Key standards
- ASME BPVC (Section VIII), API 510 (pressure vessel inspection), API 570 (piping), API 653 (storage tanks), IEC 61511 (SIS for process industries).
Documented issues
A CSB investigation update on the 2023 Honeywell Geismar explosion described how a reboiler shell at a refrigerant plant ruptured. Mechanical integrity inspections had estimated only 1.1 years of service life remaining; a replacement was recommended but management did not purchase or install the replacement before the failure. The incident released hazardous chemicals and caused major property damage. aiha.org.
Typical challenges
- Failure to act on inspection results and remaining-life estimates.
- Inspections use limited methods (e.g., UT, visual) without comprehensive assessment.
- Mechanical integrity programs lack management oversight and capital planning for replacements.
Best Practice playbook
- Adopt a risk‑based mechanical integrity program: define inspection intervals and methods (UT, radiography, corrosion probes) and assign risk categories.
- Act on inspection recommendations: schedule and fund replacements when remaining life is low; incorporate into capital plans.
- Use multi-technique assessments: combine UT thickness, internal visual, and external NDE to determine true condition.
- Record and track findings in a central system; tie them to management reviews.
- Integrate SIS (IEC 61511) testing to ensure safety instrumented systems respond to process deviations.
References
- AIHA summary of CSB’s Honeywell Geismar investigation: failure to replace reboiler shell, estimated remaining life, and chemical release. aiha.org.
