Introduction Mechanical integrity is one of the most important barriers between normal refinery operation and a major accident. In simple terms, mechanical integrity is the assurance that pressure equipment, piping, tanks, heaters, valves, flanges, small-bore connections and associated components are suitable for their intended service and remain fit for continued operation. It is not just about inspection. It is not …
Lessons from Silver Eagle: Metallurgical Failure, Inspection Oversight, and the Critical Role of Integrity Planning On 4 November 2009, a catastrophic explosion rocked the Silver Eagle Refinery in Woods Cross, Utah. The source: a sudden and violent rupture of a 10-inch carbon steel discharge line from the South Reactor (R30101) within the Mobil Distillate Dewaxing Unit (MDDW), releasing a large …
Credit: CSB On April 3, 2017, a catastrophic failure occurred at the Loy-Lange Box Company in St. Louis. A pressure vessel—the Semi-Closed Receiver (SCR), which stores hot condensate at 100 psig—violently ruptured. Propelled like a missile, it tore through the facility, launched through the roof at 120 mph, and crashed into a neighbouring building 520 feet away, killing four people …
The Importance of Integrity Operating Windows (IOWs) in Inspection Programmes
Training | Oct 22, 2024
On April 2, 2010, the catastrophic failure of a heat exchanger at the Tesoro Anacortes Refinery in Washington led to a deadly explosion, killing seven workers. The root cause was identified as High-Temperature Hydrogen Attack (HTHA), a damage mechanism that degrades steel when exposed to hydrogen at high temperatures and pressures. Although the equipment was operating under conditions deemed safe …
Residual stresses are an often-overlooked but critical factor in the long-term reliability and safety of pressure equipment such as vessels, piping, and storage tanks. These stresses, which remain within a material after fabrication processes like welding, forming, or heat treatment, can significantly influence equipment’s structural integrity under high-pressure and high-temperature conditions. In this article, we explore residual stresses, where they …
Mastering Technical Report Writing for Pressure Equipment Inspection and Assessment – In the field of pressure equipment inspection and assessment, the ability to produce a clear, accurate, and thorough technical report is an invaluable skill. These reports play a crucial role in documenting compliance, conveying the condition of critical equipment, and providing recommendations for maintenance or repair. A well-crafted report …
Pitting corrosion poses a serious threat to the integrity of metallic structures, primarily due to its highly localised nature. Unlike uniform corrosion, which affects larger areas more predictably, pitting targets small, concentrated spots on a metal’s surface, leading to the formation of cavities or “pits” that can penetrate deeply into the material. Even when the overall mass loss is minimal, …
Important Update: Changes to API ICP Exam Administration We want to inform all our visitors about a significant change announced by the American Petroleum Institute (API) regarding the administration of their Individual Certification Program (ICP) exams. Discontinuation of Remote API Proctored Exams API has recently decided to discontinue the option for remotely proctored exams for their core certification programmes, effective …
Ensuring the Integrity of Low-Pressure Vessels: Lessons from the Yenkin-Majestic Incident In this short article, I dive into the catastrophic failure at the Yenkin-Majestic resin plant, where poor design, inadequate pressure testing, and a failure to adhere to crucial safety codes led to a tragic explosion. This incident highlights the critical importance of ensuring that even low-pressure vessels are designed …
FITNESS FOR SERVICE ASSESSMENTS (FFSAs) UNDERSTANDING THE FOLIAS FACTOR We like to keep things simple on our FFS training courses at Wilkinson Coutts. In FFS codes, the term shells describes pipes, vessels, and tanks collectively. The FOLIAS factor (M) is a critical component in assessing these shells. So, what is it? It’s just a stress concentration factor to acknowledge …