In this session we will show the results of a failure in a Mechanical Integrity Program. This track will also discuss event investigation results, along with, lessons learned and path forward, in hopes to enlighten all in the industry.
Facilitator: Dean Roberts, Ergon-West Virginia Refining Inc.
In 2021, hydrofluoric acid vapors were detected by the safety instrumented subsystem (SIS) line of sight laser detection system, which activated both the rapid acid dump system and the fire suppression/unit deluge system. The source of the leak was determined to be the bypass line around the isobutane recycle cooler. Topics discussed: Residual Elements, CMLs for high RE, PMI for high RE, low flow and process deadleg identification.
Over the last few years, there has been an increase in through body leaks on cast HF Alkylation valves. This presentation will review several real life examples of casting failures on valves in HF Alkylation service including cross sections of the failure location. These failures have occurred on both low RE carbon steel and Alloy 400 (M35-1) castings. Some common causes of casting failures will be reviewed including sand inclusions, porosity and varying levels of shrinkage. Common locations of casting quality issues with HF Alkylation valves will be discussed including the bottom bowl area and the body to end flange transition on Alloy 400 plug valves. The presentation will also cover some of the methods that are being implemented in the industry to improve the casting quality of HF Alkylation valves along with efforts to standardize and consolidate requirements for these valves.
Reliability and Maintenance Bootcamp, Mechanical Integrity
This technical session is designed to give engineers and maintenance professionals a practical understanding of how API-579 Level 3 Fitness-for-Service (FFS) assessments—powered by Finite Element Analysis (FEA)—can solve complex reliability challenges in the oil and gas industry.
We will introduce advanced methods for evaluating equipment with damage mechanisms like corrosion, cracking, and dents. You’ll learn when Level 3 assessments are needed, how FEA is applied, and why these techniques offer better accuracy, safer outcomes, and longer equipment life.
Highlights include:
API-579 FFS framework and when to escalate to Level 3
Benefits of FEA: realistic modeling of stress, temperature, and pressure
Real-world case studies: pressure vessel corrosion, weld cracking, and pipe dents
Key takeaways for maintenance planning and repair decisions
Tailored for a broad operator-based audience, this session uses real examples—not just theory—to demonstrate how advanced analysis can enhance reliability, reduce costs, and support critical decisions.