the 50 major engineering failures

8/12/2019 The 50 Major Engineering Failures

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The 50 Major Engineering Failures (1977-2007) Part-1

List of Engineering Failures Contributed by Material Failures, Corrosion, Design Flaw, andConstruction Defect in Oil and Gas Production Facilities, Hydrocarbon Processing, and Oil and GasDistribution

(Part 1 of ! "Mu#a$$ad %bdu# (abdu#&re'solindocoid!

%s 'ey c#ain in world energy su))ly, t#e industry wit#in oil and gas )roduction, #ydrocarbonrefinery, storage and distribution, and )ower )lant industry stri*e to ac#ie*e t#e #ig#est le*el ofintegrity and reliability of t#eir facilities, structures, tool and e+ui)$ent syste$ ndustrysta'e#olders t#at ranging fro$ oil and gas )roducer, engineering, )rocure$ent, contractors, $aterialsu))liers, and ins)ection co$)anies fro$ day to day i$)ro*e t#e +uality standards, disco*eringnew te#cnologies, de*elo) new tec#ni+ues and $et#odologies in order to raise t#e engineeringintegrity for t#e i$)ro*e$ent of safety for )eo)le , en*iron$ent conser*ation, and securingecono$ic in*est$ent

Tak ada gading yang tak retak %s an ancient ndonesian )ro*erb is also #a))ened to engineeringstructure- t#ere will be no design wit#out flaw and t#ere will be no construction wit#out defectFailures so$eti$es occur n se*eral cases t#e after$at# of failures #a*e a significant i$)act to t#e

)eo)le safety and econo$ic ris' .ut industry gain a *aluable e/)erience eac# accident occurs0#ere always be o))ortunities to i$)ro*e o)eration )rocedures, *alue )erce)tions, tec#nical codere*isions, and regulatory i$)ro*e$ents

0#is )ublication as a result of literature wor' is ai$ed is to de*elo) an alternati*e engineeringfailure database associated wit# $aterial failures,corrosion, design flaw and construction defect t#atlead to $aterial failure in oil and gas )roduction, #ydrocarbon industry, oil and gas distribution

networ', and energy )ower )lant

1. Umm ai! "atar # $%ril &' 1977 (el! Failure' as Pro*essing Plant' & +ille!' U,

7'&50'000179'000'000)

% tan' containing 23,444 barrels of refrigerated )ro)ane at 5 6F failed at weld 7ear"$iss"accident a year earlier re)orted at si$iliar tan' weld caused 15,444 barrels of )ro)ane released 0#e

)ossible cause of /el! ailurewas corrosion by t#e influence of sul)#ate reducing bacteria t#atre$ained inside t#e tan' after #ydrotest wit# seawater 0#e wa*e of li+uid )ro)ane swe)t o*er t#edi'es before igniting a near tan' contained 1,444 barrels of but#ane t too' eig#t days toco$)letely e/tinguis#ed t#e fire (8ource, Location!

2. $ai au!i $raia # $%ril 15' 1973 (4orrosion' as Pro*essing Plant' U,

5&'700'000117'000'000)

% "inc# )i)e o)erated at 44 )sig in gas trans$ission syste$ corroded and releasing *a)or cloud0#e first ignition occured fro$ a flare 1,44 feet downwind 0#e second ignition occured w#en 9etw#i))ed )i)e section struc' t#e *a)or s)ace of a 14,444 barrels s)#eroid tan' (8ource, Location!

&. E+ois+ or/a6 # Mar*h 27' 1930 (el! Failure' shore Platorm' 12& +ille!)
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2/22

%le/andra L :ielland Platfor$, a se$i"sub$ersible oil drilling )latfor$ located at E'ofis' field7ort# 8ea ca)si;ed during a stor$ 0#e )latfor$ su))orted by fi*e colu$ns standing on fi*e $eter dia$eter )ontoons 0#e fi*e


3/22

% *essel for $onoet#anola$ine absorber was constructed ten years earlier wit# one"inc# t#ic'%80M %13 Gr A4 steel )lates rolled and welded wit# full sub$erged arc wit#out )ost weld #eattreat$ent Bust )rior to ru)ture a - in*hes *ra*+ !ete*te! at *ir*umerential /el!and by t#e ti$eo)erator close inlet *al*e crac' s)read to 5 inc#es 0#e area was already cleared for e*acuationand w#en fire brigade arri*ing t#e e/)losion occured 0#is e/)losion created se+uential fire ande/)losion wit#in refinery )lant % boiling li+uid e/)anding *a)or e/)osion (.LE?E! occured in a

al'ylation unit *essel0ec#nical in*estigation )ointed t#at crac' initiated at H%= of welded s#ell of t#e colu$n by#ydrogen crac'ing, and )rogressed by t#e $ec#anis$ of #ydrogen induced ste)wise crac'ing(H8C! 0est according to 7%CE )rocedure confir$ed t#at $aterial was susce)tible to H8C(8ource 1, !

