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

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Presentation on theme: "Your company logo Cooling Water GRP Pipe Network A hands-on Approach of System Monitoring and Prevention of Failure By Ahmad M. Al-Zain / Ramireddy Annapureddy."— Presentation transcript:

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

2 Your company logo 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 Your company logo 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 Your company logo TASNEE’s Production Capacity Chemicals TiO 2 Acrylics Total: 570 KTA 80 KTA Super Absorbent Polymer 160 KTA Butyl Acrylate 330 KTA n-Butanol (Project) Total: 1,555 KTA Plastics 400 KTA HDPE 400 KTA LDPE 720 KTA PP 35 KTA Compound Recycled Lead Alloys 42 KTA 2.4 million Batteries BOPP 30 KTA 32 KTA Plastic Sheets (PC, PMMA, ABS, HIPS)

5 Your company logo Introduction: Description of TASNEE Cooling water Network 18 cells SW cooling Tower F SW / CW Exch (x 23) x 5 CW drum City water make up Gas vent EC users LDPE users HDPE users PP Line 1 x 5 CW pumps Vital CW pumps EC vital CW users Vital SW pumps  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

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

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

8 Your company logo 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: CategoryIdentified 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 Your company logo RCA for CW GRP pipe rupture : Fish Bone Diagram

10 Your company logo Factors for GRP pipe ruptures  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  System Design Factors are recognized from Fact Tree Analysis

11 Your company logo RCA for CW GRP pipe rupture : Fact Tree Analysis

12 Your company logo CW Distribution System High LEL Rupture Point

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

14 Your company logo 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 Your company logo RCA for CW GRP pipe rupture : Fact Tree Analysis

16 Your company logo Factors for GRP pipe ruptures  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  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

17 Your company logo RCA for CW GRP pipe rupture : Fact Tree Analysis

18 Your company logo RCA for CW GRP pipe rupture : Fact Tree Analysis

19 Your company logo 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 : o 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. o 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: o Adequate soil compaction based on the varying load bearing capacity of the Soil & Proper soil back filling. o 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 Your company logo Mitigation & Monitoring Measures 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. People/Manpower/Skills Measures  Efficiency of GRP Workmanship skills enhancement : o 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. o To have the availability of trained maintenance and inspection personnel for GRP repair work. o To have the compliance with GRP manufactures standard with Execution Contractors for installation/maintenance job execution.

21 Your company logo 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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