Top 10 Root Causes for Fixed Equipment Mechanical Integrity Failures - Part 1 _ RefinerLink
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2/ 4/2 015 To p 10 Ro ot Ca uses f or Fixed Equipment Me ch anica l I nte grit y Fa ilu re s - Part 1 | Re f inerLin k ht tp: //www .r e f in erli nk. co m/ blo g/To p_10 Ro ot_Ca us e s_ Fi xe d Equip m ent_Me ch anical_ Integrit y_ Fa ilu r es _ Part 1 1/ 5 Discussion Discussion Tweet 0 Oct 12, 2014 Top 10 Root Causes for Fixed Equipment Mechanical Integrity Failures - Part 1 By John Reynolds of Inspectioneering.com RL Blogs The first part of a two part series that assesses the top ten reasons for FEMI failures that cause process safety incidents. Fixed equipment mechanical integrity (FEMI) failures are not caused by damage mechanisms; rather, they're caused due to failure to create, implement, and maintain adequate management systems to avoid failures. Nearly all failures that have occurred in our industry could have been avoided if these human systems were more robust and sustainable in providing the primary layers of protection for FEMI. The ten reasons I’ve outlined are a result of doing 60+ FEMI audits within refineries and chemical plants in the last 45+ years, tracking 150+ serious FEMI incidents in the petroleum and petrochemical industry and their causes, and defending numerous clients in the industry from lawsuits pertaining to FEMI issues. Before we jump into the first five reasons, let's start with a few quick notes: Throughout these posts, I'll be using the acronym FEMI, which stands for fixed equipment mechanical integrity. You might also know it as pressure equipment integrity management. This blog is an abridged version of an article that is coming up in an issue of Inspectioneering Journal. If you haven't subscribed yet, do so here so you won't miss the full version of this blog series. I presented this topic at the upcoming ASME Pressure Vessel and Piping (PVP) conference this year in July Anaheim, California. You might look at the list that follows and say to yourself: "Well, our site Blog Topics 14 Like Share 32 New sletter | A dver tise | Join | Log in Recent Blogs 12 Refinery 101 7 Refinery Optimization 16 Unit Operations 14 Product Value Upgrading 5 Market Analysis 20 Supply & Logistics 9 Career Advice 18 Safety & Environment 15 Reliability and Maintenance 6 Miscellaneous 11 Promotions 54 Discussion Buzz See Forum Page 3 of 3 Why, When and How to update Fuels Blending Models ? We all know that blending in a refinery... Suresh Agrawal 2 replies How does introduction of steam prevents the formation of coke in cracking operations? Chinmoy Banerjee 5 replies What is the difference between regular gasoline and straight run gasoline?? Chinmoy Banerjee 6 replies Job Postings Director, Technical Base Oils Houston, Texas,US Fitness Specialist Home Events News Jobs Discussions Directory Blogs Account
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Oct 12, 2014
Top 10 Root Causes for Fixed Equipment MechanicalIntegrity Failures - Part 1By John Reynolds of Inspectioneering.com
RL Blogs
The first part of a two part series that assesses the top ten reasons for FEMI failuresthat cause process safety incidents.
Fixed equipment mechanical integrity(FEMI) failures are not caused bydamage mechanisms; rather, they'recaused due to failure to create,implement, and maintain adequatemanagement systems to avoid failures.
Nearly all failures that have occurred inour industry could have been avoided if these human systems were morerobust and sustainable in providing theprimary layers of protection for FEMI.
The ten reasons I’ve outlined are a result of doing 60+ FEMI audits withinrefineries and chemical plants in the last 45+ years, tracking 150+ seriousFEMI incidents in the petroleum and petrochemical industry and theircauses, and defending numerous clients in the industry from lawsuitspertaining to FEMI issues. Before we jump into the first five reasons, let's start with a few quick notes:
Throughout these posts, I'll be using the acronym FEMI, whichstands for fixed equipment mechanical integrity . You might alsoknow it as pressure equipment integrity management.
