Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Emergency relief device Removal of solids from process stream

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

Operational Deviations Overpressure

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

Limit closing rate for motor

Provide surge arrester

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)

Operating procedures to close valves slowly

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural

No. 3

Operational Deviations Overpressure

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

Procedures for draining of all

blocked-in lines during shutdown

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

Pressure relief device to protect

downstream piping

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural

No. 5 6(T)

Operational Deviations Overpressure

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

Car-seal open or lock open all

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

Blockage of relief device by solids deposition (polymerization, solidification)

Provide flow sweep fitting at inlet of relief device

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

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural

No. 9 10( T)

Operational Deviations Overpressure

Failure Scenarios Deflagration and detonation in pipelines causing loss of containment

Inherently Safer/Passive

Limit temperature, pressure or

pipe diameter to prevent DDT from occurring (e.g., acetylene) Avoid/minimize use of elbows and fittings which can cause turbulence and flame acceleration

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)

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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

Operational Deviations High Temperature

Failure Scenarios External fire leading to undesired process reaction (e.g., acetylene decomposition)

Inherently Safer/Passive

Fireproof insulation with

stainless steel sheathing and banding Continuous welded pipe

13

Low Temperature

Cold weather conditions causing freezing of accumulated water or solidification of product in line or deadends

Insulation of process lines

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

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Heat tracing of lines Piping (12) Procedural Procedures to slowly warm-up downstream piping

No. 14

Operational Deviations Low Temperature

Failure Scenarios Condensation in steam lines due to cold ambient conditions resulting in steam hammer

Inherently Safer/Passive Securely anchor piping

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

Sizing of pipe to limit velocities Material selection to resist

erosion Heavier walls at tees, elbows, and other high abrasion points Minimize use of fittings where erosion can occur Use tees instead of elbows in abrasive solid service

Instructions to limit flow velocity Periodic inspection of high wear points

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural

No. 16

Operational Deviations High Flow

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

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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)

Operational Deviations Loss of Containment

Failure Scenarios Failure to isolate flow from sample connection, drain and other fittings resulting in discharge to environment

Inherently Safer/Passive

Provide deadman (selfclosing) valve

21

Loss of Containment

Breakage of sight glasses and glass rotameters due to overpressure, thermal stress, or physical impact

Eliminate the use of sight

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

Procedure to normally isolate sight glass when not in use

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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

Operational Deviations Loss of Containment

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

Pipe failure due to excessive thermal stress

Expansion loops and joints Insulation of pipe expansion

joints Additional support to prevent sagging

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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

Operational Deviations Loss of Containment

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

Loss of Breakdown of pipe/hose Containment lining (lined pipe/hose)

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

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Table 12: FailureScenariosforPipingandPipingComponents Potential Design Solutions Active Piping (12) Procedural Procedures to prevent inadvertent cross-connections Labeling and color coding of lines

No. 27

Operational Deviations Wrong Composition

Failure Scenarios Operator connects quick connect coupling to wrong connection

Inherently Safer/Passive Specify incompatible ends to prevent misconnection Avoid use of quick connects for hazardous service

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