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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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