019-RCFA Disposal pump-14520A 1'' inlet line repair on 4th November 2016.docx

Petro China (Halfaya) Production Department Maintenance Section ROOT CAUSE FAILURE ANALYSIS REPORT Equipment Failure Description Report Date: 04 November-2016 Report #: RCFA-2016-CPF1-COR-19 A. Equipment/ System Details. Facility CPF1 Equipment Tag, Make, Model Disposal pump-14520A Equipment/System description Disposal pump 1'' inlet line Date and time of abnormality 03 November- 2016 B. Brief Description of Failure Description: (Briefly mention-What Happened? / Where Happened? / When Happened? / Why Happened? / Who is Responsible for corrective action?)  2nd Nov 2016 Leak detected by CPF1 Operation Team.  3rd Nov 2016 welding repair done.  3rd Nov 2016 weld test by PT and test result accepted. Criticality: Level High (High/Medium/Low): Justification 1- Disposal Pump system could not be operated. 2- Operation system integrity affected. C. Background/Problem Statement: (List down briefly the previous history / problems faced during maintenance, since inception)  After operation info leakage area fully inspected and investigated  Crack found on the weld seam between pipe and flange; . Page 1 of 3 D. Likely Root Cause: Briefly mention about probable root causes and way forward Welding defect since construction; Description: High corrosive medium accelerate internal corrosion Likelihood High (High/Medium/Low): Information: 1- Analyze the failure mechanism. (i). Tests to Clarify 2- Inspect defective area _UT &PT. E. Analysis of Basic Root Cause Welding defect  Analyze the failure mechanism.  Welding defect caused by: poor fit-up, lack of groove, misalignment, fusion not complete. Analysis of Basic  Proper welding procedure and parameter not applied Root Cause /  Welding conducted by dis-qualified welder. Distribution of Corrosion caused leak Responsibility:  Crack &leak developed refers to presence of high chloride and salty in the media.  High dissolve oxygen presence in media Other elements  Lack of QA/QC degraded integrity of the system.  Pipe material can’t withstand the high corrosive of medium. Corrective Action to  Grind the defect area and machining groove; Eliminate Basic Root  Repaired by TIG; Cause: Implementation of Grind, welding. Corrective Action: Verification of Welding: Penetrate Test & Visual inspection. Corrective Action and Effectiveness: Follow up of 1- Continuous surveillance and monitoring the repair weld seam of vessel Corrective Action nozzle in the future. Effectiveness: 2- Enhance Welder/QA/QC during construction. 3- Establish and optimize the corrosion inhibition injection Remarks: Team Members: S. No Name Position Signature 01 Prepared by: Su Jinlong Plant Inspector Su Jinlong 02 Revised by: 03 Reviewed By: Page 2 of 3 Photos: 1. Disposal pump 1'' inlet line Found leak on weld seam of pipe and flange Preparation and repair by welding Welding on going Welding done 2. Weld test by PT and result accepted. Weld checked by PT Page 3 of 3