This blog is an abridged version of an article that is coming up in anissue of Inspectioneering Journal. If you haven't subscribed yet, doso here so you won't miss the full version of this blog series.
I presented this topic at the upcoming ASME Pressure Vessel andPiping (PVP) conference this year in July Anaheim, California.
You might look at the list that follows and say to yourself: "Well, our site
Blog Topics
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Recent Blogs 12
Refinery 101 7
Refinery Optimization 16
Unit Operations 14
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Discussion Buzz See Forum
Page 3 of 3
Why, When and How to update FuelsBlending Models ? We all know thatblending in a refinery...Suresh Agrawal2 replies
How does introduction of steamprevents the formation of coke incracking operations?Chinmoy Banerjee5 replies
What is the difference between regular gasoline and straight run gasoline??Chinmoy Banerjee6 replies
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Director, Technical Base OilsHouston, Texas,US
Fitness Specialist
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already has all of those programs." My point isn't that it is the existence of each of these FEMI programs that is most important, but rather the qualityand sustainability of them. If each operating site wants to largelyeliminate the risk of a big FEMI event at their site, then each operating sitemust obtain and sustain an "A" grade on each of these top ten FEMI issues;a score of less than that will generally not suffice. Each site needs to achieve excellence in implementation . Not justcompliance, and not just "checking the box" because of some rules and
regulations. Excellence simply means doing all the right things, and doingthem right each and every time in accordance with an up-to-date,documented FEMI management system. Now, let's briefly mention the first five of ten reasons for significant fixedequipment mechanical integrity failures in the hydrocarbon process industry.
Reason #1: Inadequate or lack of identifying and managing thehighest priority FEMI risks in each process unit
Each process unit should keep a list of the highest FEMI risks at each site--not just a FEMI bad actors list--there's a significant difference between themwhich will be explained in a future article in the Journal. The highest FEMI risk list should be prioritized with all other site resourcedemands and kept in front of all key stakeholders at the site. We need tohelp all stakeholders understand that even though most equipment damagemechanisms result in leaks with minor consequences, every once in a whilethey have huge process safety consequences such as fires, explosions,injuries, fatalities, adverse media attention, fines, lawsuits, and a threat tocontinued operations. Does your site track and mitigate its highest risk FEMI issues in each processunit?
Reason #2: Inadequate or lack of comprehensive Corrosion ControlDocuments (CCD's) for each process unit CCD's take the generic damage mechanisms found in API RP 571 and makethem specific to each process unit at each site. They capture nearlyeverything that is known about how equipment degrades in a particular fluidservice, under specific process conditions, and how to find it, avoid it, and
mitigate it. CCD's, when created properly, become the primary source of knowledge transfer to all other stakeholders in the site. I should mention that API RP 970, currently in progress of being written, willoutline the entire work process to produce a comprehensive CCD. Does your site have complete, detailed CCD's that capture everything that isknown about the potential for FEMI failures in each of your process units?
Reason #3: Inadequate or lack of a thorough, comprehensive pipinginspection program per industry standards
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process engineering know what changes should be assessed with theMOC process.
Too many sites don't communicate well with the FEMI group onabnormal or upset conditions that may lead to accelerated corrosionand unanticipated damage mechanisms.
Some process and operating personnel don't understand thatinspection schedules and strategies are based on historic records
and that inspectors are not just constantly looking for new orunexpected corrosion.
Is your MOC process as effective on process changes as it is on physical changes?
At this point, I’ve outlined the first five of ten reasons for fixed equipmentmechanical integrity failures in the hydrocarbon process industry. I’ll followthis article up with another one that contains the remaining five reasons,which are:
Inadequate implementation of guidance from industry codes andstandardsInadequate programs for learning from previous FEMI incidentsInadequate record-keeping and data analysisNot using the best available NDE and inspection technologyInsufficient training and knowledge transfer for FEMI personnel
Continue reading with part two .
You can sign up for the Inspectioneering Turnaround newsletter to get anotification when the next article is released. Also, be on the lookout for an
expanded version of this series in Inspectioneering Journal.
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