Risk Analysis of Instrument Tubing Failures along with its Mitigation Path

Volume 12 Issue 1 August - October 2016

Article

Risk Analysis of Instrument Tubing Failures along with its Mitigation Path

Anand Srivastava*, Sheikh Rafik Manihar Ahmed**

* Project Management, Fluor Daniel India Pvt. Ltd., Gurgaon, India.

** Control Systems Engineer, Fluor Daniel India Pvt. Ltd., Gurgaon, India.

Srivastava, A., and Sheikh Ahmed, R. M. (2016). Risk Analysis of Instrument Tubing Failures along with its Mitigation Path. i-manager’s Journal on Future Engineering and Technology, 12(1), 1-8. https://doi.org/10.26634/jfet.12.1.8207

Abstract

This paper explains the various causes of an instrument tubing failure, risk involved and the mitigation path to avoid such incidents in plants. These impulse tubings are employed/installed to measure pressure, flow and levels in a system and/or equipment. Corrosion on tubing fittings, incorrect installation (either due to poor workmanship or non compliance of installation/process hookup), use of incorrect tools, faulty or ignored nuts & ferrule compression fittings, inadequate design tubing support systems, mishandling & improper storage of tube and its fitting are some of the root causes. These lead to a number of problems, including safety issues, plant breakdown, costly regulatory agency fines, higher maintenance cost, energy loss and environmental hazards. The risk involved in an instrument tubing failure relates to process safety hazards, such as loss of containment due to crack in the affected tubing that leads to fugitive emissions, fires, explosions and other employee safety issues. The most serious problems occur when instrument tubing and its fitting component fails causing leakage of process fluid such as gasoline, oil, gas or other volatile, corrosive fluid (sulphur compounds) or toxic gases (such as H S). These can cause fires, explosions or other serious safety hazards such as toxic 2 chemical, gas leakage or acid spraying onto field craft. Generally, tubing failure cases are noticeable in areas such as booster stations, turbine driven pumps, compressors systems, tubing connection for pressure, flow transmitters & pressure gauge, areas where vibrations are present such as pipe racks (with air coolers), and platforms of vibration sources (turbine or diesel generator). The paper details out the possible reasons, hazards and suggested mitigation path to achieve improved availability.