INDUSTRY INSIGHTS ARCHIVE
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Improving Reliability of Bolted Flanged Joints
Author: Robert C. Davis, P.E., Consulting Engineer II
ASME VIII-1 Appendix 2 flange design rules states flanges should be sufficiently robust to withstand the stresses produced by operating loads; however, what happens if those flanges leak during operation?. Do you know what options are available to reduce or eliminate the potential risk of leakage in bolted flange joints? In this article, Bob Davis introduces several options to evaluate bolted flange designs with the goal of minimizing the risk of leakage without risking damage to any of the joint components.
SIMFLEX-IV: A Modern Pipe Stress Engineering Solution
Authors: Donald L. Brown, Ph.D., Consulting Researcher I; Edrissa Gassama, Ph.D., Senior Researcher II; Daniel Spring, Ph.D., Group Head Consulting Researcher I
SIMFLEX-IV, the latest update to E2G’s cloud-based piping stress analysis software, will help you prevent potential failures by improving the structural integrity of piping systems and supporting structures. In a single run, you will be able to assess sustained, occasional, and displacement stresses at every data point throughout the piping system. This article introduces you to fast and easy ways to integrate advanced static and dynamic piping stress analysis into your daily workflow.
Hammered Pipe Still Standing: Is It Fit for Service?
Author: Kraig S. Shipley, P.E., Piping & Fired Heaters, Principal, Engineer I
Steam piping systems that are not adequately controlling condensate levels may experience a steam hammer event, which is when a slug of condensate is propelled at high velocity down the piping system. When the large dynamic slug force hits an elbow or pipe cap, it can displace the piping system or slide the pipe shoes off the structural members. In this case study, Kraig Shipley discusses a recent consulting project that used SIMFLEX-IV to determine if a steam header was still fit -for -service after a steam hammer event.
PSM and Mechanical Integrity in the Hazardous Materials Processing and Handling World
Author: Jim McVay, Mechanical Integrity Team Leader
When well implemented, a mechanical integrity program will reduce failures, extend equipment life, increase operating limits, and optimize maintenance and inspection budgets. In this article, Jim McVay introduces several of the elements you need to consider when developing a successful mechanical integrity program and explains how everyone plays a role in the effective implementation.
Reduction of Nuisance Alarms by Implementing the Alarm Management Lifecycle, A Focus on Rationalization
Author: Melissa Westbrook, Instrumentation & Electrical Engineering Team Leader
We are all familiar with Aesop’s fable, “The Boy Who Cried Wolf.” Similarly, with alarm management, if you hear a false alarm too often, you may miss the opportunity to prevent a dangerous situation or equipment failure. In this article, Melissa Westbrook discusses the dangers of ignoring nuisance alarms and provides actionable insights into developing an alarm rationalization philosophy.
Launching the New Equity Engineering Cloud (eec) Platform
Author: Daniel W. Spring, Ph.D., Group Head Consulting Researcher I
The newly launched eec platform delivers accurate engineering calculations using the speed and flexibility of the cloud. The refreshed interface and dashboard layout are streamlined to make it faster and easier to make informed decisions on safety and reliability. The eec remains your one-stop platform to help you manage risk and control inspection costs throughout a facility’s lifecycle.
Manage the Damage
Author: Paul J. Kowalski, Staff Engineer I
In this World Fertilizer article, Paul Kowalski explains that damage mechanism reviews (DMRs) are one of the first steps in developing many key process safety management (PSM), mechanical integrity (MI), and equipment reliability programmes in fertilizer processing units. Completing a DMR can help ensure long-term reliability of fixed equipment and piping, allow for quicker run, repair, and replace decisions to be made, and is a critical component for proper material selection.
Equity Engineering Practices: Best Practices for Capital Projects, Repurposing Projects, and Lifecycle Management
Authors: Joel Andreani, Senior Vice President of Consulting Engineering, Principal Engineer II; Susie Szymanski, Practices Director
The EEPs help owner/users manage equipment and facilities from “cradle to grave,” over the entire lifecycle of their equipment and infrastructure. In this article, Joel Andreani and Susie Szymanski explore how the history of the EEPs and E2G’s dedication to expanding the collections has helped owner/users improve operational reliability and reduce costs.
Capturing Corporate Memory with Internal Best Practices – Retaining Knowledge After the Great Retirement/Resignation
Authors: Joel Andreani, Senior Vice President of Consulting Engineering, Principal Engineer II; Susie Szymanski, Practices Director
We knew the great retirement/resignation was coming; however, the last two years has expedited a rapid loss of technical knowledge. Think about your organization, if your experienced employees’ knowledge and expertise are not recorded, their 40-plus years of practical experience and knowledge will be lost. Read how the Equity Engineering Practices (EEPs) integrate legacy documents and employee knowledge to support effective asset lifecycle management.
Is Advanced Statistical Analysis the Next Step in Your Piping Inspection Journey?
