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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..!!