Reactor Corrosion Root Cause Analysis (RCA) Case Study:
After experiencing a loss of thickness in the high-pressure tubular reactor downstream of a peroxide injection point, the client requested that ECI Group perform a formal RCA. ECI Group worked with our partners in the Plant Improvement Alliance: Uhde High Pressure Technologies and Burckhardt Compression to deliver the study.
The RCA study utilised Apollo Methodology which starts with the final effect (in this case a failure of the high-pressure tubular reactor thickness) and works backwards to identify causes and conditions that must be present for the effect to exist. The RCA identified potential issues with the peroxide quality, peroxide dispersion, and presence of peroxide during shutdowns.
A Computational Fluid Dynamic (CFD) study was performed to evaluate the effect of several variables on the dispersion of peroxide into the main process stream.
ECI Group provided recommendations to improve raw material (peroxide) quality controls as well as improving installation and maintenance procedures to prevent future problems.
As well as insightful case studies, the workshop included training modules that covered key areas such as sealing surface rework, lens ring flange connection assembly, high-pressure tubing threading techniques, and maintenance practises for high-pressure hydraulic control values and injection pumps.
The workshop was a huge success. The training sessions allowed for in-depth discussions and practical applications of the topics presented, and it was great to network with key players from across the LDPE industry. We’re looking forward to attending future High Pressure Maintenance Workshops in the future!
For more information on ECI Group’s high-pressure capabilities, or the services offered by the Plant Improvement Alliance, please don’t hesitate to contact us.