. an P

Terminal' 50 +ille! 8'000 injure!' U, 19'980'00029'000'000)

% 1"inc#es )i)eline between cylinder and s)#ere storage ru)tured nitial blast caused a series of.LE?Es 0#e oustanding cause of escalation was t#e ineffecti*e gas detection syste$ and as a

result of lac' of e$ergency isolation 0#is e/)losion and fire is )er#a)s t#e $ost de*astatingincident e*er 0#e #ig# deat# toll was due to t#e )ro/i$ity of t#e LPG ter$inal to residenceco$)le/ >ntil now t#ere isno *lear inormationabout t#e cause of )i)e ru)ture (8ource 1,!

7. >as Pie!ras ?ene@uela- Ae*emer 1&' 1938 (B6!rogen Emrittlement' einer6' U,

2'07'00039'000'000)

% fracture occured in ouisiana- U Ma6 5' 1933 (Erosion-4orrosion' einer6' 8 +ille!' 20 injure!' 8500

e:a*uate! U, 258'700'000&&'000'000)

%n elbow at de)ro)ani;er colu$n )i)ing syste$ in a fluid catalytic crac'ing (FCC! unit failed %large *a)or wit# esti$ated 4,444 )ounds of C2 #ydrocarbon cloud esca)ed fro$ t#e failed elbowand ignited in FCC c#arge #eater 0#e e/)losion of FCC unit was t#e $ost se*ere da$age % re)ort

)ointed t#at t#e failed elbow suffering e/cessi*e locally t#inning 0#e failed elbow was located

downstrea$ of t#e in9ection )oint w#ere a$$oniated water was added to reduce )ro)ani;ercondensation or fouling(8ource 1, !

9. Pi%er $l%ha orth ea UC #


4/22


5/22

15. orth hine erman6 # Ae*emer 10' 1991(Erosion-4orrosion' einer6' U,

50'500'0002'000'000)

% Pi)e failed at 0"9unction in #ydrocrac'er unit resulted in #ydrocarbon and #ydrogen release 0#erelease of t#e gas ignited and e/)losion occured and $ade se*ere da$age to t#e #ydrocrac'er unitand ad9acent substantial )art of t#e )lant 0#e #ydrocrac'er unit was s#ut down for se*en $ont#s

0#e failure of t#e )i)e was contributed by erosion"corrosion due to )lant aging (8ource!

1. ua!alajara Me=i*o # $%ril 22' 1992 (4orrosion' Fuel Pi%eline' 20 +ille!' 500 injure!'

15'000 e:a*uate!' U, &00'000'000)

Guadala9ara, Me/ico second largest city, e/)erienced series of ten $assi*e e/)losion t#at e+uals toA,4 ric#ter scale fro$ fuel )i)eline blast %n in*estigation into t#e disaster re*ealed t#at t#e $ost

)ossible cause for t#e e/)losion was t#e interference of fuel )i)eline wit# new water )i)ing syste$0#e fuel )i)eline was carbon steel and t#e sewer syste$ was ;inc"coated co))er 0#ese two lineswere close enoug# to interfere eac#"ot#er 0#ree days before t#e e/)losion, t#ere were co$)laintsfro$ t#e city residents about gasoline"li'e s$ell co$ing fro$ t#e water )i)e and sewer syste$(8ource 1, , Location!

17. estla+e >ouisiana U #


6/22

%n e/)losion fro$ failed #eat e/c#anger in t#e #ydrode"sul)#uri;ation unit caused #ydrogenrelease and ignited fire and e/)losion 0ec#nical in*estigation to t#e failure noted a co$)le/ity oft#e failure $ec#anis$ 0#e cause of t#e failure initiated by re)etition of *ariation of te$)eraturelead to decrease of dia$eter gas'et retainer and bending defor$ation of roc' ring 0#ese e*entscontributed to brea' out of roc' ring and $ade s)outs #ydrogen gas (8ource, Location!

