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am (KO pot, filter, etc.) with automatic blowdown of solids Tracing of piping to minimize solid deposition Piping (12) Procedural Removal of solids from process stream (KO pot, filter, etc) with manual blowdown of solids Periodic manual system cleaning Operator response to high pressure alarm Periodic cleaning via flushing, blowdown, internal line cleaning devices (e.g., pigs) Use parallel switchable flame arresters
No. 1
Failure Scenarios
Inherently Safer/Passive
Blockage of piping, valves or Size piping system to maintain flame arresters due to solid minimum required velocity deposition to avoid deposition Piping designed for maximum expected pressure Eliminate flame arrester
Overpressure
Valve in line rapidly closed resulting in liquid hammer and pipe rupture
operated valves via appropriate gear ratio Limit closing rate for pneumatic actuator via restriction orifice in air line Use slow closing manual valves (i.e., gate instead of quarter turn)
9/15/2012
Chapter 12
12-1
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural
No. 3
Failure Scenarios Thermal expansion of liquid in blocked-in line leading to line rupture
Inherently Safer/Passive
Elimination of potential for Pressure relief device blocking in by removing Expansion tank valves and other closures (e.g. blinds) Drill small hole in valve gate to allow pressure equalization
Overpressure
Automatic control valve opens inadvertently leading to high pressure downstream of the valve
Design all downstream piping and equipment to handle full upstream pressure Provide limit stop to prevent control valve from opening fully, or a restriction orifice
9/15/2012
Chapter 12
12-2
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural
No. 5 6(T)
Failure Scenarios Block valve upstream or downstream of relief device accidentally closed resulting in loss of relief capability
Inherently Safer/Passive Eliminate all block valves in relief path Provide trans-flow three-way block valve at inlet of dual relief device installation
block valves upstream and downstream of relief valves per applicable codes and provide administrative procedures to regulate opening and closing of such valves
7 8(T)
Overpressure
Use rupture disks alone or in Manual periodic or continuous combination with safety flush of relief device inlet valves with appropriate with purge fluid rupture disk leak detection Automatic flush of relief device inlet with purge fluid
9/15/2012
Chapter 12
12-3
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural
No. 9 10( T)
Inherently Safer/Passive
Multiple rupture Inert purging prior to start-up disks/explosion vents located at appropriate points on piping Detonation or suitable deflagration arresters between protected equipment and potential ignition sources Liquid seal drum isolating ignition source (e.g., flare) Operate outside flammable range, e.g., O2 analyzer or hydrocarbon analyzer control inert purge or enrichment gas addition Detect gas flame and actuate fast closing valve or suppression system Electrical tracing with temperature limitation controls Operator action in response to high temperature indication and alarm
11
High Temperature
Faulty tracing or jacketing of line leading to hot spots resulting in exothermic reaction
Use of insulating material between tracer and pipe (sandwich tracer) Use of heat transfer media with maximum temperature limited to a safe level (jacketed pipe)
9/15/2012
Chapter 12
12-4
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Fire detection system with automatic water spray Piping (12) Procedural Fire detection system with manual water spray
No. 12
Failure Scenarios External fire leading to undesired process reaction (e.g., acetylene decomposition)
Inherently Safer/Passive
13
Low Temperature
Cold weather conditions causing freezing of accumulated water or solidification of product in line or deadends
Elimination of collection points or deadends Deadends should be sloped to avoid accumulation Blowdown lines should be sloped to avoid accumulation
Heat tracing of lines Procedures to maintain a Automatic drainage of potential minimum flow through line collection points Manual draining of potential collection points
9/15/2012
Chapter 12
12-5
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Heat tracing of lines Piping (12) Procedural Procedures to slowly warm-up downstream piping
No. 14
Failure Scenarios Condensation in steam lines due to cold ambient conditions resulting in steam hammer
15
High Flow
High fluid velocity in pipe which causes erosion especially if two phase flow or abrasive solids are present leading to loss of containment
9/15/2012
Chapter 12
12-6
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural
No. 16
Failure Scenarios High pressure drop across control valve causing flashing/vibration leading to loss of containment
Inherently Safer/Passive Locate valve as close to the vessel inlet as possible Provide multiple intermediate pressure letdown devices (valve or orifices) Use valve type suitable for high pressure drop and flashing service Securely anchor piping
17 18
Reverse Flow
Differential pressure on joining lines, drains or temporary connections causing back flow of product resulting in undesirable reaction, overfilling, etc.
Use incompatible fittings to prevent unwanted connections Use separate lines to final destination
Check valve on lower pressure line to prevent reverse flow Automatic isolation on detection of low differential pressure
Procedures for proper isolation of interconnected lines Manual isolation on detection of low differential pressure
9/15/2012
Chapter 12
12-7
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Automatic closed loop sampling system Piping (12) Procedural Provide double block and bleed valves, valve plugs, caps, blinds, etc.
No. 19 20( T)
Failure Scenarios Failure to isolate flow from sample connection, drain and other fittings resulting in discharge to environment
Inherently Safer/Passive
21
Loss of Containment
Breakage of sight glasses and glass rotameters due to overpressure, thermal stress, or physical impact
glasses and rotameters Provide flow restriction orifice in glass connection Provide physical protection against damage (i.e., armored sight glass) Provide glasses with pressure design rating exceeding maximum expected pressure
Provide excess flow check valves to limit discharge due to sight glass or rotameter failure
9/15/2012
Chapter 12
12-8
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Provide automatic isolation on detection of high flow, low pressure, or external leak Use fusible link valves for automatic closure under fire conditions Piping (12) Procedural Provide manual isolation via remotely located valve Procedural restrictions to avoid damage (crane restrictions, climbing restrictions) Periodic inspection for leaks
No. 22
Failure Scenarios Loss of containment from piping due to leak, flange leak, valve leak, pipe rupture, collision, or improper support
Inherently Safer/Passive Maximize use of all-welded pipe Avoid use of underground piping Use double walled pipe Minimize use of unnecessary fittings Use of higher integrity closures (e.g., clamped connectors) Shielding at flanges to prevent operator exposure Use of minimum diameter pipe for physical strength Proper design and location of piping supports Physical collision barriers
23 24( T)
Loss of Containment
9/15/2012
Chapter 12
12-9
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Provide excess flow check valve upstream and check valve downstream of hose Automatic isolation based on detection of high flow, low pressure or external leak Use fusible link valves for automatic closure under fire conditions Piping (12) Procedural Pressure test transfer hose before use Manual isolation based on detection of high flow, low pressure or external leak Periodic replacement of hoses Provide hose protection (e.g., ramp) when laying hoses across roadway Avoid sharp angle changes in direction
No. 25
Failure Scenarios Degradation of transfer hose between use results in hose leak
Inherently Safer/Passive Eliminate hose connections (hard piped) Use higher integrity hose (e.g., metallic braided) Use higher pressure hose
26
Use pipe metallurgy which does not require lining Use semi-conductive liner to reduce degradation due to static build-up Use thicker liner material Limit liquid velocity to minimize static buildup
Periodic thickness testing of metal pipe wall Periodic process stream analysis for metals content
9/15/2012
Chapter 12
12-10
Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural Procedures to prevent inadvertent cross-connections Labeling and color coding of lines
No. 27
Inherently Safer/Passive Specify incompatible ends to prevent misconnection Avoid use of quick connects for hazardous service
9/15/2012
Chapter 12
12-11