Dealing With Aging Process Facilities and Infrastructure

Informationen zum Autor The Center for Chemical Process Safety (CCPS) was founded in 1985 to develop technology and management practices that mitigate or eliminate chemical process incidents. Since that time, CCPS has published more than 100 books and held dozens of international conferences, each representing the most advanced thinking in process safety. CCPS is supported by the contributions and voluntary participation of more than 190 companies globally. This book was developed as a collaborative effort by CCPS sponsor company representatives. Klappentext Examines the concept of aging process facilities and infrastructure in high hazard industries and highlights options for dealing with the problem while addressing safety issuesThis book explores the many ways in which process facilities, equipment, and infrastructure might deteriorate upon continuous exposure to operating and climatic conditions. It covers the functional and physical failure modes for various categories of equipment and discusses the many warning signs of deterioration. Dealing with Aging Process Facilities and Infrastructure also explains how to deal with equipment that may not be safe to operate. The book describes a risk-based strategy in which plant leaders and supervisors can make more informed decisions on aging situations and then communicate them to upper management effectively. Additionally, it discusses the dismantling and safe removal of facilities that are approaching their intended lifecycle or have passed it altogether.Filled with numerous case studies featuring photographs to illustrate the positive and negative experiences of others who have dealt with aging facilities, Dealing with Aging Process Facilities and Infrastructure covers the causes of equipment failures due to aging and their consequences; plant management commitment and responsibility; inspection and maintenance practices for managing life cycle; specific aging asset integrity management practices; and more.* Describes symptoms and causal mechanisms of aging in various categories of process equipment* Presents key considerations for making informed risk-based decisions regarding the repair or replacement of aging process facilities and infrastructure* Discusses practices for managing process facility and infrastructure life cycle* Includes examples and case histories of failures related to agingDealing with Aging Process Facilities and Infrastructure is an important book for industrial practitioners who are often faced with the challenge of managing process facilities and infrastructure as they approach the end of their useful lifecycle. Zusammenfassung Examines the concept of aging process facilities and infrastructure in high hazard industries and highlights options for dealing with the problem while addressing safety issuesThis book explores the many ways in which process facilities! equipment! and infrastructure might deteriorate upon continuous exposure to operating and climatic conditions. It covers the functional and physical failure modes for various categories of equipment and discusses the many warning signs of deterioration. Dealing with Aging Process Facilities and Infrastructure also explains how to deal with equipment that may not be safe to operate. The book describes a risk-based strategy in which plant leaders and supervisors can make more informed decisions on aging situations and then communicate them to upper management effectively. Additionally! it discusses the dismantling and safe removal of facilities that are approaching their intended lifecycle or have passed it altogether.Filled with numerous case studies featuring photographs to illustrate the positive and negative experiences of others who have dealt with aging facilities! Dealing with Aging Process Facilities and Infrastructure covers the causes of equipment failures due to aging and their consequences; plant management commitment and responsib...

