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The Reliance Group was founded by Dhirubhai H. Ambani (19322002) It is India's largest private sector enterprise with businesses in the energy and materials value chain. Chairman and Managing Director: Mukesh Ambani Group's annual revenues are in excess of US$ 66 billion.
Updated 2006-07
CHLOR-ALKALI
Products:
Chlorine (Primary Product) Hydrogen Sodium hydroxide (caustic) solution.
98% H2SO4
Cl2 Treatment
H2 Unit
HCL
HYPO
G CELL
HYDROGEN
78% H2SO4
Utilities
Anolyte Dechlorination
Catholyte system
Project :
Failure Study Of FRP Piping At Chlor-alkali Plant
SCOPE :
Study failure of FRP piping at Chlor-Alkali plant & Collect failure data & Study type of failure
Materials:
Classification of Composite
WHY FRP ?
Infinite potential Low weight: Mechanical strength High impact strength Formability Chemical resistance Corrosion resistance Thermally insulating Fire resistance
4 5
6
----------
S no. 1 2 3 4 5
6
Designed Temp.(oC) 95 95 80 95 80
60
Application Area Acidified Brine H2 at Cell to Stack Pure Brine (after Ion-exchange Column) Caustic Solution in Cell House Pure Brine (after Ion-exchange Column)
Waste Water Containing Chlorine
3.5 0.4 7 8 9 10 PQ31A PQ31B PQ31C PQ31E 3.0 6.0 4.0 3.0 0.4 0.1
60 60 60 65 60 60 60 60
33% HCL Acid Chlorine Waste Moist Air Waste Water from Pump Flushing DM water Sodium Bisulphate Waste Water Chlorine Free Chlorine Waste Air Moist Containing H2SO4 Chlorine Waste Air Containing HCL
Total INCH-METER
Calculated using Microsoft Excel Includes over 750 pipelines
FRP HT (PW class) FRP PP & PPH lined (PL class) FRP PVC lined (PQ class) FRP PVDF lined (PD class) FRP Resin Altac-382 (PX class) FRP V (PR class) = = = = = = 7974.35 18181 7315.3 109.2 15347.6 2216.75 INM INM INM INM INM INM
2. Resin
Different type of resins Timeline of resins
Liner
Characteristics
98% H2SO4, dry chlorine and low pressure wet chlorine gas
alkalis, salts, organic solvents and most acids, particularly hydrochloric and phosphoric acid.
halogens such as chlorine and bromine, strong acids such as hydrofluoric and nitric acids, organic solvents and oils.
strong acids, chlorinated hot bases hydrocarbons, aromatic compounds and high concentrations of free chlorine.
Resin
Timeline of resins
Bisphenol A Fumarate polyester resin Chlorendic acid polyester resin (improvement in corrosion performance )
Polyester
Bisphenol A vinyl ester resin (more resistant to thermal and mechanical stress) Epoxy novolac vinyl ester resin (enhanced resistance to organic solvents and higher Epoxy Vinyl working temperature) Ester Brominated epoxy vinyl ester resin ( fire retardance in addition to corrosion resistance )
Selection of Resins
It is done with the help of chemical resistance table. Example:
Ashland, Derakane epoxy vinyl ester resins chemical resistance guideResin selection guide for corrosion resistant applications Vipel, Vinyl Ester Resin Guide-To Corrosion Resistant Vipel Resins DSM, Durability & Protection- Guide to Chemical Resistance Reichhold, DION Corrosion Guide
DEFECTS IN COMPOSITE
1. Delamination: It refers to situations in which failure (or inadequate adhesion) occurs on a plane between adjacent layers within a laminate. Reason: inadequate resin concentration cracks
2. Cracking: It is a discrete single crack type defect in the composite usually through thickness and normally affecting both matrix and fibers. 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 environmental degradation
3. Disbond : The term disbond here is defined as a separation of the the composite material from another material to which it has been adhesively bonded. Reason: Inadequate resin
4. Porosity and voids At Microlevel : porosity At Macrolevel : voids Reason: entrapped air, moisture or volatile products
2.
3.
4.
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
S no.
1 2 3 4 5 6 7 8 CHU CHU-ELS CLU-CCD CLU-CLL SBU SBU-ADC SBU-CDC SBU-SBP
UNIT
Number of failures
17 34 17 5 68 21 24 25 TOTAL 211
For formerly installed FRP pipes (more than 3 years): Cause behind failure : Ageing failure, impact cracks and environmental factors.
Reference: R. M. V. G. K. Rao & N. Balasubramanian(2001) Moisture Absorption Phenomenon in Permeable Fiber Polymer Composites, Indian Institute of Science. It can be generalized that higher the volume fraction of voids in a composite lowers the volume fraction of fibers and higher the diffusivity which in turn decreases the durability and longevity of FRP pipes.
2. To follow standard welding procedure for FRP pipes and skilled workmanship
S no. 1. Specified Practice as per UDHE Actual Practice
For a good joint the pipe end must be sanded with After cutting, to be weld surface is not cleaned sandpaper or right angle grinder. Keep it free of oil, fat appropriately using sand paper and nor it is or water. wiped to remove dust and dirt. All cut edges must be coated with a mixture of resin and No such coating is applied hardener before positioning for joining. Pipe is clamped Clamp is not provided to support pipe. It although depends on the space for support/clamp. Resins must be mixed with prescribed % of hardner, These are mixed by just sheer anticipation. Initiators, Promoters, and Accelerators. Higher % of accelerator reduces gel time. Lesser % increases gel-time leading to improper bonding. Higher % of initiator leads to faster curing leading to insufficient time for application of resin. Lesser % initiator doesnt lead to full curing.
2.
3.
4.
5.
Filler cement eg Maxhesive should be used Not used. before strapping FRP layers
6.
Roller should be used to roll out any trace of Most of the work is done by brush air bubble from coated glass fiber with only. catalysed resin. Air bubbles lead to formation of voids and these lead to pin hole, debonding and delamination.
7.
If there is any wrinkle formation then it must Wrinkles are be removed removing it.
strapped
without
Keep moisture away from all parts and materials. Moisture inhibits cure and affects bond.
Inspection
In Chlor-Alkali DMD Complex: Visual inspection for detection of any signs of cracks, pits, rust, or corrosion(main testing). Burst test to test pipelines for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual leak detection, and pressurization of the vessel to the specified test pressure. The location of a leak can be visually identified more easily if the water contains a colorant. Strength is usually tested by measuring permanent deformation of the container. Borcol hardness tester to indicate the completeness of resin cure in FRP laminates.
In-process Inspection:
1. Ultrasonic Testing
To quickly and accurately measure the thickness of FRP parts and 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 arrival time of the reflected waves and estimate the location of voids. It also can be used for thickness measurement.
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.
Thank you..!!