PHA Methodology and Training Practices Addressing Auto-Refrigeration Brittle Fracture Hazards - 25 Years Later

Nearly 25 years ago, the Morris, IL Equistar Chemical ethylene plant experienced a brittle fracture failure of a heat exchanger.  Subsequent to that incident, the company undertook a program to identify auto-refrigeration brittle fracture (ARBF) failure risks throughout the company's processes and to mitigate those hazards.  The company's effort to prevent a repeat of this type of incident also includes a detailed ARBF awareness and response training program, as well as a “Lessons Learned” training program.  This paper will present details of these efforts, summarize the focused PHA methodology utilized to identify ARBF scenarios and provide an overview of the continuing efforts to address ARBF risks.