(76d) Improved Flange Joint Reliability Can Help Prevent Loss of Containment

Review of Chemical Plant Process Incidents leading to Loss of Containment shows that Flange Joint Integrity is the single largest contributor of process releases. In response to this data, DuPont has undertaken a holistic approach to improving the reliability of these critical systems. We choose to refer to flange joints as systems to highlight the complex interactions and functions the various components in a flange joint must perform; failure of an individual element can lead to a Loss of Containment. This paper will review the various components within the flange system, including technical design, development of installation standards, maintenance training, installation Quality Control, Leak Testing, and Root Cause Failure Analysis.

Historically, flange joint improvement has examined these components individually, however this approach misses the mark by assuming the flange is a simple device, where in reality, it is a complex interaction of elements, both human and physical. Further, by closing the loop with a standardized Why Tree to assist sites with Root Cause Failure Analysis, we believe the feedback required to make continuous improvement in Flange Systems will ultimately lead to a reduction of these all too common releases.