembly begins to leak, creating a safety hazard. A rotor with its blades separates from the nacelle and spins off a wind turbine, crashing to the ground. Under constant vibration from the engine of an ocean freighter, loose bolts on a large piece of mining equipment work their way off the bolted joints and roll around the hull, inflicting further damage to the equipment.

AVOID GASKET SURPRISES

 https://www.chemicalprocessing.com/articles/2020/maintenance-avoid-gasket-surprises/

COMMON CAUSES OF FLANGE LEAKS AND THEIR SOLUTIONS

 https://www.sealxpert.com/common-causes-of-flange-leaks-and-their-solutions/

Is it Possible to Turnaround a Turnaround? - POWER Magazine

Is it Possible to Turnaround a Turnaround? - POWER Magazine: By Paul Muir, CRO, Mobideo Why are Turnarounds So Challenging “A large turnaround can include up to 150,000 individual activities. With this level of complexity, approximately half of all shutdown projects are delayed by more than 20% and 80% go over budget by more than 10%. Frequently, the work scope increases unexpectedly by up to […]

SMARTBOLTS.COM - LOOSE BOLTS - CAUSES

 http://www.smartbolts.com/insights/loose-bolts-causes-ways-prevent/

"A pressurized bolted flange joint assembly begins to leak, creating a safety hazard. A rotor with its blades separates from the nacelle and spins off a wind turbine, crashing to the ground. Under constant vibration from the engine of an ocean freighter, loose bolts on a large piece of mining equipment work their way off the bolted joints and roll around the hull, inflicting further damage to the equipment".

How to Clean Natural Gas Piping with Gas Blows

How to Clean Natural Gas Piping with Gas Blows: Before new fuel gas piping can be connected to a combustion turbine (CT), it must be cleaned by “decompression” gas blows. Here's how to do it.

How to Conduct Steam Blowing Procedures with Remote Personnel

How to Conduct Steam Blowing Procedures with Remote Personnel: Many power projects have been disrupted due to COVID-19. However, managers at Larsen & Toubro Ltd. found a way to complete steam blow requirements in spite of the pandemic, using secure internet

Improving Asset Inspections with Drones and AI

Improving Asset Inspections with Drones and AI: The U.S. bulk electric system has more than 360,000 miles of transmission lines, which means power companies have a lot to inspect. Drones and AI can help.

Preventing and Mitigating Oil Fires in Power Plants

Preventing and Mitigating Oil Fires in Power Plants: It has been said that a picture is worth a thousand words. However, photos of the conflagrations that have resulted from ignition of minor lube oil leaks on a typical steam turbine room floor will leave you speechless. Full-scale physical simulations of oil fires by the insurance company FM Global leave no doubt that power plant fire prevention and mitigation is a judicious blend of art and science.

Worker seriously injured when pipe assembly failed pressure test

 http://www.resourcesandenergy.nsw.gov.au/__data/assets/pdf_file/0006/587193/SA15-08-Worker-seriously-injured-when-pipe-failed-pressure-test.pdf

Safety Alert for Installation of Installation of Spring SupportsSpring Supports

 https://pipingtech.com/wp-content/uploads/2017/10/travelstop.pdf

Pipe supports failure

 https://www.youtube.com/watch?v=YC8Lip9BIUY

Hazards of hydraulic accumulators

 https://www.machinerylubrication.com/Read/30331/hydraulic-accumulators-dangers

External chloride stress corrosion cracking of stainless steel

 https://www.hse.gov.uk/safetybulletins/lokring-pipe-connectors.html