CATION UNIT (R-4610 A/B)

RELIABILITY ISSUES

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER

2

FGC

GT/ HRSG

STG

IA/ PA

DEMIN II DEMIN I/ WWTU I

RW

CT II

CATION UNIT (R-4610 A/B)

TOP SHOWER NOZZLES

CATION UNIT (R-4610 A/B)

PERFORATED PLATE

FILTRATION NOZZLES

CATION UNIT (R-4610 A/B)

HEADER

SPARGERS

RESIN BEDANGLE IRON

CATION UNIT (R-4610 A/B)

LUG PLATES

HEADER SUPPORTS

OPERATIONS:CATION REGENRATION CYCLE

1. Operations 24 hours approx.2. Small Backwash 15 min3. Draining 10 min4. Dosing (5% HCl) 65 min5. Rinsing (PW) 45 min6. Slow Rinsing (RW) 25 min

• Backwash after 15 regenerations

ORIGINAL METULLURY

HEADERSS321

SPARGERSSS321 WITH METALLIC MESH

ANGLE IRONCS RUBBER LINED

U-CLAMPS, NUT/STUD/BOLTSSS321

CORROSION ON SS321 METALLIC MESH SPARGERS

CORROSION ON HEADER AND SOCKETS

CORROSION ON CS HEADER SUPPORT

CORROSION ON SS321 METALLIC SPARGERS

UPGRADED METULLURY

HEADERSS16L

ANGLE IRONSS316 RUBBER

LINED

U-CLAMPS, NUT/STUD/BOLTSSS316

SPARGERS SS16l WITH NYLON MESH

FAILURE ANALYSIS

RUBBER LINING DAMAGED

BENT ANGLE IRON

LOOSE U-CLAMPS DUE TO CORROSION

RUPTURED MESH

MARKER OBSERVATIONS

Missing U-clamps of Spargers

Main Header U-clamp dislodgement

Missing Nuts / lose bolts

Severely corroded Nuts and Bolts

Broken socket weld / Sparger

Leaching near weld joints and base metal

Ruptured Mesh

Sparger Angle iron support found dislodged

Dislodged / loose Spargers

Bent distributor Header / Angle Iron Support

Damaged rubber lining

Aug-09 Aug-09 Oct-09 Nov-09 Feb-10 Nov-10

Feb-11 Apr-11 Oct-11 Jan-12 Nov-12 May-13 Aug-13

MO

DIF

ICA

TIO

N

Oct-10

CATION UNIT A (R-4610A) HISTORY PROFILE SINCE COMMISSIONING

Jul-09 Aug-09 Jan-10 Feb-10 May-10 Aug-10 Nov-10

Jan-11 Feb-11 Nov-11 Jan-12 Jul-13

CATION UNIT B (R-4610B) HISTORY PROFILE SINCE COMMISSIONING

Dec-09

MO

DIF

ICA

TIO

N Dec-12 Sep-13

Sep-10

MARKER

OBSERVATIONSR-4610 A

BEFORE MODIF.

AFTERMODIF.

Missing U-clamps of Spargers 5 2

4 0 Main Header U-clamp dislodgement

5 3 Missing Nuts / lose bolts

1 1 Severely corroded Nuts and Bolts

3 1 Broken socket weld / Sparger

4 1 Leaching near weld joints and base metal

0 1 Ruptured Mesh

Sparger Angle iron support found dislodged 1 0

Dislodged / loose Spargers 6 4

Bent distributor Header / Angle Iron Support 2 1

Damaged rubber lining 4 0

MARKER

OBSERVATIONSR-4610 B

BEFORE MODIF.

AFTERMODIF.

Missing U-clamps of Spargers 7 2

7 0 Main Header U-clamp dislodgement

1 1 Missing Nuts / lose bolts

1 1 Severely corroded Nuts and Bolts

5 3 Broken socket weld / Sparger

4 2 Leaching near weld joints and base metal

5 1 Ruptured Mesh

Sparger Angle iron support found dislodged 1 0

Dislodged / loose Spargers 11 5

Bent distributor Header / Angle Iron Support 0 2

Damaged rubber lining 6 3

MARKER OBSERVATIONS REASON

Missing U-clamps of Spargers

CORROSION

Main Header U-clamp dislodgement

Missing Nuts / loose bolts

Severely corroded Nuts and Bolts

Broken socket weld / Sparger

Leaching near weld joints and base metal

Ruptured Mesh

Sparger Angle iron support found dislodged

Dislodged / loose Spargers

HYDRAULIC IMPACT

Bent distributor Header / Angle Iron Support

Damaged rubber lining

ACTION TAKEN/ TO BE TAKEN REASON

•Metallurgy has been upgraded to SS316l • Inspection Frequency is defined to be 6 months

CORROSION

• Additional supports to be installed

HYDRAULIC IMPACT

OPERATION’S OVERVIEW

1. Operations 24 hours approx.2. Small Backwash 15 min3. Draining 10 min4. Dosing (5% HCl) 65 min5. Rinsing (PW) 45 min6. Slow Rinsing (RW) 25 min

• Backwash after 15 regenerations

OPERATION’S OVERVIEW

1. Operations 24 hours approx.2. Backwash after 15 regenerations

2 kg-F/cm2

PASCAL’S PRINCIPLE

38,000 kg-F

BENT ANGLE IRON SUPPORT

Angle IronSS 316

EXISTING

U ClampSS 316

Bolted Arrangement

REPLACING ANGLE IRON WITH C-CHANNEL3”

3”

L3x3x5/16

2”

2”

6”

C6x10.5X5/16

Ixx = 1.51 in4 Ixx = 15.2 in4

Load (w) is constantLength (l) is constantElastic Modulus (E) is same

= 10 in Angle Iron

in C-Channel

= 1/10 in Angle Iron

in C-Channel

PROPOSED

C-ChannelSS 316(bolted)

H-BeamSS316(bolted)

U ClampsSS 316

Bolted Arrangement

Thank you