PetroChina International Iraq FZE Iraq Branch

Production Department
Maintenance Section – Corrosion

ROOT CAUSE FAILURE ANALYSIS REPORT

Report Date: 25-02-2023 Report No.: RCFA-2023-CPF1-COR-001

A. Equipment/ System Details
Facility: CPF1
Equipment Tag, Make, Model: Reverse Demulsifier (SK-11680)
Equipment/System Description: ¾” Outlet Line of Reverse Demulsifier (SK-11680)
Materials of Construction ASTM A312 TP316L
Date and Time of Abnormality: 05th Dec, 2022
B. Brief Description of Failure
Description: (Briefly Mention-What Happened? / Where Happened? / When Happened? / Why
Happened? / Who is Responsible for corrective action?)
 5th Dec 22: 05 Leak observed for subjected line by CPF1 operation team. Leak point inspected &
work order issued to cut & replace all 05 leak points.
 20th – 22nd Jan -23: 04 Nos. leak points cut & replaced by welding. Pickling & passivation done.
Penetrant testing done.
Criticality:
Level  High
(High/Medium/Low):
 Reverse Demulsifier Tank out of service.
Justification:  Operation & maintenance activities were affected.
C. Background/Problem Statement
(List down briefly the previous history / problems faced during maintenance, since inception)
 Previously same line leaked many times.
D. Likely Root Cause
Briefly mention about probable root causes and way forward
Description:  Internal Corrosion (Pitting)
Likelihood (High/Medium/Low):  High
Information:  Visual Inspection
(i). Tests to Clarify
E. Probable Failure Mode/Cause
Briefly mention about probable failure mode and way forward
Failed Component:  Elbow/Pipe/Tee (3/4”)
Failure  Leak
Mode of Failure:  Internal Corrosion (Pitting)
 SS316 stainless steel is susceptible to pitting corrosion in
Cause Description:
chloride environment.
Has This Failure Occurred on
Similar Equipment or Group of  Yes
Equipment?
Evaluate the Reliability of this Abnormal & Chronic &
☐ Normal ☐
Unusual
☒ Repetitive
Failure?
F. Consequence of Failure
Consequence of Failure  Financial Loss
 Downtime
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 Associated with Above Failure:

G. Analysis of Basic Root Cause

Analysis of Basic Root Cause are as Follows:
 Poly Aluminium Chloride (PAC) is the Chemical Injected from
Reverse Demulsifier (SK-11680). pH value of PAC is 2.3±0.3
Analysis of Basic Root Cause / which is highly acidic.
Distribution of Responsibility:  300 series stainless steel grade is susceptible to pitting corrosion
in chloride environment.
 As the acidic nature of PAC accelerated the rate of corrosion
causing pitting corrosion & further with leak.
Corrective Action to Eliminate  Leak area cut and replaced
Basic Root Cause:  GTAW Welding technique used for weld repair.
 ¾” PIPE.ASTM A312 TP316L SMLS, BE, 2.87mm THK – 5m
Length
 ¾” TEE, ASTM A403 WP316L, SMLS, BW 2.87mm THK,
B16.9 – 1No.
Implementation of Corrective  ¾” ELBOW, ASTM A403 WP316L, SMLS, BW 2.87mm THK,
Action: B16.9 – 1No.
 Cut & replaced the leak location with 5m ¾” spool, ¾” Tee
(1No.) & ¾” Elbow (1No.) by GTAW/SMAW welding.
 Penetrant testing done to ensure the integrity of repair weld
joints.
Standards Referred:  API 570/ASME B31.3/ASME PCC-2/API571
Verification of Corrective
 Visual Inspection, Penetrant Testing.
Action and Effectiveness:
Follow up of Corrective Action
 Continuous surveillance and inspection during repair.
Effectiveness:
H. Action to Restore Function
Type of Repair: ☒ Permanent Repair ☐ Temporary Repair
I. Preventive Action
What should be done to
Prevent this Failure  Corrosion resistant material shall be used during construction.
Reoccurring?
J. Photos:

General Overview 1st Leak Point 2nd Leak Point

3rd Leak Point 4th Leak Point

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 5th Leak Point Pitting Corrosion

Pitting Corrosion After Welding Penetrant Testing

After Welding Penetrant Testing After Welding

Penetrant Testing After Welding Penetrant Testing

Team Members:
Name Position Signature

Prepared By Vignesh Panchabakesan Plant Inspector

Reviewed by Ibrahim Yousif Corrosion Superintendent

Approved By Saravanan Beemen Maintenance Section Head

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