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Matthew Caserta is a registered professional engineer in the states of Ohio and Texas and has over 15 years of a wide breadth of engineering experience in chemical processing, oil refining, and consulting.  Mr. Caserta's varied background provides unique insights into process interactions, equipment reliability and corrosion and materials concerns.  The past 10 years of Mr. Caserta's career has focused on fixed equipment reliability and inspection, as well as Mechanical Integrity. 

He has been involved in risk-based inspection assessments, mechanical integrity audits, and process engineering.  He has a strong knowledge of damage mechanisms through practical experience.  He has experience as a Chief Inspector planning and executing turnarounds, supervising day-to-day inspection needs, and managing projects. 

Integrity Operating Windows (IOWs), a Key Piece to Your Integrity Program, But Where Else Should They Be Integrated?

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Integrity Operating Windows (IOWs) are a key component of a world class mechanical integrity program.   IOWs are not a new concept, as they have been around in different forms for many years.  However, with the publication of the first edition of API RP 584, Integrity Operating Windows , in 2014 and the more recent first edition of API 970, Corrosion Control Documents , in 2018, more focus has been placed on these limits within the refining industry. IOWs can be defined as established limits for process parameters that affect the integrity of equipment and piping when operations deviate from these limits.  API 584 defines IOWs in three categories: Critical – Parameters where rapid deterioration occurs when the limit is exceeded (typically hours to days) Standard – Parameter where exceedances over a specified period of time will cause increased degradation (typically weeks to months or within a turnaround interval) Informational –...
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Why Risk-Based Inspection (RBI) Works

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The API Inspection Codes were originally based on failure prevention and did not consider the consequences of failure or potential damage mechanisms.  Risk-based inspection (RBI) assessments result in an equipment risk ranking based on the probability of failure (a leak occurring) and the consequence associated with that leak.  Applied properly, RBI provides the benefit of increasing operating efficiencies and unit run lengths of process facilities while maintaining or reducing the current level of risk. As stated above, risk has two components, probability and consequence.  In risk-based inspection, the probability of failure is determined by evaluating the initial design conditions and the amount of damage that can potentially occur while the equipment is in operation.  Uncertainty in the model is also address by crediting previous inspections.  Consequences are commonly evaluated in terms of environmental, health, and safety impact areas or financial loss (lost opportunity, repair costs, etc.).  Consequences are also evaluated based...
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Are Your Heaters Affecting Your Reliability?

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From a process standpoint, your Fired Equipment items are not only some of the most critical but some of the most risky items in day-to-day operations. Add in the presence of open flames and failures can be dramatic.  In today’s refining climate, fired equipment is required to run 4, 5, 6 or even 7 years between outages.  To achieve a reliable operation for runs of this length, a solid shutdown, maintenance, inspection, repair, and start-up strategy is critical. Recently a Midwest refinery contracted Becht Engineering to complete a detailed review of their fired equipment for an upcoming turnaround.  Becht used a team of experienced refining experts to provide an in-depth review of more than a dozen fired equipment items.  To provide a holistic approach, Becht utilized experts with backgrounds in process engineering, heat transfer, mechanical integrity, inspection, and operations.  The goal of the review was to ensure the fired equipment would...
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