ASSET INTEGRITY ISSUES

Failure to correct equipment deficiencies that are outside acceptable limits39 is one of the leading causes of PSM non-compliance in the petroleum refinery sector. Non-compliance for equipment deficiencies broke down into four major groups:

1. Lack of proper maintenance or repair, 38. 29 CFR 1910.119(j)(1)(i)-(vi)39. 29 CFR 1910.119(j)(5)OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION18
2. Inappropriate installation (such as inappropriate sizing),
3. Missing protective system (such as not including relief devices), and
4. Insufficient structural support.

Equipment most commonly cited for deficiencies were relief devices, followed by piping circuits, pressure vessels, and alarm systems.

Source:Osha.gov

 

VALVE MAGAZINE - mistakes and misconceptions in valve leak testing

This is a good article. Many times, the points mentioned in the article are missed.

https://www.valvemagazine.com/magazine/sections/features/7388-mistakes-and-misconceptions-in-valve-leak-testing.html

Pneumatic testing fatality

A worker was killed and another seriously injured during leak testing on a heat exchanger.
The workers were using inert gas when a tube bundle ejected with great force striking them both.
An investigation into the cause of the incident found the following immediate causes:
1. Use of an unsafe work procedure for leak testing of the heat exchanger, no test ring was used and the use of high risk pneumatic test method.
2. Failure to stop test when instructed.
3. Inadequate protection from the potential of tube bundle propelling outwards.
Source:IChemE

Worksafe - safe selection and use of flexible hose assemblies

https://www.worksafe.vic.gov.au/safety-alerts/safe-selection-and-use-flexible-hose-assemblies

Air Receivers and Relief Valves

An accident with an air receiver teaches us many lessons. Read about it in this link
Source: US coast guard

TANK EXPLOSION

TANK EXPLOSION
An incident where a damaged pump caused an explosion
Source: US Coast Guard

Small bore rubing failure incident

https://www.iadc.org/wp-content/uploads/2018/04/SA-18-03.pdf

Maintenance Management of Aging Oil and Gas Facilities

Riaz Khan, Ammeran B. Mad, Khairil Osman and Mohd Asyraf Abd Aziz (January 16th 2019). Maintenance Management of Aging Oil and Gas Facilities [Online First], IntechOpen, DOI: 10.5772/intechopen.82841. Available from: https://www.intechopen.com/online-first/maintenance-management-of-aging-oil-and-gas-facilities

Stress corrosion cracking incident

Stress corrosion cracking incident

Be proactive not reactive with plant hoses

https://www.plantservices.com/articles/2010/01hydraulichoses/

Piping hydrostatic testing

Piping hydrostatic testing

Why gaskets should not be reused

Why gaskets should not be reused - a good case study

Extending the Life of Aging Pipeline Infrastructure

Good article by GPT Industries
Extending the Life of Aging Pipeline Infrastructure

Off the shelf anti-vibration system | Engineer Live

Off the shelf anti-vibration system | Engineer Live

Safety And Reliability: Two Sides Of The Same Coin

Safety And Reliability: Two Sides Of The Same Coin: Maintenance and reliability efforts are critically important in today’s industrial environment where increasingly complex and interdependent equipment are utilized.

Common Causes of Gasket Failure

Common Causes of Gasket Failure: During the course of our 50 years in business, Associated Gaskets has seen many different types of gasket failures. Sometimes these were seen late at night when we were called out to help with an emergency, other times it was when one of our own gaskets was returned after failing …

https:/Stored energy-injury caused by failure of expansion joint

https://www.imca-int.com/alert/1393/stored-energy-injury-caused-by-failure-of-expansion-joint-in-fire-fighting-equipment/

Cut your losses with relief valve monitoring by Emerson Process Management

http://www2.emersonprocess.com/siteadmincenter/PM%20Articles/P28-29%20Inside%20Process.pdf

A reliable plant is good for safety

https://reliabilityweb.com/articles/entry/a_reliable_plant_good_for_personal_and_process_safety

Integrity Manuals: The Most Significant Factor in Avoiding Asset Failure

Integrity Manuals: The Most Significant Factor in Avoiding Asset Failure: This special report, authored by Richard Fish, Asset Integrity Specialist, demonstrates the importance of integrity manuals when it comes to combating asset corrosion.