Hazardous thermal hydraulic loading conditions and unintended plant shut downs from turbine trips that are identified shortly after a plant start up may be the tip of the iceberg of even greater interrelated hazards and costly damages. This paper presents a case study to further illustrate (from ASME PVP2002-1124 paper) additional considerations for the testing and risk analysis to identify a systematic approach to reduce the hazards and risks of equipment failure from thermal hydraulic forces and secondary hazards (such as fires) to the plant and personnel. This paper examines problems of turbine trip caused by fuel computer controlled regulator valves that results in thermal hydraulic forces from compressor pressure wave surges in the process system that result in piping “Y” fitting (45° laterals) failures in the process piping from crack growth and brittle fracture which lead to process chemical release and fires.

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