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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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OUTLINE
Tasnee Highlights, Capacity Introduction
CW GRP pipe failure incidents
Investigation & RCA for GRP pipe ruptures
Factors for GRP pipe ruptures
Mitigation & Monitoring Measures
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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.
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TASNEE’s Production Capacity
Chemicals
TiO2
Acrylics
Total: 570 KTA
80 KTASuper
Absorbent Polymer
160 KTAButyl
Acrylate
330 KTAn-Butanol (Project)
Total: 1,555 KTA
Plastics
400 KTAHDPE
400 KTALDPE
720 KTAPP
35 KTACompound
Recycled Lead Alloys42 KTA 2.4 million Batteries
BOPP30 KTA
32 KTA Plastic Sheets(PC, PMMA, ABS, HIPS)
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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
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CW GRP pipe failure incidents
CW Pumps
A
S
D
B
C
SW / CW Exchangers (Total no's: 23) CW Users100” CW header
#1
#2#3
#5
#4
CW drum
Incident in CW/SW exchanger & CW pump
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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
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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
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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
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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
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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
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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.
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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.
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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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