Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Search
  • Books
  • Software
  • Projects
  • Process
  • Tools
  • Basics
  • Formula
  • Power Plant
  • Root Cause Analysis
  • Electrical Basics
  • Animation
  • Standards
  • 4-20 mA Course
  • Siemens PLC Course
Reading: Seawater Pipeline Spools from day-1 leaks threaten Plant Shutdown
Share
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • Design
  • PLC
  • Interview
  • Control System
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > Root Cause Analysis (RCA) > Seawater Pipeline Spools from day-1 leaks threaten Plant Shutdown

Seawater Pipeline Spools from day-1 leaks threaten Plant Shutdown

Root Cause Analysis (RCA): Seawater pipeline spools from day-1 leaks threaten NH3 plant indefinite shutdown.

Last updated: September 28, 2022 3:15 pm
S Raghava Chari
Root Cause Analysis (RCA)
No Comments
Share
4 Min Read
SHARE

Root Cause Analysis (RCA): Seawater pipeline spools from day-1 leaks threaten NH3 plant indefinite shutdown.

Contents
RCA Queries and answersSeawater Pipeline Spools Leaks ProblemThe innovative solution benefits
Article Type:Root Cause Analysis (RCA)
Category:Mechanical
Equipment Type:Pipelines and Miscellaneous Problems
Author:S. Raghava Chari

Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.

RCA Queries and answers

Why do the final spools only leak and not the rest of the seawater pipelines?

The spools that came from Japan did not fit due to excessive axial and lateral offsets between the surface condenser nozzles and the concrete floor buried pipes vertical legs connected to the nozzles.

Hence, the erectors bolted the cut flanges from the spools to condenser flanges, adapted the pipes to match the flanges, and welded these in-situ.

Then they removed the damaged lining and rush epoxy-coated the bores to meet the start-up deadline. Perhaps the rushly done epoxy coatings are inadequate. Hence, the spools only leak!

Seawater Pipeline Spools Leaks Problem

CLs’ severe lateral and axial misalignments mentioned above, precludes spools prefabrication, lining, and replacing finished spools at convenient schedules.

A week of constant thinking flashed an answer to the author He stopped the 3.5 bar pressure seawater 6-10 dia jets by driving wooden taper plugs epoxy sealed them.

Then welded longitudinally split two halves of the next larger sized pipe as a jacket (below fig). Molten asphalt fill in the annular space serves as an in‑situ jacket bore seawater corrosion even in case the entire original pipe corrodes away.

Jacket Added Seawater Pipe Spool

Crew jacketed the entire 42 Nos. of spools working general shift hours only.

Non-amenability to prefabrication made spools replacement impractical during the plant’s 15‑day turnaround (TA) 30-months hence.

Again, another innovation – cement lining the spools solved the problem; with two bonus benefits viz. low costs, and stronger adherence to even corroded rough surfaces. Rubber or other linings require new spools of sandblast cleaned smooth surfaces.

The innovative solution benefits

Below listed are the innovative solution benefits

  1. It averted rush total unplanned shutdowns from potential heavy spool leaks effectively, safely and inexpensively
  2. Cement lined spools last forever
  3. The debuting company met the export orders in time and earned a good name as a reliable ammonia supplier and a decent profit too.  The cement-lined spools were performing well when the author retired from the plant several years hence.

Author: S. Raghava Chari

Do you face any similar issues? Share with us through the below comments section.

If you liked this article, then please subscribe to our YouTube Channel for Instrumentation, Electrical, PLC, and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • Leaking Plug Valves
  • Flange Joint Problems
  • Pipe Elbow Sudden Burst
  • Fan Motor Journal Bearing Failures
  • Fired Boiler Induced Draft Fan Failures
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

Control Valves Leak Tightness Restoration Pose Difficulties
Cooling Tower Fans Frequently Failing
Antifriction bearings (AFB) Problems and Delays Plant Restarts
Pressure Correction Pneumatic Instrumentation
Solenoid Valve Failure in Plant Start-Up: Identifying the Root Cause
Gas Cooler Re-tubing Done Successfully (Root Cause Analysis)
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
210kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Inability to Test Repaired HT Motors in Workshop Posed Problems
NH3 Storage Tanks Ammonia Gas Venting Issue – Root Cause Analysis
Magnetic Flow Meter Liner Damaged and Winding Burnt
Critical High KiloWatt Motor Winding Burnout Threats
Unreliable Ammonia Flow Transmitter Reading and Problems
Centrifugal Compressor near ½-RPM Frequency High Magnitude Shaft Vibrations
Rupture Discs bursts caused too many Urea Plant Shutdowns
Malfunctioning Inlet Check Valves caused chaos at Compressor stop/trip

Keep Learning

Temperature Sensors Fault

18 Temperature Sensors Fault Leads to Plant Shutdown

Root Cause Analysis for Plant Trip Due to Work on Incorrect Tag

Root Cause Analysis for Plant Trip Due to Work on Incorrect Tag

Damaged Magnetic Flow Meter Flow Tube

None Could Repair Slightly Damaged Magnetic Flow Meter Flow Tube

Surface Condenser Condensate Evacuation Pumps

Condensate Pump Frequent Wrecks Threatens Long Plant Outages

Pump Mechanical Seal and thrust bearing Problem

Pump 3-monthly Seal Leaks threaten entire Plant Shut down Indefinitely

Testing of Pneumatic Systems

Panel and Field Pneumatic Controller’ Bumpless Transfer Issues

Reactor Top lid lapped

Urea Reactor Top Bolted Plug developed Leaks

Solving Critical Control Valve Hunting

Solving Control Valve Hunting: Instrument Troubleshooting

Learn More

Integral Wind-Up Limitation

What is Integral Wind Up ?

Relay Parts

Difference Between NO and NC Contacts

W Type Transit Time Flow Meter

Transit Time Flow Meter – Types, Advantages, Disadvantages

RTD installed after the Orifice Plate

Why RTD installed after the Orifice Plate ?

Ratio control

What is Ratio Control ?

Actuator Sensor Interface (ASi) Protocol in PLC

Actuator Sensor Interface (ASi) Protocol in PLC

Best YouTube Channels for Cyber Security

Best YouTube Channels to Learn Cyber Security

What is a cable gland?

How Many Types of Cable Glands Are There?

Menu

  • About
  • Privacy Policy
  • Copyright

Quick Links

  • Learn PLC
  • Helping Hand
  • Part Time Job

YouTube Subscribe

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?