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Description: (Briefly mention-What Happened? / Where Happened? / When Happened? / Why Happened? / Who is
Responsible for corrective action?)
Criticality:
Level High
(High/Medium/Low):
Justification K-23210 B Flame Arrestor line could not be operated.
Fire system could not be operated.
HP Gas Compressor K-23210 B disturbed and obstructed.
C. Background/Problem Statement:
(List down briefly the previous history / problems faced during maintenance, since inception)
Welding defect during construction stage
Due to abnormal vibration welding defect increased and leak occurred at welding area
Defective spool replaced by new one and after PT completed material crack observed on HAZ
area due to fast cooling (vessel full of water )
Crack removed , PT done before and after re-welding to confirm crack clearance
New joint and vessel painted
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D. Likely Root Cause:
Information: Inspect the welding (PT) for gas high pressure points
(i). Tests to Clarify
1- Welding defect
50% weld seam of the nozzle was unfused;
50% tear on the pipe which part of weld was fused;
Analysis of Basic Stress on fused part of the nozzle affected the welding
Root Cause / 2- Vibration and restrain
Distribution of Continuous abnormal vibration of HP Gas Compressor system lead to
Responsibility:
failure of defective welding
The nozzle restrained by connected pipe
Welding seam affected by stress and restrained.
Welding defect occurred during construction stage
Vibration and restrain was due to the service condition.
Corrective Action to Replace defective nozzle
Eliminate Basic Root
Grind the surface-remove the crack and re-weld
Cause:
Repaired the fractured Nozzle by TIG (welding method);
Implementation of Grinding, welding and coating.
Corrective Action:
Verification of Welding: Penetrate Test & Visual inspection.
Corrective Action and
Effectiveness: Coating: Visual inspection.
Follow up of 1- Continuous surveillance and monitoring the repair weld seam of vessel
Corrective Action
nozzle.
Effectiveness:
2- Enhance Welder/QA/QC during construction.
Remarks:
Team Members:
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Photos:
Page 3 of 5
Weld surface after repair PT
Page 4 of 5
Crack repair PT result Accepted
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