List of contents

List of Tables xi
 
List of Figures xiii
 
Acknowledgments xv
 
Preface
 
1. Introduction 1
 
1.1 Overview 1
 
1.2 Purpose 2
 
1.3 Aging: Concerns, Cause and Consequences 2
 
1.4 How Aging Occurs 6
 
1.4.1 Metallic Corrosion 7
 
1.4.2 Corrosion Under Deposits 8
 
1.4.3 Corrosion Under Insulation and Fireproofing 8
 
1.4.4 Manufacturing Defects 9
 
1.4.5 Excessive Wear and Tear 10
 
1.4.6 Fatigue 11
 
1.4.7 Non-Metallic Aging 12
 
1.4.8 Aging of Physical Structures 12
 
1.4.9 Process Chemicals Aging 13
 
1.4.10 Aging of Specialized Equipment 14
 
1.4.11 Obsolescence 14
 
1.4.12 Redundancy 15
 
1.4.13 Brownfield Construction 16
 
2. Aging Equipment Failures, Causes and Consequences 19
 
2.1 Aging Equipment Failure and Mechanisms 19
 
2.2 Consequences of Aging Equipment Incidents 20
 
2.3 Mechanical Failure of Metal 23
 
2.3.1 Deformation of Materials 23
 
2.3.2 Ductile vs. Brittle Fracture 24
 
2.3.3 Metal Fatigue 24
 
2.3.4 Corrosion/Erosion 25
 
2.3.5 Warning Signs 29
 
2.3.6 Aging Equipment Failure Case Studies 30
 
2.4 System Functional Aging 33
 
2.4.1 Aging Equipment Failure Mechanisms 34
 
2.5 Aging Structures 35
 
2.5.1 Warning Signs 36
 
2.5.2 Aging Structure Case Study 36
 
3. Plant Management Commitment and Responsibility 41
 
3.1 Promoting Site Safety Culture 41
 
3.2 Management Challenges 41
 
3.3 Monitoring Aging Process and Measuring Performance 42
 
3.4 Human Resources Requirements 44
 
3.5 Planning for Equipment Retirement and Replacement 45
 
3.6 Appreciating the Importance of Aging Infrastructure to the Business Enterprise 47
 
3.6.1 Structural Assets 47
 
3.6.2 Roads 47
 
3.6.3 Impoundments and Dikes 47
 
3.6.4 Fire Water, Cooling Water and Sewers 48
 
3.6.5 Electrical Distribution Systems 48
 
3.6.6 Marine Facilities 48
 
3.6.7 Other Process Facility Infrastructure 48
 
3.7 Addressing Aging Infrastructure in Decision Process 49
 
3.7.1 Questions Executives Need to Ask 49
 
3.7.2 Mergers and Acquisitions 50
 
4. Risk Based Decisions 51
 
4.1 Risk Management Basics 51
 
4.1.1 Risk Ranking 53
 
4.1.2 Risk Mitigation Controls 55
 
4.2 Risk Based Decisions 55
 
4.2.1 When to Apply Risk Based Decisions 57
 
4.3 How to Apply Risked Based Decisions 57
 
4.3.1 Determine Hazard Scenarios. 60
 
4.3.2 Assess Consequences 60
 
4.3.3 Assess Likelihood 61
 
4.3.4 Determine Risk 61
 
4.3.5 Develop Risk Mitigation Controls 62
 
4.3.6 Implement Risk Controls 63
 
4.3.7 Information Required for Risk Based Decisions 63
 
4.3.8 Documentation of Risk Based Decisions 64
 
4.4 Embracing Risk Based Management 65
 
4.4.1 Alignment of Management and Operations with Risk Based Decisions 65
 
4.4.2 Incorporate Corporate Responsibility and Economic Value 65
 
4.5 Dealing with Unexpected Events 66
 
4.6 Risk Based Decisions Success Metrics 67
 
5. Managing Process Equipment and Infrastructure Lifecycle 69
 
5.1 Lifecycle Stages 69
 
5.2 Asset Lifecycle Management 69
 
5.2.1 Management Strategy Development 70
 
5.2.2 Organizational Design 70
 
5.2.3 Long-Term Asset Planning 72
 
5.3 General Topics 72
 
5.3.1 Manage by Operational Integrity 72
 
5.3.2 Mana

Product details

• Authors: . CCPS, Ccps (Center For Chemical Process Safety), Center for Chemical Process Safety (CCPS)
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 30.04.2018
• EAN: 9781119430834
• ISBN: 978-1-119-43083-4
• No. of pages: 208
• Subjects: Natural sciences, medicine, IT, technology > Technology > Chemical engineering; Chemie, Verfahrenstechnik, chemistry, Industrial Engineering, Chemical Engineering, Industrial Chemistry, chemische Verfahrenstechnik, Technische u. Industrielle Chemie, Industrielle Verfahrenstechnik, Produktion i. d. Industriellen Verfahrenstechnik, Industrial Engineering / Manufacturing, Process Development, Verfahrensentwicklung