20. >a Me!e' Fran*e o:emer 9' 1992 (Pi%e >ea+ing' einer6' U,20'000'000&13'000'000)

% )i)e failed at 0"9unction in #ydrocrac'er unit resulted in #ydrocarbon and #ydrogen releasedetection 8ubse+uent fire and e/)losion caused se*ere da$age to FCC unit, gas )lant, controlroo$, and two new )rocess unit under construction 0#e e/)losion also causing offsite da$agenearby residential wit#in t#e radius of 3 $iles away 0#e business interu)tion loss due to t#isaccident is esti$ated at >8 1ouisiana U # $ugust 2' 199& (4ree%' einer6 Plant' UA

5'200'00073'000'000)

%n elbow in t#e feed line of co'er unit ru)tured w#en feed switc#ing were )erfor$ed Ot#er )i)esin unit ru)tured subse+uently releasing $ore #ydrocarbons and fueling $ore fire to t#e )lant.ecause of t#e accident t#e co'er unit was s#ut down for t#ree wee's n*estigation to t#e failedelbow noted t#at carbon steel elbow was wrong $aterial c#osen wit# less cree) resistance instead ofCr alloy steel

22. im%son:ille a*ramento U-


7/22

Polyet#ylene )i)e trans)orting )ro)ane gas to consu$er was failed leading to fire and e/)losion0#e e/)losion occurred in fi*e stories full occu)ied business center at s#o))ing district io Piedras8an Buan Puerto ico 0#e lea'ing of )lastic )i)e was belie*ed due to construction e/ca*ationda$age around t#e )i)eline More t#an 4 )i)es and conduits surrounding t#e )lastic )i)e w#ic#were being constructed, being used and #ad been abandoned Construction e/ca*ation da$age to

)lastic )i)e was rat#er una*oidable and t#ere s#ould be )i)eline design wit# #ig#er integrity wit#in

#ig# conse+uence area (HC%! li'e io Piedras s#o))ing district(8ource!

28. Martine@ 4aliornia U # ongor! ?i*toria $ustralia -e%temer 25' 1993 (Drittle Fra*ture' as Pro*essing Plant'

2 +ille!' 3 injure!' UA 10'000'000171'000'000)
http://www.ntsb.gov/publictn/1997/PAR9701.htmhttp://www.ntsb.gov/publictn/1997/PAR9701.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://shippai.jst.go.jp/en/Detail?fn=0&id=CC1200098&kw=yokkaichi+miehttp://www.rediff.com/news/sep/15ap.htmhttp://www.rediff.com/news/sep/15ap.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://ops.dot.gov/stats/IA98.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://www.ntsb.gov/publictn/1997/PAR9701.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://shippai.jst.go.jp/en/Detail?fn=0&id=CC1200098&kw=yokkaichi+miehttp://www.rediff.com/news/sep/15ap.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://ops.dot.gov/stats/IA98.htmhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htm


8/22

Figure 8#owing GP 4 Heat E/c#anger of Longford Gas Plant

O)eration error of a by)ass *al*e allowed condensate to s)ill o*er into ot#er )arts of t#e syste$

e*entually causing t#e failure of war$ oil )u$)s 0e$)erature of a #eat e/c#anger decreasedsufficiently to lead to $aterial brittle transition O)erator t#en $ade error of restarting t#e war$ oilflow w#ic# caused t#e #eat e/c#anger to fracture %n initial release a))ro/i$ately ,444 )oundsof #ydrocarbon *a)or e/)loded and $ade t#e )lant burned for two and a #alf days ?ictoria wassaid to be in c#aos for 1 days 0#e accident caused a large socio"econo$ic e/cess 0#ere were14,444 litigants signed a class action suit t#at $ade it a largest class action in %ustralian legal#istory (8ource 1,,2!

&0. Derre lEtang Fran*e # *toer ' 1993 (4orrosion' einer6'UA 22'000'0002&'000'000)

% )i)e failed due to corrosion and released gas ignited w#en contacting #ot )rocess line 0#e firecaused t#e failure of 'erosene air cooler and adding $ore fuel too t#e fire 0#e fire created se*ereda$age to 1A,444 barrels")er"day crude unit and a 1A,444 barrels")er"day refor$er Corrosionwaslargely associated wit# t#e )resence of $ore corrosi*e na)#tanic acid (8ource!

