Colloquim PPT - Copy

7/29/2019 Colloquim PPT - Copy

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ColloquiumSummer Internship @ Reliance Industries Limited

Harsh Kumar Singh (2010ME10678)


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Introduction to Reliance Industries Limi

The Reliance Group was founded by Dhirubhai H. Ambani2002)

It is India's largest private sector enterprise with businesseenergy and materials value chain.

Chairman and Managing Director: Mukesh Ambani

Group's annual revenues are in excess of US$ 66 billion.


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CHLOR-ALKALI

Products: Chlorine (Primary Product)

Hydrogen

Sodium hydroxide (caustic) solution.


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PROCESS FLOW DIAGRAM

Primary

Brine

Secondary

Brine

Cl2 Treatment HCl Unit

H2 Unit

Waste Air

Dechlorination

Waste water

Treatment

Catholyte

system

Anolyte

Dechlorination

HOUSECELLRectifo

rmer

CEU

CCU

G

S

L

Salt

chemicals

Power

Utilities

98% H2SO4

CHL

CAU

HCL

HYP

HYD

78%

SOLID

WAST

LIQUI

WAST

SCRU

NON

GAS


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Project :Failure Study Of FRP Piping At Chlor-alkali Plant

SCOPE :

Study failure of FRP piping at Chlor-Alkali plant & Cofailure data & Study type of failure


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Materials:


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Classification of Composite


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WHAT IS FIBER- REINFORCED PLASTICS

Fiber reinforced polymers are made of two primary constitufibers and a polymer matrix. The structure gives completelychemical and physical properties than the properties of the materials. Apart from this additives can give additional propcolour, UV protection, flame retardant nature etc.


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WHY FRP ?

Infinite potential Low weight: Mechanical strength

High impact strength

Formability

Chemical resistance

Corrosion resistance

Thermally insulating

Fire resistance


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FRP Piping @ CA plant DMD

Specification by : UDHE India

Largest subsidiary in the ThyssenKrupp Uhde network

Specification includes:

Manufacturing standards Pipeline designation

Temperature and pressure ratings

Welding procedure for lined and non-lined FRP pipes


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FRP piping in CA PLANT

S no. Piping Class Resin Used Liner

1 PD31 Alpolit-745 S Polyvinyldiflouride(PVDF)

2 PL31/ PL31A/ PL31B/

PL31C

Alpolit-745 S Polypropylene(PPH)

3 PQ31/ PQ31A/

PQ31B/ PQ31C/

PQ31E/ PQ31F

CPol-3601 Polyvinylchloride(PVC)

4 PR31/ PR31A Derakane 411-45 ----

5 PW31 Alpolit UP797 ----

6 PX31/ PX31A/ PX31B/

PX31C/ PX31D/ PX31E/

PX31F

Altac-382 ----


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S no. Piping

Name

Designed

Pressure(psi)

Designed Temp.(oC) Application Area

1 PD31 4.0 95 Acidified Brine

2 PL31 0.4 95 H2 at Cell to Stack

3 PL31A 8.0 80 Pure Brine (after Ion-exchange Column4 PL31B 7.0 95 Caustic Solution in Cell House

5 PL31C 3.5 80 Pure Brine (after Ion-exchange Column

6 PQ31 3.0 60 Waste Water Containing Chlorine

3.5 60 33% HCL Acid

0.4 60 Chlorine Waste Moist Air

7 PQ31A 3.0 60 Waste Water from Pump Flushing

6.0 65 DM water

8 PQ31B 4.0 60 Sodium Bisulphate

3.0 60 Waste Water Chlorine Free

9 PQ31C 0.4 60 Chlorine Waste Air Moist Containing H2

10 PQ31E 0.1 60 Chlorine Waste Air Containing HCL


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Quantum of FRP Piping

Inch-Metre (INM) = It is defined as the multiplication of diapipe (in inches) and length of pipe (in metres). It reflects theof the piping that is required for a particular unit.

