Anda di halaman 1dari 18

MUHAMMAD REHAN KHAN

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

23rd Nov 2010

VCM leakage detected from


the man way of PLY-1E

Polymerizer was on hold for batch charging

Man way opened and the O-ring


was replaced

8th January 2011

VCM leakage detected from


the man way of PLY-1E

Polymerizer was on hold for batch charging

Man way opened and the O-ring


was replaced

1st February 2011

VCM leakage detected from


the man way of PLY-1E

Polymerizer was on hold for batch charging

Man way opened and the O-ring


was replaced

2nd April 2011

VCM leakage detected from


the man way of PLY-1E as
well as 2E

Both polymerizer were on waiting for batch


charging from 48 hrs and 24 hrs respectively

Man way opened and the O-ring


was replaced

2nd October 2011

Pressure test of all three


Polymerizers failed while
they were hold on for more
than 10 hours

All the Polymerizers were on hold due to the


power outage from GT B

Man way opened and the O-rings


were replaced

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

Design Pressure & Temperature = 1.55MPa & 93 0C


VCM

COATING AGENT

Operating Pressure & Temperature = 0.85MPa &


550C
MOC: 16MnR (C-Mn-Si Steel) +304 (GB6654,
A537M)
ID = 3810mm, H = 7068mm
Empty Weight = 44.7 M Tons

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)

V/A and Leak test done (5.5 hours)

Poly takes on service and found OK (Total outage 8-9 hours)

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

4. Improper machining of O-ring gland i.e. Sharp edges (Not the


case)
5. Elastomer too soft (Not the case)

Thermal expansion of
mating surfaces
DATA:
MANWAY

Material = 0Cr18Ni9 (SS304)


Ambient Temp. = 30 C
Temp. Of Ring = 43 C
AFA Coating T = 850C
Batch Charging T = 650C
Reaction T = 590C
Discharge T = 580C
THERMAL EXPANSION

l = L * k * T (k = 17.2 X 10-6 m/m-K)

l = 0.2mm

CLOSING RING

SIZE OF THE O-RING AND GROOVE


DIMENSION
O-rings dimensions
O ring diameter = 7.5mm
OD = 633mm
Volume of the O-ring (2pi2 Rr2) = 86,856
mm3
Grooves dimensions
Actual W = 6.5mm, H = 5.72mm
Volume of the Groove = 92,222mm3
Standard Groove Dimensions
As per AS568B for O ring diameter = 7.5mm,
W = 6.2mm, H = 6.2mm
Volume of the Std. Groove = 94,345 mm3
Which is greater than the total actual volume

Softening of Elastomer due to


incompatibility

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

VCM STARTS PENETRATING AND CAUSES O-RING TO SWELL

SWELLING OF O-RING FURTHER CONTRIBUTES TO THE COMPRESSION

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

the crushing of the O-ring from its edges


EPDM is not suitable with the VCM service . During investigation

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

like PVC I polymerizer


Use Teflon or FFKM O-rings instead of EPDM
Machined the groove for increasing its volume to suit with our O-

ring dimensions
Use standard size of O-ring for this groove i.e.

ID = 633.48 +- 2.92, d = 6.99+-0.15 as per AS568B # 474

COST ANALYSIS
Total Outage time = 8-9 hours

Total loss of PVC / batch = 18 Tons

1 Tons = $1,070 (Reference: www.icis.com)

For one batch, we face the loss of 19,260$ (Rs 16,37,000)

FFKM O-ring cost = $ 3,000

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

Anda mungkin juga menyukai