&1. ;!jerhe iger Aelta igeria # *toer 17' 1993 (Pi%e >ea+ing'Fuel Pi%eline'100 +ille!)

Pi)e lea'ed a day before t#e e/)losion Large nu$ber of *icti$ due to )eo)le fro$ surrounding)i)eline rig#t of way gat#ers to fetc# t#e fuel s)ill 0#e )i)e t#at burst runs )arallel to i*er Et#io)eand #as two $a9or foot )at#s to it fro$ t#e road 0#e )i)eline was laid in t#e early 1A4 0#e area isacti*ely culti*ated by t#e local )eo)le 7e/t to t#e buried fuel )i)e is a gas )i)eline about 1 $eters

a)art Poor )i)eline $aintenance was associated wit# t#e lea'ing (8ource!

&2. Cno=:ille Tennesse U # Feruar6 9' 1999 (Drittle Fra*ture' 15 e:a*uate!' UA 3'100'000)
http://www.vgrs.vic.gov.au/public/longford.htmhttp://www.austlii.edu.au/cgi-bin/disp.pl/au/cases/vic/VSC/2001/263.html?query=longfordhttp://www.austlii.edu.au/cgi-bin/disp.pl/au/cases/vic/VSC/2001/263.html?query=longfordhttp://www.qrc.org.au/conference/_dbase_upl/03_spk003_Hopkins.pdfhttp://www.qrc.org.au/conference/_dbase_upl/03_spk003_Hopkins.pdfhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://www.waado.org/Environment/IdjerheFire/idjerhe_ERA_Ola.htmlhttp://abduh137.files.wordpress.com/2008/04/longford-gp905-he.jpghttp://www.vgrs.vic.gov.au/public/longford.htmhttp://www.austlii.edu.au/cgi-bin/disp.pl/au/cases/vic/VSC/2001/263.html?query=longfordhttp://www.qrc.org.au/conference/_dbase_upl/03_spk003_Hopkins.pdfhttp://www.marshriskconsulting.com/st/PDEv_C_371_SC_228136_NR_306_PI_234871.htmhttp://www.waado.org/Environment/IdjerheFire/idjerhe_ERA_Ola.html


9/22

Figure 8#owing Circu$ferential Crac' of :no/*ille Pi)eline (708. >8!

% )i)e failed releasing 2,44 barrels of diesel fuel 0#e )i)e was 14"inc#es in dia$eter, %P L "

5 8M8 5 ')si, electric resistance weld (E! carbon steel and wit# 4 inc#es in t#ic'nessCircu$ferential crac' was found at t#e failed seg$ent 0#e )ossible cause for crac'ing was noted

by t#e low toug#ness of t#e $anufactured )i)e $aterial 0#e )i)e was constructed in 13 w#ent#ere was no ade+uate toug#ness re+uire$ent fro$ a*ailable )i)e code and design 7ational0rans)ortation 8afety .oard #ad alreadygi*en reco$$endation for toug#ness re+uire$ent to De)art$ent of 0rans)ortation esearc# and8)ecial %d$inistration %gency (8P%! w#en a si$ilar failure occurred in 15 in 7ew Bersey n444 res)onding t#e re+uest fro$ 8P%, %$erican Petroleu$ nstitute (%P! added $ini$u$toug#ness re+uire$ents to %P 8)ecification L (8ource!

&&. Martine@ 4aiornia U # Feruar6 2&' 1999 (4orrosion' 8 +ille!' 1 injure!)

Lea'age and fire occurred and originated fro$ a #eat e/c#anger 0#e #eat e/c#ganer condensed*a)or fro$ a #ig# te$)erature and #ig# )ressure se)arator at t#e outlet of t#e reactor of a fuel oil#ydro" desulfuri;ation unit One #eat transfer tube of t#e fin"fan cooler was was corrodedCorrosion was caused by inade+uate re"design of #eat e/c#anger c#anging ser*ice (8ource!

&8. in*hester Centu*+6 U #


10/22

&5. Bunt Te=as U- Mar*h &' 2000 (4orrosion' Fuel Pi%eline' UA 80'000'000)


11/22

Figure s#owing $icrogra)# corroded")it of Carlsbad Pi)eline

% 4"years, 24"inc#"dia$eter natural gas trans$ission )i)eline ru)tured 0#e release gas ignitedand burned for $inutes n*estigation of t#e failed seg$ent re*ealed se*ere internal )it"corrosionas $a9or contributing cause of t#e failure %t t#e ti$e of failure t#e )i)e wit#stand 8D 1,44,444 for legal fine and >8D ea+ing' einer6' UA

120'000'000128'000'000)

% )i)e seg$ent lea' resulted fire in a refinery co'er unit % re)ort said t#at s$o'e fro$ t#e firerose to o*er 2,444 feet and t#e co'er unit was s#ut down for a))ro/i$ately two $ont#s 0#e e/actcause of )i)e lea'in is still under in*estigation (8ource, Location!