Inch-Diameter (IND) = It is defined as the multiplication of dof pipe (in inches) and number of joints present in the pipelrepresents the amount of work that is to be done on installe

pipeline. It is best suited to minimize IND for installation of p


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Total INCH-METER

Calculated using Microsoft Excel Includes over 750 pipelines

FRP HT (PW class) = 7974.35 INM

FRP PP & PPH lined (PL class) = 18181 INM

FRP PVC lined (PQ class) = 7315.3 INM

FRP PVDF lined (PD class) = 109.2 INM FRP Resin Altac-382 (PX class) = 15347.6 INM

FRP V (PR class) = 2216.75 INM

Total INM = 51144.2 INM


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Properties of FRP piping

1. Liner

PVC (Polyvinyl Chloride) PP (Polypropylene)

PVDF(Polyvinylidene Fluoride)

2. Resin Different type of resins

Timeline of resins


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Liner PVC (Polyvinyl Chloride) PP (Polypropylene) PVDF (Poly

Fluoride)

Characteristics Excellent mechanical and

chemical resistance

properties at low cost

PP is light weight and

high in chemical

resistance.

Superior ch

resistance a

resistance.

Working

temperature

range

0 to 60C -20 to 90C -40 to 120

High chemical

resistance

towards

98% H2SO4, dry chlorine

and low pressure wet

chlorine gas

alkalis, salts, organic

solvents and most acids,

particularly hydrochloricand phosphoric acid.

halogens su

and bromin

such as hydnitric acids,

solvents an

Low chemical

resistance

towards

chlorinated

hydrocarbons, ketones

and esters

strong acids, chlorinated

hydrocarbons, aromatic

compounds and high

concentrations of free

chlorine.

hot bases


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Chemical Resistance Chart for linersChemical Compound PVC PP PVD

Ammonia Gas (NH3 up to 60 oC) A A A

Barium Carbonate (BaCO3 up to 60 oC) A A A

Barium Sulphate (BaSO4 up to 60 oC) A A A

Calcium Chloride (CaCl2 up to 60 oC) A A A

Calcium Carbonate(CaCO3 up to 60 oC) A A A

Chlorine Gas Cl2

(wet & 60 oC )

B X A

Chlorine Gas Cl2(wet & 100 oC )

--- X A

Chlorine Gas Cl2

(up to 150 ppm moisture & 60 oC)

A X A

Chlorine Gas Cl2

(up to 150 ppm moisture & 100 oC)

--- X A


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Resin Timeline of resins

Polyester

Bisphenol A Fumarate polyester resin Chlorendic acid polyester resin (improvement i

corrosion performance )

Epoxy VinylEster

Bisphenol A vinyl ester resin (more resistant tothermal and mechanical stress)

Epoxy novolac vinyl ester resin (enhancedresistance to organic solvents and higherworking temperature)

Brominated epoxy vinyl ester resin (fireretardance in addition to corrosion resistance


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Resins Used @ CA plant

1. Altac 382: propoxylated bisphenol A fumarate unsaturatpolyester resin

2. Alpolite UP 745/56: teraphthalic acid/neopentyl glycol r

3. Aloplite UP 797: chlorendic acid/ neopentyl glycol resin

4. CPOL 360: Isophthalic Acid/neopentyl glycol resin

5. Derakane 411-45: bisphenol-A epoxy resin


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Selection of Resins

It is done with the help of chemical resistance table.

Example: Ashland, Derakane epoxy vinyl ester resins chemical resistance

Resin selection guide for corrosion resistant applications

Vipel, Vinyl Ester Resin Guide-To Corrosion Resistant Vipel Res

DSM, Durability & Protection- Guide to Chemical Resistance

Reichhold, DION Corrosion Guide


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DEFECTS IN COMPOSITE

1. Delamination: It refers to situations in which failure (orinadequate adhesion) occurs on a plane between adjacelayers within a laminate.

Reason:

inadequate resin concentration

cracks


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2. Cracking: It is a discrete single crack type defect in the cousually through thickness and normally affecting both matrfibers.

Reason: It mostly occur as part of the curing

Process under the thermal or residual

stresses induced

hole drilling and trimming

impact damage Surface cracking can arise from impact damage or environ

degradation


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3. Disbond : The term disbond here is defined as a separatiothe composite material from another material to which it haadhesively bonded.

Reason: Inadequate resin


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4. Porosity and voids

At Microlevel : porosity

At Macrolevel : voids

Reason: entrapped air, moisture or volatile

products


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In-Field Defects in FRP piping

1.

2.


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3.

4.


