MUHAMMAD REHAN KHAN

CONTENTS
Background
PVC II Polymerizer
Man way specifications
Sequence of event
Analysis of failure
Probable causes
Conclusion
Recommendations
Cost Analysis





BACKGROUND
PVC II Polymerizer faces the VCM leakage most of the time when it get discharges
and taken on hold for next batch charging for more than 4 to 5 hours
NOTE: All the failures are of same nature and follows the same sequence, this was the
reason that led to the development of this Case Study and complete investigation.

Date Event Observation Action Taken
23
rd
Nov 2010 VCM leakage detected from
the man way of PLY-1E
Polymerizer was on hold for batch charging Man way opened and the O-ring
was replaced
8
th
January 2011 VCM leakage detected from
the man way of PLY-1E
Polymerizer was on hold for batch charging Man way opened and the O-ring
was replaced
1
st
February 2011 VCM leakage detected from
the man way of PLY-1E
Polymerizer was on hold for batch charging Man way opened and the O-ring
was replaced
2
nd
April 2011

VCM leakage detected from
the man way of PLY-1E as
well as 2E
Both polymerizer were on waiting for batch
charging from 48 hrs and 24 hrs respectively
Man way opened and the O-ring
was replaced
2
nd
October 2011 Pressure test of all three
Polymerizers failed while
they were hold on for more
than 10 hours
All the Polymerizers were on hold due to the
power outage from GT B
Man way opened and the O-rings
were replaced
PVC II Polymerizer
Design Pressure & Temperature = 1.55MPa & 93
0
C

Operating Pressure & Temperature = 0.85MPa & 55
0
C

MOC: 16MnR (C-Mn-Si Steel) +304 (GB6654, A537M)

ID = 3810mm, H = 7068mm

Empty Weight = 44.7 M Tons


REACTION TEMPERATURES:

AFA Coating T = 85
0
C

Batch Charging T = 65
0
C

Reaction T = 59
0
C

Discharge T = 58
0
C
HP SEAL WATER CATALYST
DISPERSANT
SHORT STOP STEAM POLISHED WATER
VCM
FLUSH WATER MODIFIER
SHORT STOP
STEAM
COATING AGENT
INJECTION WATER
HP FLUSH WATER
ABOUT MANWAY
O-ring arrangement for man way

EPDM O-RING
SEQUENCE OF EVENTS




Polymerizer get discharge and hold on 4 to 5 hours for next batch charging
VCM leak from the man way which is detected by the VCM detectors and then soap test
Poly get depressurize completely (2.5 hours) and the o ring is replaced (1 hour)
V/A and Leak test done (5.5 hours)
Poly takes on service and found OK (Total outage 8-9 hours)
ANALYSIS OF FAILURE
CHEWED/ CHIPPED
APPEARANCE
PROBABLE CAUSES
1. Difference in thermal expansion of the mating surfaces i.e. man way and its
closure ring





2. Size of the O ring and its groove dimension
3. Softening of Elastomer due to incompatibility
4. Improper machining of O-ring gland i.e. Sharp edges (Not the case)
5. Elastomer too soft (Not the case)
Thermal expansion of mating surfaces
DATA:

Material = 0Cr18Ni9 (SS304)
Ambient Temp. = 30 C
Temp. Of Ring = 43 C

AFA Coating T = 85
0
C
Batch Charging T = 65
0
C
Reaction T = 59
0
C
Discharge T = 58
0
C

THERMAL EXPANSION

l = L * k * T (k = 17.2 X 10
-6
m/m-K)


l = 0.2mm
MANWAY
CLOSING RING
SIZE OF THE O-RING AND GROOVE DIMENSION

O-rings dimensions
O ring diameter = 7.5mm
OD = 633mm
Volume of the O-ring (2pi
2
Rr
2
) = 86,856 mm3

Grooves dimensions
Actual W = 6.5mm, H = 5.72mm
Volume of the Groove = 92,222mm3

Standard Groove Dimensions
As per AS568B for O ring diameter = 7.5mm,
W = 6.2mm, H = 6.2mm
Volume of the Std. Groove = 94,345 mm3
Which is greater than the total actual volume
O-ring groove is undersized
Softening of Elastomer due to incompatibility
EPDM IS NOT SUITABLE FOR VCM
OBSERVATIONS
SEQUENCE OF FAILURE
POLY GETS ON HOLD FOR MORE THAN 5 HOURS AND THE COOLING
OF MAN WAY LEFT THE SPACES IN THE O RING
SWELLING OF O-RING FURTHER CONTRIBUTES TO THE COMPRESSION
VCM STARTS PENETRATING AND CAUSES O-RING TO SWELL
THERMAL EXPANSION OF MAN WAY COMPRESSES IT MORE
WHICH CAUSES CRUSHING
O-RING INSTALLED (OVER COMPRESSED DUE TO UNDERSIZE GROOVE)

AFTER WHICH THE O RING DO NOT SEAL ANY MORE AND VCM LEAKAGE OSERVED

VCM
CONCLUSION
As per AS568B, the groove of the man-way O-ring is undersized which after
closing the man way, over compressed the O-ring and cause it to tear from the
edges

The different thermal expansions of man way and its ring causes the crushing
of the O-ring from its edges

EPDM is not suitable with the VCM service . During investigation PVC powder
found on the d/s of the O-ring which should not be a case in 100% sealed O-
ring. This EPDM O ring was suggested by the TCC vendor

RECOMMENDATIONS
Replaced the man way arrangement with a flanged arrangement like PVC I
polymerizer

Use Teflon or FFKM O-rings instead of EPDM

Machined the groove for increasing its volume to suit with our O-ring
dimensions

Use standard size of O-ring for this groove i.e.
ID = 633.48 +- 2.92, d = 6.99+-0.15 as per AS568B # 474
COST ANALYSIS
Total Outage time = 8-9 hours






Total loss of PVC / batch = 18 Tons
1 Tons = $1,070 (Reference: www.icis.com)
For one batch, we face the loss of 19,260$ (Rs 16,37,000)
FFKM O-ring cost = $ 3,000
REFERENCES
DISCHTOMATIC O-ring handbook
Parker O ring handbook
Standard (AS568), Metric O-Ring sizes
PVC II Process description by TCC
B-reports of O-ring failure
QUESTIONS