81. a/!hatain Cu/ait #


12/22

% 23"inc#es dia$eter natural gas )i)eline ru)tured at a ;one of near neutral )H stress corrosioncrac'ing (8CC! Following t#e ru)ture t#e sweet natural gas ignited 0ec#nical in*estigation re)ortdeter$ined t#at )i)eline ru)tured due to o*erstress e/tension of )re"e/isting crac's 0#e crac's #adinitiated on t#e outside surface of t#e )i)e and )rogressed in a $ode of failure of transgranular8CC 0#e )i)eline was constructed 1A4 by double sub$erged arc welded straig#t sea$ )i)e byt#e accordance of %P L Grade 3 (8ource, Location!

8&. Mooma $ustralia # iui! Metal Emrittlement' > Plant' 27 +ille! 72

injure!' UA &0'000'000)
http://www.tsb.gc.ca/en/reports/pipe/2002/p02h0017/p02h0017.asphttp://maps.google.com/maps?f=q&hl=en&geocode=&q=brookdale+manitoba&ie=UTF8&ll=50.148746,-99.533386&spn=0.737429,1.867676&t=h&z=9&iwloc=addrhttp://www.tcetoday.com/MagPDFs/752australia.pdfhttp://maps.google.com/maps?f=q&hl=en&geocode=&q=moomba+australia&sll=50.148746,-99.533386&sspn=0.737429,1.867676&ie=UTF8&ll=-28.109083,140.207176&spn=0.015861,0.029182&t=h&z=15&iwloc=addrhttp://abduh137.files.wordpress.com/2008/04/moomba-failed-nozzle.jpghttp://www.tsb.gc.ca/en/reports/pipe/2002/p02h0017/p02h0017.asphttp://maps.google.com/maps?f=q&hl=en&geocode=&q=brookdale+manitoba&ie=UTF8&ll=50.148746,-99.533386&spn=0.737429,1.867676&t=h&z=9&iwloc=addrhttp://www.tcetoday.com/MagPDFs/752australia.pdfhttp://maps.google.com/maps?f=q&hl=en&geocode=&q=moomba+australia&sll=50.148746,-99.533386&sspn=0.737429,1.867676&ie=UTF8&ll=-28.109083,140.207176&spn=0.015861,0.029182&t=h&z=15&iwloc=addr


13/22

Figure s#owing destroyed 8'i'da L7G Plant

% re)ort noted t#at t#e e/)losion was t#e conse+uence of a catastro)#ic failure in one of t#e coldbo/es of >nit 54, w#ic# led to a *a)our cloud e/)losion of eit#er L7G or refrigerant 0#e $ost)robable source of ignition was t#e boiler at t#e nort# end of >nit 54 0#e re)ort concluded t#at t#eesca)ed gas was fro$ t#e cryogenic #eat e/c#anger (8ource,Location!

85. Bumer Estuar6 Cillingholme UC # $%ril 1' 2001 (Erosion 4orrosion' einer6' UA

32'800'000)
http://www.saunalahti.fi/ility/Dossiers/Doss%20Skikda.htmhttp://www.saunalahti.fi/ility/Dossiers/Doss%20Skikda.htmhttp://maps.google.com/maps?f=q&hl=en&geocode=&q=skikda+algeria&ie=UTF8&ll=36.868017,6.97928&spn=0.014386,0.029182&t=h&z=15http://abduh137.files.wordpress.com/2008/04/copi_humbercase.jpghttp://abduh137.files.wordpress.com/2008/04/algeria_d.jpghttp://www.saunalahti.fi/ility/Dossiers/Doss%20Skikda.htmhttp://maps.google.com/maps?f=q&hl=en&geocode=&q=skikda+algeria&ie=UTF8&ll=36.868017,6.97928&spn=0.014386,0.029182&t=h&z=15


14/22

Figure s#owing destroyed Hu$ber Estuary efinery (H8E >:!