Advanced statistical analysis can provide measurable benefits and new insights into corrosion management, especially when the knowledge is shared across an organization. In this Inspectioneering Journal article, Chris Massengale and Robert Clarke discuss how the implementation of this advanced analysis with other best practices will provide a better understanding of corrosion risks, optimize maintenance costs, and create safer facilities.
How Playing Battleship Helps with CML Optimization
As a child, many of us played the game Battleship. But did you know this game provides a great introduction to Bayesian updating and corrosion monitoring location (CML) optimization? Using the Battleship analogy, Branden Stucky introduces the Bayesian Optimized Asset Reliability (BOAR) assessment and provides insight into how to combine expert knowledge with collected data to identify corrosion rates.
Let E2G’s SMEs Train Your Future SMEs!
Knowing the fundamentals of industry programs, codes and standards, and technology will prepare new engineers for long-term success. At E2G, we have developed a new training course that supports knowledge transfer between industry experts and junior engineers, plus fills the gap for those companies without a formal training program. This article expands upon the June 16th webinar in which Mark Harmody introduced the curriculum for the Fundamentals of Asset Lifecycle Management course (FALCM).
Educating the Next Generation – Training SMEs
Authors: Mark Harmody; Joel Andreani
With baby boomers making up the largest portion of today’s workforce, it’s time to implement a corporate knowledge-sharing program. E2G has developed a training program for our engineers and clients that is devoted to mechanical integrity programs and centered around our life-cycle management philosophy. In this article, Mark Harmody discusses the curriculum and how we apply the program at E2G.
Updates to ASCE 7 and the Impact on Equipment Standards
The recent changes made to ASCE 7 will have a trickle-down impact on API and ASME codes, plus the International Building Code (IBC). In this article, Derek Slovenec and Joel Andreani discuss the most significant load changes (seismic, wind, tornado, snow, and rain) and the potential impact on ASME and API standards that reference ASCE 7.
Fitness-for-Service of Aboveground Storage Tanks – Applicability of API 579
Fitness-for-Service (FFS) is a recognized industry practice for assessing equipment mechanical integrity when unanticipated damage is found and can often be used to extend service life while minimizing downtime and avoiding costly repairs. In this article, Katelyn Gustoff and Joel Andreani examine the applicability of using API 579-1/ASME FFS-1 (API 579) FFS and API 653 assessment standards with in-service ASTs.
Level Measurement in Mature Atmospheric Storage Tanks
Author: Bart Smith
Mature storage tanks were typically constructed between 1950 to 1970. As the installation of remote monitoring solutions increases in mature tanks, maintenance personnel must start addressing the best way to make the required change or addition. In this article, Bart Smith explores the history of tank level management and measurement techniques and provides recommendations for updating instrumentation to improve safety and reliability.
A Methodology for Difficult Level Application Evaluations
Author: Melissa Westbrook
Harsh process conditions, extreme material properties, or limited infrastructure are contributing factors to difficult level applications. By implementing a consistent methodology for difficult level applications, you will achieve high uptime and system reliability. In this article, Melissa Westbrook outlines a simple documentation and methodical analysis to support new or existing instrumentation at your facility.
Aboveground Storage Tank Overfill Prevention – Updated Standards, Regulatory Focus, and E2G Services
Author: Joel L. Andreani, P.E.
This article discusses how the combination of the changes in the fifth edition of API 2350, Overfill Prevention for Atmospheric Storage Tanks in Petroleum Facilities (2020), and the adoption of this standard by various regulatory bodies has put additional requirements for overfill prevention on owners/operators of AST facilities.
Prevention of Overfill for Atmospheric Storage Tanks
Author: Phillip J. Smith
The 5th edition of the ANSI/API Overfill Prevention for Storage Tanks in Petroleum Facilities was recently released. In this article, read about the recent changes to API 2350 and an 11-step procedure that you can apply at your processing facility.
An Unfinished Chapter
Author: Philip A. Henry, P.E.
This article, published in the September 2021 issue of World Fertilizer, discusses the improvements to the API codes and standards and how those changes impact the 3% rule.
Asset Criticality Assessment: How to Implement and Improve Your Reliability Program
Author: James R. Olson
What is asset criticality and why is it important to your reliability program? This article outlines how to prepare for a criticality assessment, assemble the team, and perform the assessment.
Application of API RP 691 Risk-Based Machinery Management to Existing Process Plants
Author: Thomas D. Hess, Jr. P.E.
Incorporate machinery risk management into a mechanical integrity program to prevent loss of containment, equipment failures, and a potential process safety event. This article reviews the risk management methods of API 691 and provides easy-to-follow recommendations.
Mitigating Piping Vibration Risk: Case Studies on Using the Level 1, Level 2, & Level 3 FFS Approach
Presenter: Michael F.P. Bifano
Piping vibration failures are not uncommon in the oil and gas, petrochemical, and chemical processing industries. In this webinar, Dr. Bifano discusses and compares the future API 579 Part 15 method to current industry approaches (ASME OM-3) and uses several case studies to help you identify, evaluate, and mitigate piping vibration.