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5. Ageing Damage

Average industrial life of FRP Pipes: 8-10 years

It includes:a) Surface Attack

b) Stripping

c) Mud-Cracking

d) Erosion/Corrosion

e) Permeation

f) Osmotic Blistering


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Failure Data Analysis

1. Study of Database from SAP system

2. Root and Cause Analysis


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Study of Database from SAP systemDuration : 01/01/10 to 07/06/13

S no. UNIT Number of fai

1 CHU 17

2 CHU-ELS 34

3 CLU-CCD 17

4 CLU-CLL 5

5 SBU 686 SBU-ADC 21

7 SBU-CDC 24

8 SBU-SBP 25

TOTAL 211


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CONCLUSION FROM STUDY OF SAP DATABASE

Types of most common defects identified from SAP databas

Pinhole:- because of entrapping of air bubbles Impact crack:- because of high magnitude impacts, conce

resin at one spot and insufficient reinforcement

Delamination:- because of poor glass saturation, too highconcentration and failure to remove air-inhibition coat be

adding layers. Ageing Damage


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Conclusion & RecommendationFor newly installed FRP pipes( less than 3 years):

Causes behind failure : Manufacturing defects and poorworkmanship in case of leakage. Manufacturing defects: it ipoor bonding strength, high volume fraction of voids, improglass reinforcement, improper distribution of resin while pipproduction, insufficient curing time, moisture entrapment e

For formerly installed FRP pipes (more than 3 years):

Cause behind failure : Ageing failure, impact cracks andenvironmental factors.

1 Inclusion of volume fraction of voids in certification of pipe


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1. Inclusion of volume fraction of voids in certification of pipe

Reference: R. M. V. G. K. Rao & N. Balasubramanian(2001)Moisture Absorption Phenomenon in Permeable Fiber PolymComposites, Indian Institute of Science.

It can be generalized that higher the volume fraction of voidcomposite lowers the volume fraction of fibers and higher tdiffusivity which in turn decreases the durability and longevFRP pipes.

higher volume fraction ofvoids

higher the porosity andpermeability

Also reduction inmechanical properties

shorter the life of FRPpipes

2. To follow standard welding procedure for FRP pipes and skilled wor


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2. To follow standard welding procedure for FRP pipes and skilled wor

S no. Specified Practice as per UDHE Actual Practice

1. For a good joint the pipe end must be sanded with

sandpaper or right angle grinder. Keep it free of oil, fat

or water.

After cutting, to be weld su

appropriately using sand

wiped to remove dust and

2. All cut edges must be coated with a mixture of resin and

hardener before positioningfor joining.

No such coating is applied

3. Pipe is clamped Clamp is not provided t

although depends on

support/clamp.

4. Resins must be mixed with prescribed % of hardner,Initiators,Promoters, and Accelerators.

Higher % of accelerator reduces gel time. Lesser %

increases gel-time leading to improperbonding.

Higher % of initiator leads to faster curing leading to

insufficient time for application of resin. Lesser %

initiatordoesnt lead to full curing.

These are mixed by just she


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5. Filler cement eg Maxhesive should be used

before strapping FRP layers

Not used.

6. Roller should be used to roll out any trace of

air bubble from coated glass fiber with

catalysed resin. Air bubbles lead to formation

of voids and these lead to pin hole, debonding

and delamination.

Most of the work is do

only.

7. If there is any wrinkle formation then it must

be removed

Wrinkles are strappe

removing it.


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3. To maintain storage condition of resins and fibers as per cer

Keep moisture away from all parts and materials. Moisture cure and affects bond.


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Inspection

In Chlor-Alkali DMD Complex:

Visual inspection for detection of any signs of cracks, pits, rcorrosion(main testing).

Burst test to test pipelines for strength and leaks. The test ifilling the vessel or pipe system with a liquid, usually water, may be dyed to aid in visual leak detection, and pressurizativessel to the specified test pressure. The location of a leak c

visually identified more easily if the water contains a coloraStrength is usually tested by measuring permanent deformathe container.

Borcol hardness tester to indicate the completeness of resinFRP laminates.


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In-process Inspection:

1. Ultrasonic Testing

To quickly and accurately

measure the thickness of FRP partsand find defects

Principle: ultrasonic waves penetrate

materials at different speeds

depending on their density and type. In case of cracks or voids, ultrasonic devices can pick-up a

time of the reflected waves and estimate the location of valso can be used for thickness measurement.


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2. Acoustic Emission

Acoustic emission testing identifies and

locates active defects in laminates by

detecting minute acoustic impulses that

are generated as a defect propagates

under load.


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Thank you..!!

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Colloquim PPT - Copy