(64d) How Can Simplification Enhance Process Safety?

This paper addresses the question of how simplification through material standardization in the area of gasket material can enhance process safety. The paper describes the process used by W. L. Gore to assess whether standardization of process piping gaskets increases safety. Testing for critical performance factors is central to that assessment process. After establishing where gaskets are the ?weak link? in a process piping system, it explains the relationship between reliability and process safety. We first focused the investigation on manufacturing and maintenance/reliability groups, where simplification is an important stated goal. Often, the piping gaskets, which serve as an important link in the reliability/safety effort, get a lesser amount of attention. Next, the paper describes the testing work done to objectively determine impact to process reliability. Going further, the paper describes the gasket properties that are required to achieve process reliability and safety. Learnings on key properties indicated the difficulties of meeting the varied challenges of sealing across different pipe classes ? where pipe classes have distinctly different requirements. The paper also explains how findings were confirmed in the primary process industries. The paper provides results of third party tests on several of the most commonly used gasket materials. This testing reveals how the inherent properties of those materials compare. The types of tests discussed are those which measure resistance to blow out, torque retention (for maintaining seal tightness), as well as basic strength tests. Included among the materials examined were PTFE and ePTFE based products that offer the best balance of properties for consideration as simplification candidates. A broad and thorough investigation of comparative properties was conducted, and is contained in the paper. Finally, and in support of the off-line testing, real-world case studies are provided to connect reliability and process safety with the test findings.