Safety Case Assessment Guide -

Mechanical
Soh Zi Quan, MHD
20 October 2016

A Great Workforce A Great Workplace

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Importance of Mechanical Integrity

Loss of Containment  Potential Major Accident

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Containment

Primary
When things go as
intended

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Loss of Containment

Secondary
When things go
wrong

Mitigation

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How do you know your plant is safe?

My plant
equipment are
working
well….

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 A Great Workforce A Great Workplace

How do you know your plant is safe?

I think….

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What we are looking out for…

Well-
Considered,
Thorough, &
evidence
based,
management
system

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Plant Lifecycle

Initial Integrity Continuing Integrity

Design Operation Maintenance

Modification
Construction

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Design – Mechanical Integrity

5.2.1.1: Show that installations have been

Design designed to an appropriate
standard
5.2.1.3: Show layout limits risks
5.2.1.4: Show impact of utility failure on
critical mechanical equipment
5.2.1.5: Detail presence and integrity of
mechanical measures for
containment & mitigation
5.2.1.6: Show all foreseeable direct causes
of major accidents have been
accounted

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Design – Mechanical Integrity

5.2.1.7: Show how normal loads and

Design foreseeable extremes have been
accounted
5.2.1.8: Show that materials of
construction used are suitable
5.2.1.12: Show systems for classifying areas
of potential flammable atmosphere
and associate equipment selection

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Construction – Mechanical Integrity

5.2.2.1: Show how installations have been

Construction constructed to appropriate
standards
5.2.2.2: Show how construction is assessed
and verified

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Maintenance – Mechanical Integrity

5.2.4.1: Show an appropriate maintenance

Maintenance regime is established
5.2.4.2: Show appropriate procedures for
to account for hazardous
conditions
5.2.4.3: Show critical equipment and
systems are examined by a
competent person at suitable
intervals
5.2.4.4: Show that results of periodic
examination and maintenance are
used to ensure continued safety

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Modification/Decommissioning –
Mechanical Integrity

5.2.5.1: Show systems for ensuring

Modification
modifications are adequately
designed, installed and tested
Show decommissioned facilities do
not increased risk to remaining
facilities

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Common Unit Operations

Heat
Pipework Storage Tank Exchanger

Distillation
Reactor Pumps Column

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Using pipework as an illustration

Heat
Pipework Storage Tank Exchanger

Distillation
Reactor Pumps Column

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A real life example….

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Sulfidation Corrosion

Corrosion (Sulfidation)
• Rxn between Sulphur compounds & Iron
• Causes thinning in iron-containing materials

Material (Carbon Steel)

• >9.0%wt Cr increases resistance
• >0.1%wt Si increases resistance

Temperature
• 230oC to 540oC
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Pipework Design for Sulfidation Corrosion

5.2.1.1: Show that installations have been

Pipework designed to an appropriate
standard
5.2.1.3: Show layout limits risks
5.2.1.4: Show impact of utility failure on
critical mechanical equipment

Design 5.2.1.5: Detail presence and integrity of

mechanical measures for
containment & mitigation
measures
5.2.1.6: Show all foreseeable direct causes
of major accidents have been
accounted

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 A Great Workforce A Great Workplace

Pipework Design for Sulfidation Corrosion

5.2.1.7: Show how normal loads and

Pipework foreseeable extremes have been
accounted
5.2.1.8: Show that materials of
construction used are suitable
5.2.1.12: Show systems for classifying areas
of potential flammable atmosphere
Design and associate equipment selection

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 A Great Workforce A Great Workplace

Key CSB Findings

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Pipework Construction for Sulfidation Corrosion

5.2.2.1: Show how installations have been

Pipework constructed to appropriate
standards
5.2.2.2: Show how construction is assessed
and verified

Construction

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Pipework Maintenance for Sulfidation Corrosion

5.2.4.1: Show an appropriate maintenance

Pipework regime is established
5.2.4.2: Show appropriate procedures for
to account for hazardous
conditions
5.2.4.3: Show critical equipment and
systems are examined by a
Maintenance competent person at suitable
intervals
5.2.4.4: Show that results of periodic
examination and maintenance are
used to ensure continued safety

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Key CSB Findings

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Key CSB Findings

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Key CSB Findings

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Key CSB Findings

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What if there are insufficient demonstration?

“This conversation might take a while…..”

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Thank You

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