On 13 %)ril 441 a fire and e/)losion occurred at Hu$ber efinery following t#e catastro)#icfailure of an o*er#ead gas )i)e n*estigation was carried by 0#e Co$)etent %ut#ority and t#e )lanto)erator co$)any by legislati*e $ec#anis$ under Control of Ma9or Ha;ard (COM%H! egulation1 Hu$ber refinery was one of a))ro/i$ately 1444 $a9or #a;ard site under t#is regulation 0#e

co$)etent aut#ority consisted of Healt# and 8afety E/ecuti*e (H8E! >: and En*iron$ent %gency(E%!

Figure s#owing failed elbow of Hu$ber Estuary efinery (H8E >:!

0#e cause of t#e )i)ing syste$ failure was t#e erosion corrosion of t#e 3"inc#es dia$eter )i)e,'nown P5232, w#ic# carried t#e o*er#ead line fro$ t#e De"et#ani;er (512! to t#e #eat e/c#anger(5! in saturate gas )lant (8GP! unit 0#e failure occurred down strea$ of a closely waterin9ection )oint E/a$ination to t#e failed elbow reco*ered fro$ t#e da$age site s#owed wallt#ic'ness t#inning fro$ A"< $$ to a $ini$u$ 42 $$ #en t#e )i)e failed it burst o)encatastro)#ically causing a full bore ty)e of release t#e )i)e contents0#e water in9ection )oint was not t#e original design of t#e )i)ing syste$ ater in9ection to t#e*a)or strea$ between t#e to) de"et#ani;er colu$n and t#e #eat e/c#anger was addressed to sol*et#e )re*ious )roble$ of salts or #ydrates fouling in #eat e/c#anger 5@2 %n in9ection )oint wascreated in P5232 by )i)ing water to an e/isting 1 inc#es *ent )oint on t#e )i)e wit#out in9ection+uill or dis)ersal de*ice and $ade t#e water entering t#e )i)e as a free 9et

8i$ilar %ccident- il$ington California >nited 8tates < October 1, 7ort# #ine est P#aliaGer$any 14 Dece$ber 11,o''aic#i Mie Ba)an May 1A, Mina %l"%#$adi :uwait Bune444 (8ource, Location!

8. hislenghien Delgium-


15/22

Figure s#owing a da$aged industrial )ar' as t#e e/cess of G#isleng#ien Pi)eline E/)losion

% )i)e lea' caused a $a9or underground #ig#")ressure natural gas )i)eline e/)losion Most of t#edead are officials and fire"fig#ters res)onding to re)orts of a gas lea' 0#e e/act cause of t#e )i)elea' is still not clear % #eat transfer $at#e$atic $odel can be used to describe a ductile"brittletransition of )i)e $aterial due to significant cooling of t#e surrounding )i)e"wall 0#is brittletransition occurred w#en t#e fluid wit# certain *elocity esca)e t#roug# an initial t#roug#"walldefect 0#e significant reduction in t#e fracture

toug#ness co$bined wit# t#e acco$)anying )ressure stresses t#en result in fracture growt# andru)ture of t#e )i)e seg$ent (8ource 1, , Location!

87. Mihama


16/22

Figure s#owing 8e*erely Da$aged 0e/as City efinery

On 2 Marc# 44, 1 )eo)le were 'illed and o*er 1A4 #ar$ed as t#e result of a fire and e/)losionon t#e iso$eri;ation unit at a refinery )lant in 0e/as City >nited 8tates 0#e accident was ane/)losion caused by #ea*ier"t#an"air #ydrocarbon *a)ors co$busting after co$ing into contactwit# an ignition source 0#e se*erity of t#e accident was increased by t#e )resence of $any )eo)lecongregated in t#e *icinity of origin of e/)losion Detailed in*estigations were carried by t#e )lanto)erator and >nited 8tates C#e$ical 8afety .oard Fro$ t#e #ealt# and safety )ers)ecti*e #ig#nu$ber of fatalities was concluded to be caused by loss of contain$ent, inade+uate trailer sitting att#e )lant layout and t#e fault of design engineering of t#e blowdown stac'

Figure s#owing failed elbow in 0e/as City efinery E/)losion

0#e release of gas was originated at t#e lea'ing elbow $ade of carbon steel in t#e e/c#anger )i)ingsyste$ resid #eat #ydrotreater unit (H>! n*estigation to t#is H> accident deter$ined t#atina))ro)riate $aterial as inad*ertently installed in a #ig# )ressure and #ig# te$)erature #ydrogenline 0#e failure of t#e elbow was noted by t#e $ec#anis$ of #ig# te$)erature #ydrogen attac'(H0H%! (8ource 1,!

