valve selection & risk
TRANSCRIPT
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Valve Selection & Risk An End-user’s Perspective
Stephen R. TreichlerMechanical Services Manager – BASFFreeport, Texas
Introduction – Confessions, Caveats, and Codicils – User vs Owner
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Valve Selection & Risk An End-user’s Perspective
Introduction – Confessions, Caveats, and Codicils
Risk – Pre-FEED:
Philosophies of valve selection / hazard analysis practices
Human Factors and Design – ergonomics to confusing configurations
Risk – After the thrill of the EPC is gone
Other risks:
Manufacturing quality
Entropy – external effects (CUI and other gorillas in our midst…)
Future Risks: Keeping up with the Joneses
The Probability and Consequences of Competition and Consolidation
The Probability and Consequences of Regulatory “Support”
PATH FORWARD
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Valve Selection & Risk An End-user’s Perspective
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A Personal Sidebar…
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A Personal Sidebar…
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A Personal Sidebar…
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A Personal Sidebar… “RISK”
API 580 - Risk is the combination of the probability of some event
occurring during a time period of interest and the consequences,
(generally negative) associated with the event.
In mathematical terms, risk can be calculated by the equation:
Risk = Probability × Consequence
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Risk – a la API 580
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Risk Matrix
Risk – Pre-FEED:
Process Safety / Hazard Analysis Practices
Philosophies of Valve Selection (Commodity vs Specialty)
Design with Humans in Mind – ergonomics to confusing configuration
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Valve Selection & Risk
Process Safety / Hazard Analysis Practices
HAZOPS Valve Selection, SIF Determinations, etc.
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Process Safety / Hazard Analysis Practices
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BP, Texas City, Texas, 2005
Phillips, Pasadena, Texas 1989
BP, Gulf of Mexico, 2010
Accessibility
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Actuation in lieu of Accessibility
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Ergonomics
in Design…
Risk – After the thrill of the EPC is gone…
FIRST: Were the right decisions made?
Entropy
Manufacturing QC
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Valve Selection & Risk
Installation Error: CS vs 316SS
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Installation Error - 4” SS Ball Valves
50X magnification of the PTFE seats
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Trouble-shooting
and After-the-fact
Material Selection
Broken Valve Stem – RC: Fatigue
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CUI: You can run …
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CUI: You can run but you cannot hide….
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CUI: You can run but you cannot hide….
OEM QC Issues
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OEM QC Issues
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OEM QC Issues
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OEM QC Issues
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OEM QC Issues
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OEM QC Issues
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A Little Thing…
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Broken Valve Follower
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Broken Valve Follower Synopsis
• Manual block valve in bypass line around FV- XXX
• 12/01/2014 (9:38A.M.)
• While attempting a repair, the follower failed on a process service @ 465 psig / -150°F.
• The failure potential of failing without any interaction was highly possible due to the broken
follower.
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Broken Valve Follower Contributing Cause
Manufacturing defect - metallurgy was outside of required specification (correct
spec stamped on follower). Carbon and Manganese content too high.
Manufacturing defect unknown previously. Could only have been found with
destructive testing.
Future Risks: Keeping up with the Joneses
Retrofits of old process technologies to meet needs
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Future Risks: Keeping up with the Joneses
The Probability and Consequences of Competition and Consolidation
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Future Risks: Keeping up with the Joneses
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Future Risks: Keeping up with the …?
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SMEs?
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Future Risks: Keeping up with the Joneses
The Probability and Consequences of Regulatory “Support”
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The Probability and Consequences of Regulatory “Support”
Shall we start with
OSHA 1910: “PSM”
and Mechanical
Integrity…?
Future Risks: Keeping up with the Joneses
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Keeping up with the Joneses –
But - Ever increasing regulatory expectations are a fact of life.
Is the valve industry in the loop as to what the Federal Government and
the States are expecting (EPA Consent decrees, NSF 61, etc.)?
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Keeping up with the Joneses –
Ever increasing regulatory expectations are a fact of life.
Is the valve industry in the loop as to what the Federal Government and
the States are expecting (EPA Consent decrees, NSF 61, etc.)?
I am not sure your customers are….
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PATH FORWARD -
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PATH FORWARD -
The Owner community’s expectations:
Safety
Sustainability
The USER community’s expectations:
Safety
Reliable and Sustained Operation
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Path Forward: How do we keep this…
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…from becoming this…
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…or, worse, this?
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Thank you…
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Backup slides…
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