Reliability Enhancement

of AV-GU Chlorine Line

Prepared by :
Muhammad Saim Khan
Dated:7th Dec 2018
Introduction

Concern
Frequent leakages on non-
metallic piping.

Objective
Mitigation of Chlorine/hypo
leakages by finding a reliable &
better alternative to AV-GU

Scope
Scope of this project is to
evaluate and analyze
advanced/better substitutes to
AV-GU piping and come up with
the best suitable one
Agenda

Non-Metallic
Piping in Area 1 5 Failure Analysis

Service Fluid Substitutes to

Characteristics 2 6 AV-GU

AV-GU 3 7 Quality Controls

Current Condition
of Line
4 8 Action Plan
Leakage History
Non-Metallic
Piping

Sodium Hypo Hydrochloric

Chlorine Brine
Chlorite Acid

18

16
3
14

12
Chlorine
10

8 12 Hypo
6 0
4 HCl
5 1
2
3
2
0 1
0
AV-GU CPVC-FRP CPVC
Service Fluid Characteristics

Service
Wet Chlorine Gas

Carbon Di
Parameters Water
Oxide,
Vapours,
❑ Temperature: 87 c 14 % 0.11 %
❑ Pressure: 16kPa
Oxygen
❑ pH: 3.5-4 (Acidic) 0.18%

Chlorine,
85.71 %

Reaction
What are AV pipes?
 Composition:
❑ Base material
❑ External surface

 AV Types:
❑ SU Type

❑ GU Type

 Structure of AV-GU Pipe:

❑ Rigid (PVC Pipe)
❑ Surface-treated portion
❑ Special primer
❑ FRP Layer
❑ Finished surface layer
FEATURES OF ASAHI AV-GU Pipes

Excellent chemical resistance

1
Greater mechanical strength
2
Good external heat resistance
3
Light weight
4
Low coefficient of expansion
5
High Temperature Differential
6
Current condition of AV-GU Line

 Total Leakage Areas: 7

❑ PVC Box Installed : 5

Leakage Areas on AV-GU Chlorine Line

In-Adequacy

Improper Pipe Supports

Improper Routing of Pipe (A-1400 Entrance)

Failure Analysis
Operational
Reason 1
Variation
In-adequate Fabrication
Reason 2
Techniques

Reason 3 No Design Review

Improper Piping
Supports Reason 4
Dis Advantages of AV-GU

HIGHLY SKILLED
DEPENDABILITY
LABOR REQUIRED

MINIMAL MARGIN
LONGER LEAD TIME FOR ERROR WHILE
FABRICATION

LOW LIFE AFTER

DIFFICULT REPAIRING
BUILD-UP
Compatible materials with CGW
CPVC/UPVC-FRP
Composites
FRP

CS-PTFE

Lined Pipes CS-PVDF

Wet Chlorine Gas

CS-PP
Very Expensive
Titanium

Metals Tantalum

HASTELLOY® C-22
FRP Pipes
 Advantages:
❑ Economical(Cost Effective)
❑ Corrosion Resistant
❑ High Strength
❑ Lightweight
❑ Temperature Stable
❑ Excellent Flow Characteristics
❑ Size Variety
❑ Custom Manufactured
❑ Abrasion/erosion Resistant
CPVC/UPVC + FRP Pipes
 Advantages
❑ Long-term reliability
❑ Corrosion resistant
❑ Lightweight, easy to transport
❑ No flame used for joining
❑ Economical (UPVC > CPVC)
❑ High temperature differential
❑ Pressure rating (CPVC > UPVC)
❑ Mechanical strength (CPVC > UPVC)
❑ Widely used in Chlor Alkali Plants e.g. GE Industrial Plant
Evaluation of Alternatives
Alternative Weightage CPVC + UPVC + FRP AV-GU
FRP FRP
Leadtime 0.15 7 5 6 4

T&D 0.2 8 8 6 3

Repair & 0.175 8 8 9 4

Maintenance

Spares 0.15 9 9 8 4
Availability
Benchmarking 0.10 9 5 3 5

Reliability 0.125 8 4 5 9

Economical 0.10 7 8 9 4

Overall Score 1.00 8.0 6.9 6.7 4.525

Quotation (CPVC-FRP)
Potential Vendor : HENGSHUI JRAIN FRP CO. LTD

Unit Total
Item Description Qty
Price Price
Pipe 18'' .. Specification : SCH 80. Material : CPVC. ASTM F-441 Length: 06 Meter.
1 (including FRP outside) 13 $ 5630 $73,190
Elbow Pipe Fitting.. 18'' Specification: 90 Degree, SCH 80. Material: CPVC (including FRP
2 outside) 6 $ 2215 $13,290
Flange 18'' , Matl PVC, Grade CPVC, Conctype SW, Lap Joint, , Rating 150#, Stud ANSI
3 B16.5, ANSI B 16.5 (including FRP outside) 12 $4461 $53,553
4 Fitting - Socket - 18'' CPVC Sch. 80 (including FRP outside) 16 $915 $14,640
Elbow Pipe Fitting.. 18'' Specification : 45 Degree, SCH 80. Material : CPVC (including FRP
5 outside) 4 $2040 $8,160
6 Welding Rod 30KG $65 $1,680
7 Packing and Port Charge in China and Sea Freight to Karachi $3000
8 On site joining and FRP lamination service for the joints (around 1 month) $18000
9 Jrain team’s travelling charge $12000
Total Price $197,512
Benchmarking
Quality Controls
Workmanship skill
improvement

PVC-FRP
Material quality
Fabrication/Leak Test
verification
Standardization

Engineering Adequate pipe

Simulation & Supports
Analysis
Action Plan
Material Lead Time
Selection

04
Proposals review finalization
and strategy &
finalization as Budget Approval

03
per stress
analysis results Waiting for FAO
from AKCC for Pipe
fabrication and
3D Modelling for
Stress Analysis
and Pipe Routing 02 installation

01