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;
.

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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

Analysis of Basic
Root Cause /
Distribution of
Responsibility:
Corrective Action to
Eliminate Basic Root
Cause:
Implementation of
Corrective Action:
Verification of
Corrective Action and
Effectiveness:
Follow up of
Corrective Action
Effectiveness:
Welding defect
 Analyze the failure mechanism.
 Welding defect caused by: poor fit-up, lack of groove,
misalignment, fusion not complete.
 Proper welding procedure and parameter not applied
 Welding conducted by dis-qualified welder.
Corrosion caused leak
 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.
 Grind the defect area and machining groove;
 Repaired by TIG;
Grind, welding.
Welding: Penetrate Test & Visual inspection.
1- Continuous surveillance and monitoring the repair weld seam of vessel
nozzle in the future.
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:

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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

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