89. i!oarjo East


17/22

%erial *iew s#owing location of 8idoar9o ru)ture )i)e nearby $ud *olcano big #ole (:LH!

7atural gas )i)eline wit# 554 )sig )ressure failed and caused a $a9or e/)losion Most of t#e*icti$s were go*ern$ent officials in an acti*ity of sur*eying $ud *olcano site 0#e $ud *olcano

was a )re*iously $a9or gas blow out e*ent in location near t#e accident 0#e $ost )robable cause of)i)eline failure was largely associated wit# geo#a;ard %t least industrial gas consu$er affectedby t#e gas su))ly interu)tion because of t#e e/)losion including national )ower )lant PL7 and)etroc#e$ical )lant Petro'i$ia Gresi' (8ource 1, , 2!

50. Free To/n ierra >eone # Ae*emer 21' 2007 (Pi%e >ea+ing' atural as Pi%eline' 17

+ille!)

% gas e/)losion on a crowded street 'illed 1A )eo)le 0#e e/)losion tore t#roug# a crowded s#o)0#ere is no clear infor$ation on t#e e/act cause of t#e )i)e lea'ing (8ource!
http://www.kompas.com/kompas-cetak/0611/23/utama/3116542.htmhttp://www.menlh.go.id/i/art/ledakan_gas1.pdfhttp://www.sinarharapan.co.id/http://africa.reuters.com/top/news/usnBAN123863.htmlhttp://abduh137.files.wordpress.com/2008/05/sidoarjo_pipeline-explosion.jpghttp://www.kompas.com/kompas-cetak/0611/23/utama/3116542.htmhttp://www.menlh.go.id/i/art/ledakan_gas1.pdfhttp://www.sinarharapan.co.id/http://africa.reuters.com/top/news/usnBAN123863.html


18/22

?. %eration an! Maintenan*e

O)eration *ariables ($ec#anical load, te$)erature, fluid c#e$ical, conta$inant, en*iron$ent, etc!s#ould be 'e)t in control %ny uncontrolled *ariable could lead to une/)ected $aterial under"

)erfor$ and un"antici)ated da$age growt# e s#ould #ig#lig#t corrosion and $aterial defect ast#ese are t#e biggest da$age contributor, Figure Maintenance in ob9ecti*e of e+ui)$ents and structures integrity s#ould consider as)ects as follows-" Materials Ca)acity0#e ca)acity of $aterials $ust be wit#in its )erfor$ance to wit#stand all designed ser*ice load,detain t#e growt# of finger")rint defect, and defend against corrosion and corrosion growt# 8er*iceload and finger )rint defect is designed wit#in t#e design code, w#ilst in ser*ice da$age is 'e)twit#in defect codification" Control of O)eration ?ariableO)eration *ariables s#ould be controlled, any de*iation can be unfa*orable for $aterial

)erfor$ance (ser*ice te$)erature, )ressure, flow rate, erosi*e conta$inants, CO@H8 gas

concentration! >ncontrolled abrasi*e conta$inants can lead to erosion corrosion and uncontrolledH8 lead to 8CC" Control of Defect and Da$age%ny )ossible defect and da$age s#ould be under safety criterion Crac' )ro)agation, fatigue, andcorrosion growt# s#ould be under )redicti*e in range of ti$e, $ec#anical load, and te$)erature

Figure Pi)eline %ccident ecords

Da$age assess$ent is t#e $ost critical )art of integrity $anage$ent Many o)erator co$)anies)erfor$ fitness for ser*ice assess$ent during design or $anufacture, but t#e $ost econo$ic wayt#e FF8 s#ould be )erfor$ed in ti$e during ser*ice Defect $anage$ent and standardi;ations effortin oil and gas industry can be su$$ari;ed as follows-a Defect Codification% consensus between 7%CE, L%, and %8ME toget#er create defect infor$ation standard1w#ic# categori;ed t#reats as follow-

" 0i$e De)endent (corrosion, 8CC!" 8table ($anufacturing defect, welding defect!" 0i$e inde)endent (weat#er related, *andalis$!
http://abduh137.files.wordpress.com/2008/03/pipeline-failure-records.jpg


