(119a) Effectively Addressing Damage Mechanism Reviews in a Process Hazard Analysis: A Checklist Approach

Effectively
Addressing Damage Mechanism Reviews in a Process Hazard Analysis: A Checklist
Approach

Tazim S.
Rehmat, ABSG Consulting
Inc., 300 Commerce Drive, Suite 200

Irvine, CA, 92602 (714) 734-2526, TRehmat@ABSConsulting.com

Gary
Carrithers, ABSG Consulting
Inc., 10301 Technology Drive,

Knoxville, TN, 37932 (502) 592-9386, GCarrithers@ABSConsulting.com

Randal
Montgomery, ABSG Consulting
Inc., 10301 Technology Drive,

Knoxville, TN, 37932 (865) 671-5832, RMontgomery@ABSConsulting.com

David
Whittle, ABSG Consulting
Inc., 10301 Technology Drive,

Knoxville, TN, 37932 (865) 671-5819, DWhittle@ABSConsulting.com

Sayed Termah, ABSG Consulting Inc., 15011
Katy Freeway Suite 100,

Houston, TX 77094 (281) 994-0859, STermah@abs-group.com

Keywords:  Damage mechanism review, process hazard
analysis, mechanical integrity

Abstract

Performing damage mechanism
reviews (DMRs) to determine credible degradation modes and susceptibilities of
processing equipment has become an important step in developing effective
mechanical integrity plans in the refining and chemical processing industries.
DMRs aid in formulating inspection plans to mitigate risk from loss of
containment and/or unplanned outages and are the subject of a corresponding API
Recommended Practice API RP 571.  In addition, California OSHA’s
(Cal/OSHA’s) recently revised Process Safety Management for Petroleum
Refineries now requires that DMRs be performed and process hazard analyses
(PHAs) address DMR reports that are applicable to the process unit being
analyzed. 

A refinery PHA team subject to
that regulation will now need to consult with individuals with expertise in
damage mechanisms when performing the review of applicable DMR reports. 
To help effectively address this requirement, the primary PHA methodology can
be supplemented with a checklist to help the PHA team identify DMR issues that
may be applicable to the process unit.  This paper describes the
application and contents of a checklist that the PHA team can use to help identify
DMR issues such as (1) identifying and demonstrating known corrosion and damage
mechanisms (high temperature hydrogen attack, chloride stress corrosion cracking,
etc.) are understood and controlled, (2) confirming a DMR report appropriately
documents applicable damage mechanisms to the process unit, and (3) confirming
a DMR is performed for incident investigations where a damage mechanism is
identified as a contributing factor.