CONTENTS
Background
PVC II Polymerizer
Man way specifications
Sequence of event
Analysis of failure
Probable causes
Conclusion
Recommendations
Cost Analysis
BACKGROUND
PVC II Polymerizer faces the VCM leakage most of the time when it get
discharges and taken on hold for next batch charging for more than 4
to 5 hours
Date
Event
Observation
Action Taken
NOTE: All the failures are of same nature and follows the same sequence,
this was the
reason that led to the development of this Case Study and complete
STEAM
INJECTION WATER
PVC II Polymerizer
SHORT STOP
HP FLUSH WATER
MODIFIER
FLUSH WATER
COATING AGENT
REACTION TEMPERATURES:
AFA Coating T = 850C
Batch Charging T = 650C
CATALYST
HP SEAL WATER
Reaction T = 590C
Discharge T = 580C
DISPERSANT
SHORT STOP
STEAM
POLISHED
WATER
ABOUT MANWAY
O-ring arrangement for man way
EPDM O-RING
SEQUENCE OF EVENTS
Polymerizer get discharge and hold on 4 to 5 hours for next batch charging
VCM leak from the man way which is detected by the VCM detectors and then soap test
Poly get depressurize completely (2.5 hours) and the o ring is replaced (1 hour)
ANALYSIS OF FAILURE
CHEWED/
CHEWED/ CHIPPED
CHIPPED
APPEARANCE
APPEARANCE
PROBABLE CAUSES
1. Difference in thermal expansion of the mating surfaces i.e. man
way and its closure ring
2. Size of the O ring and its groove dimension
3. Softening of Elastomer due to incompatibility
Thermal expansion of
mating surfaces
DATA:
MANWAY
l = 0.2mm
CLOSING RING
OBSERVATIONS
SEQUENCE OF
FAILURE
O-RING INSTALLED (OVER COMPRESSED DUE TO UNDERSIZE GROOVE)
THERMAL EXPANSION OF MAN WAY COMPRESSES IT MORE
WHICH CAUSES CRUSHING
VCM
POLY GETS ON HOLD FOR MORE THAN 5 HOURS AND THE COOLING
OF MAN WAY LEFT THE SPACES IN THE O RING
AFTER WHICH THE O RING DO NOT SEAL ANY MORE AND VCM LEAKAGE OSERVED
CONCLUSION
As per AS568B, the groove of the man-way O-ring is undersized
which after closing the man way, over compressed the O-ring and
cause it to tear from the edges
The different thermal expansions of man way and its ring causes
PVC powder found on the d/s of the O-ring which should not be a
case in 100% sealed O-ring. This EPDM O ring was suggested by
the TCC vendor
RECOMMENDATIONS
Replaced the man way arrangement with a flanged arrangement
ring dimensions
Use standard size of O-ring for this groove i.e.
COST ANALYSIS
Total Outage time = 8-9 hours
REFERENCES
DISCHTOMATIC O-ring handbook
Parker O ring handbook
Standard (AS568), Metric O-Ring sizes
PVC II Process description by TCC
B-reports of O-ring failure
QUESTIONS