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Cooling Water GRP Pipe Network

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Presentation on theme: "Cooling Water GRP Pipe Network"— Presentation transcript:

1 Cooling Water GRP Pipe Network
A hands-on Approach of System Monitoring and Prevention of Failure By Ahmad M. Al-Zain / Ramireddy Annapureddy

2 OUTLINE Tasnee Highlights, Capacity Introduction
CW GRP pipe failure incidents Investigation & RCA for GRP pipe ruptures Factors for GRP pipe ruptures Mitigation & Monitoring Measures

3 TASNEE Highlights Established in the 1985 , first Industrialization Joint-Stock Wholly Owned by Private Sector . Major Businesses : Petrochemicals, Titanium dioxide and downstream products and services. Fully integrated operations including project development and implementation, operations and marketing. Over 7,000 Employees in five continents.

4 TASNEE’s Production Capacity
Acrylics Chemicals Plastics 400 KTA HDPE LDPE 720 KTA PP 35 KTA Compound 80 KTA Super Absorbent Polymer TiO2 160 KTA Butyl Acrylate Recycled Lead Alloys 42 KTA 2.4 million Batteries 330 KTA n-Butanol (Project) Total: 1,555 KTA 32 KTA Plastic Sheets (PC, PMMA, ABS, HIPS) Total: 570 KTA BOPP 30 KTA

5 Introduction: Description of TASNEE Cooling water Network
CW drum City water make up Gas vent All CW/SW piping is Underground except: Suction / Discharge lines of pump Inlet / outlet of CW/SW exchangers All CW/SW piping are made of GRP material Vital CW pumps x 5 CW pumps EC vital CW users EC users LDPE users HDPE users PP Line 1 Vital SW pumps SW / CW Exch (x 23) 18 cells SW cooling Tower F x 5

6 CW GRP pipe failure incidents
Incident in CW/SW exchanger & CW pump #2 #3 CW drum SW / CW Exchangers (Total no's: 23) 100” CW header CW Users A #5 S D B C #1 #4 CW Pumps

7 CW GRP pipe failure incidents
72” CW supply header to PE/PP Incident in EC plant Process area SW / CW Exchangers (Total No's: 23) 76” CW supply header to EC 100” CW header 100” CWS header 28” CW header 3E-3713 (RGH reactor Methanol condenser) #6 76” CW Return header from EC to CWR main header

8 Investigation & RCA for GRP pipe ruptures
Investigation & RCA used Fishbone Diagram methodology and Fact Tree Analysis for finding the possible causes leading towards GRP pipe failures. Using Fish Bone Diagram the identified root causes are as follows: Category Identified root cause Operation Water surge/hammering CW users leakage Process Gas ingress into system Maintenance & Reliability Maintenance & Inspection procedures Materials Lack of industrial QC procedures for GRP elements. Design Supports for Pipe & Pump and Soil settlement issues Flexibility of the system for load variations GRP header dynamic compatibility Degassing system compatibility

9 RCA for CW GRP pipe rupture : Fish Bone Diagram

10 Factors for GRP pipe ruptures
System Design Factors are recognized from Fact Tree Analysis Deficiency in the Design of the existing CW network Soil Settlement issues - Soil compaction & Proper back filling - Monitoring system for soil settlement Support for GRP lines - Surge/Stress analysis to find the dynamic load variation in pipe network - Piping system flexibility to handle the dynamic loads Gas relieving system adequacy to release the gas/vapors entered into the CW system - Large amount of gases ingress into the CW system - Venting system is not sufficient at individual CW user side

11 RCA for CW GRP pipe rupture : Fact Tree Analysis

12 CW Distribution System
Rupture Point High LEL

13 CW Expansion Drum Venting
10” vent open with nitrogen dilution 24” manhole crack open 24” Vent line N2 line Water Makeup Vent line is dipped under water level. Gas removal is restricted 20 mm siphon (vent) hole Degassing pipes Cooling water return

14 Factors for GRP pipe ruptures
People/Manpower/Skills are recognized from Fact Tree Analysis Poor Workmanship Leading to GRP Line Failure GRP Workmanship skills during the project execution stage & maintenance time - Time & Capital cost constraints during project period - Availability of trained maintenance and inspection personnel for GRP work Lack of compliance with GRP manufactures standard with Execution Contractors

15 RCA for CW GRP pipe rupture : Fact Tree Analysis

16 Factors for GRP pipe ruptures
The following Process Factors are recognized. GRP is not the suitable application for two phase Flow service Effective monitoring tools for detecting gas ingress into CW system The following Policies/Procedures Factors are recognized. Availability of industrial standards with Reliability & Maintenance for GRP Pipes Lack of QC &QA procedures for GRP maintenance & inspection

17 RCA for CW GRP pipe rupture : Fact Tree Analysis

18 RCA for CW GRP pipe rupture : Fact Tree Analysis

19 Mitigation & Monitoring Measures
GRP failure Mitigation Measures & System Monitoring points are recognized from investigation & RCA study for new and existing CW GRP systems . CW GRP System Design Measures Proper design study (Surge & Stress analysis) to be performed & validated during project stage : To find the dynamic load variation in the GRP network as the analysis will identify the stress concentrated areas in the pipe network & for additional supports allocation. To have the system flexible enough to handle the dynamic loads. Soil Settlement issues shall be rectified for U/G GRP pipe system as continuous Soil settlement will allow the GRP pipes to settle further more than the allowable limit and put an additional stress on the GRP line branches and finally will lead to failures/ruptures. So, It is required to have: Adequate soil compaction based on the varying load bearing capacity of the Soil & Proper soil back filling. Continuous monitoring system for soil settlement is made available at the existing set up & the same has to be considered during design phase. CW system design has to be considered during project stage with the case of amount of gas ingress and continuous relieving of the same as GRP is not proven for two phase flow.

20 Mitigation & Monitoring Measures
People/Manpower/Skills Measures Efficiency of GRP Workmanship skills enhancement : Consideration of Proper Time & Capital cost constraints during project period as it could have resulted into handing over the jobs to sub-contractors in executing the pipe installation work ending up with less efficiency. To have the availability of trained maintenance and inspection personnel for GRP repair work. To have the compliance with GRP manufactures standard with Execution Contractors for installation/maintenance job execution. Process & Operations Measures Installing gas monitoring systems at the tactical locations of in CW network & at CW end-users as it will provide an early signal about the gas leakage and will help in troubleshooting exercise to isolate the particular end-user instead of doing the exercise for the whole network. Proper & immediate Operations response with safety required for mitigation and relieving of the ingress gas into CW GRP system for avoidance of rupture at weak joints of the pipe.

21 Mitigation & Monitoring Measures
Policies/Procedures Measures Standards for maintenance and inspection procedures are to be made available for Plant existing system GRP repair works. QC &QA procedures shall be made available with Plant Reliability & Maintenance for GRP pipes inspection. CW network exchangers inspection plan shall be made available with Plant Reliability & Integrity team.

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