Identifying and Understanding the Risk of Acoustic-Induced Vibration Failures
Authors: Nathan D. Libertowski; Michael F.P. Bifano
Acoustic-induced vibration (AIV) is often more difficult to identify than other vibration mechanisms, such as flow-induced turbulence, slug flow, mechanical excitation from machinery, and acoustic pulsation. This article discusses ways to identify and mitigate AIV at a plant, plus how to proactively prevent AIV using design controls.
Case Study: Creep Assessment of a Heater Tube Using SagePlus™
High operating temperatures can lead to a variety of damage, including creep. During the SagePlus™ User Group Meeting, Matt S. Schaser shared a case study that estimated the remaining life of heater tubes operating at temperatures in the creep range.
2021 SagePlus™ and API RBI User Group Round-Up
“Great effort to provide useful content. I got the feeling I was part of an embracing community working together for the
Establishing Fracture Mechanics Based on Minimum Allowable Temperatures for Low-Temperature Applications of ASME B31.3
Authors: Seetha Ramudu Kummari, Ph.D., P.E.; Kraig S. Shipley, P.E.
Although rare, the consequences of brittle fracture are typically catastrophic, and preventing brittle fracture is essential when establishing fixed equipment life-cycle management strategies. This article discusses E2G’s proprietary Level 1 and Level 2 procedures for establishing minimum allowable temperatures (MATs) for low-temperature applications of ASME B31.3 piping.
Renewable Energy & Other Changes in Service Scenarios: Evaluating Plant Assets for Re-Use
Author: Joel Andreani
Read a comparison of a reuse project to FFS/SFS, addresses several repurposing questions, and explains the keys to conducting a successful conversion. In addition, be introduced to the upcoming changes to the Equity Engineering Practices (EEPs) that will deliver additional protocol documents to support safe and reliable operations.
Converting Units to Process Renewable Feeds: Materials & Corrosion Concerns
Author: Nathaniel G. Sutton
In this article, Nathaniel Sutton examines the different metallurgical issues and corrosion challenges prevalent in the bio-oil and biomass oils markets and introduces several areas of consideration when converting a conventional petroleum processing unit over to renewable feeds.
No Documentation, No Problem. OSHA Compliance is Still Feasible.
Author: Brian R. Macejko
Conducting suitability-for-service (SFS) assessments helps owner-operators obtain OSHA compliance for any fixed equipment that lacks documentation. In this article, Brian Macejko highlights E2G’s six-step process, based on API 510 Pressure Vessels, that helps owner-operators comply with OSHA requirements.
Tank RBI, Not Just an Inspection Deferral Tool
Author: Joel Andreani
Learn how applying quantitative RBI principles to storage tanks will result in optimized inspection intervals and reduced risk of loss of containment. This article discusses the difference between qualitative and quantitative tank RBI and how tank RBI is a central part of a facility’s overall tank integrity management program (IMP).
Fitness-for-Service for Aboveground Storage Tanks
Author: Katelyn J. Gustoff
This article explores applying the API 579-1/ASME FFS-1 (API 579) FFS standard to aboveground storage tanks and shares several case studies to illustrate how FFS techniques can help you make informed run-repair-replace decisions for a facility’s storage tanks.
Special Emphasis Areas in a Mechanical Integrity Program
Author: Joel Andreani
Implementing a mechanical integrity (MI) program at a processing facility is essential for maintaining safe and reliable operations. In this article, Joel Andreani investigates an important subset of an MI program: special emphasis mechanical integrity (SEMI) programs.
Improving Your Mechanical Integrity Program
Author: James R. Olson
Learn how to support the full life-cycle management of your assets by evolving your MI program to meet changing business and technological requirements. In this article, James Olson will highlight a variety of techniques that will proactively help you and your organization free up both time and resources.
Turnarounds: Executing a Problem-Solving Team
Author: Kraig S. Shipley
A successful turnaround has five main stages: setting goals, project scoping, detailed planning, execution, and post-turnaround planning. This article focuses on the advantages of a problem-solving team to resolve equipment inspection discovery and efficiently minimize lost opportunity costs.
The Importance of Pre-Turnaround Reviews
Authors: Paul J. Kowalski; Brian L. Jack
A turnaround can cost hundreds of thousands or even millions of a dollars per day. In this article, you’ll learn how Risk-Based Inspection (RBI) helps to manage the costly impact of turnarounds through proper pre-planning to minimize the overall downtime.
Evaluating a Tank Fixed Roof Structural Failure
Author: Derek Slovenec
Aboveground storage tanks are susceptible to damage from many factors, including environmental loads, process upset conditions, strength reduction due to metal loss, tank settlement, or some combination thereof. This damage often manifests as buckling of the tank shell, which is thin relative to its large surface area.
Q&A: Structural Integrity Programs
Authors: Derek Slovenec; Joel Andreani
Aging or deteriorating structures, foundations, and other infrastructure cost U.S. businesses billions of dollars each year. Problems with structures and foundations are often a result of design flaws, construction defects, deteriorating conditions, extreme environmental events, and/or changes in applied loads.