19/22

%n in"#ouse standard by 8#ell12 offer $ore sc#e$atic defect infor$ation (no$enclature, geo$etrydefinition, and infor$ation structure!

b Defect nfor$ation Gat#eringecent )rogress in non destructi*e testing bot# inline (MFL, >0! and stand" alone 7D0 ins)ection()#ased"array >0, 0OFD >0, long range >0!, abo*eground ins)ection (%C?G, DC?G, Pearson,C"8can! can be utili;ed for getting t#e best infor$ation of $aterial defect

c Defect %ssess$entMany docu$ent #as )ublis#ed to )ro*ide t#e industry t#e )rocedure to assess defect in e+ui)$entand structure 8o$e of t#e$ are fitness for ser*ice assess$ent (%P A and .8 A14!, structuralintegrity assess$ent )rocedure (870%P!, and D7?"F141 for corrosiond Data ntegration0#e o))ortunity to de*elo) an integrated infor$ation syste$ for $ore effecti*e and efficientinternal cor)orate co$$unication s#ould ta'e t#e ad*antage of G8 data )rogra$$ing, intelligent

)igging, and ris' $anage$ent )olicy15,1, Figure 3 0#e out)ut for t#is syste$ can be ins)ection)lan, ris' le*el infor$ation, and furt#er direct assess$ent )lan

Figure 3 8creens#ot of an a))lication for G8"is' %ssess$ent Data ntegration

?;. Engineering is+ Management

0o a*oid defect fro$ $anufacture out)ut nearly i$)ossible, as well as to a*oid t#e defect initiationduring ser*ice .ut defect or da$age is controllable Engineering ris' $anage$ent dealing wit#defect assess$ent, defect $a))ing@ins)ection% ty)ical ris' $anage$ent )rocess is s#own in Figure A

Figure A 0y)ical is' Manage$ent Process
http://abduh137.files.wordpress.com/2008/03/risk-mgmt.jpghttp://abduh137.files.wordpress.com/2008/03/gis-rbi.jpg


20/22

Met#od for defect assess$ent was long ti$e defined by researc#er in .attelle in 1A, andde*elo)ed furt#er for 7G"1< E+uation w#ic# t#en beco$e t#e basis for assess$ent $et#od in%8ME .21G and $odified .21G (80E7G! n England, in 1


21/22

ecent de*elo)$ent of FF8 )rocedures de$and re+uire $ore guidance to esti$ate residual stress,$aterial and t#er$al #istory, loading #istory, and 7DE infor$ation reliability

Failure $nal6sis # Aont ma+e mista+e t/i*eG

Many e+ui)$ent fail e*en in strict co$)any +uality standard because t#ere always a de*iation fro$t#e initial assu$)tions Failure analysis is reco$$ended action w#en t#ere is a failure occurs in

order to find out t#e root cause and to gi*e feedbac' to o)eration set"u) and $aterial )rocure$ent

Figure Flow of wor' for fitness for ser*ice assess$ent in Pi)eline Defect %ssess$ent Manual

Failure is li'ely to occur in #ig# )ressure syste$, su$$ari;ed root causes of failure fro$ H8E >:studies1< are as follows-" nade+uate design and@or $aterial for t#e loading and o)erating t#e en*iron$entK

" ncorrect and@or defecti*e $anufactureK" >n"antici)ated in ser*ice da$ageK" 8yste$ error in o)erationK" Malfunction of instru$ent" Hu$an errorsK" E/ternal E*ent (fire, i$)acts, etc!ConclusionEngineering integrity is one funda$ental ele$ent in corridor of integrity $anage$ent in oil and gasindustry Engineering integrity s#ould be considered as a syste$ w#ere one ele$ent affect t#e ot#erEngineering integrity as a syste$ ranges fro$ $aterial selection and ,)re"ser*icetesting@co$$issioning, during o)eration and $aintenance, defect@da$age related ris' $anage$ent,

to da$age $itigationDe*elo)$ent of engineering integrity needs $ultidisci)linary contribution of e/)ertise in $aterialand $anufacturing )rocess and )rocess s)ecialist incor)orated wit# t#e ad*ance tec#nology fro$
http://abduh137.files.wordpress.com/2008/03/pdam-flow.jpg


22/22

ins)ection co$)anies .est Practice for is' .ased ns)ection as a Part of Plant ntegrityManage$ent, 0 and oyal 8un%lliance Engineering for t#e Healt# and 8afety E/ecuti*e >:,441

the 50 major engineering failures

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