Cation unit reliability issues & modification
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CATION UNIT (R-4610 A/B)
RELIABILITY ISSUES
MUHAMMAD REHAN KHANMAINTENANCE ENGINEER
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2
FGC
GT/ HRSG
STG
IA/ PA
DEMIN II DEMIN I/ WWTU I
RW
CT II
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CATION UNIT (R-4610 A/B)
TOP SHOWER NOZZLES
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CATION UNIT (R-4610 A/B)
PERFORATED PLATE
FILTRATION NOZZLES
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CATION UNIT (R-4610 A/B)
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HEADER
SPARGERS
RESIN BEDANGLE IRON
CATION UNIT (R-4610 A/B)
LUG PLATES
HEADER SUPPORTS
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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
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ORIGINAL METULLURY
HEADERSS321
SPARGERSSS321 WITH METALLIC MESH
ANGLE IRONCS RUBBER LINED
U-CLAMPS, NUT/STUD/BOLTSSS321
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CORROSION ON SS321 METALLIC MESH SPARGERS
CORROSION ON HEADER AND SOCKETS
CORROSION ON CS HEADER SUPPORT
CORROSION ON SS321 METALLIC SPARGERS
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UPGRADED METULLURY
HEADERSS16L
ANGLE IRONSS316 RUBBER
LINED
U-CLAMPS, NUT/STUD/BOLTSSS316
SPARGERS SS16l WITH NYLON MESH
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FAILURE ANALYSIS
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RUBBER LINING DAMAGED
BENT ANGLE IRON
LOOSE U-CLAMPS DUE TO CORROSION
RUPTURED MESH
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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
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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
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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
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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
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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
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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
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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
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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
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OPERATION’S OVERVIEW
1. Operations 24 hours approx.2. Backwash after 15 regenerations
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2 kg-F/cm2
PASCAL’S PRINCIPLE
38,000 kg-F
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BENT ANGLE IRON SUPPORT
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Angle IronSS 316
EXISTING
U ClampSS 316
Bolted Arrangement
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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
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PROPOSED
C-ChannelSS 316(bolted)
H-BeamSS316(bolted)
U ClampsSS 316
Bolted Arrangement
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Thank you