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 …