LFI No.

:LFI20210548
LEARNING FROM INCIDENT
During Field round, drop wise Naphtha leak observed from C05 Column OVHD line
F
I
Title of incident: N
Crude Column Overhead line drop wise naphtha leak observed in CDU-1 A
Incident No: IM2021018358 Date: 11th Jan 21 L
Targeted Recipients: O&M and Support teams Risk Rating: Low
What happened:
On 11th Jan 2021, at 09:00 Hrs. leak was reported from 42 Inch overhead piping. The subject
piping comes out horizontally from top of Crude column and after two elbows, becomes vertical
until the third elbow. Piping downstream of third elbow is horizontal, going into Crude column
overhead condensers S48A/B. Leak was in the vertical section of the piping 2 meters above the
3rd elbow. Naphtha was found dripping through the insulation on this 42 Inch piping. The leak
location was at a height of approx. 48 meters from the ground level.

The leak was temporarily arrested using a cold compound and shutdown of the unit was avoided.
Later on a metal sleeve was welded over the leak location.

Why it happened
 Leak in the Crude column overhead line is due to internal HCL dew point corrosion.
 Even though Dew point monitoring is a part of IOW, existing Dew point calculations did not capture
the effects other critical parameters like Sulfates and Amines which are likely to elevate dew point
temperatures and cause condensation.

ACHIEVE GOAL ZERO DTA-SAFETY

RIL CONFIDENTIAL Date : 26/05/2021

 LFI No. :LFI20210548
LEARNING FROM INCIDENT
During Field round, drop wise Naphtha leak observed from C05 Column OVHD line
F
 Inherent weld defect aggravated corrosion in the immediate vicinity of the weld due to eddy’s at
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the ID leading to localized wall loss which ultimately resulted into a leak. N
 Strategic thickness measurements at the accessible locations on the vertical section were found
satisfactory and so corrosion was not envisaged in the 42 Inch vertical piping 20meters away from A
the Column Top. As a result, periodic complete scanning of the vertical section of overhead piping
was not included in the inspection strategy.
L
Photographs:
Radiograph of weld indicating leak locations

Thickness profile of vertical section of overhead piping

ACHIEVE GOAL ZERO DTA-SAFETY

RIL CONFIDENTIAL Date : 26/05/2021

 LFI No. :LFI20210548
LEARNING FROM INCIDENT
During Field round, drop wise Naphtha leak observed from C05 Column OVHD line
F
I
Similar incidents N
Similar leaks have been observed in the vertical section of overhead piping in DTA & SEZ CDU A
trains.
L
Lessons learnt
 Delta dew point calculations shall be dynamic and shall capture effects of sulphates and amines.
Any changes in these ingredients can disturb/elevate the dew point temperature in the overhead
circuit which can promote or accelerate corrosion.
 Inspection strategy for overhead piping shall cover thorough inspection (volumetric) of complete
line in place of strategic or accessible locations.

IMPACTED PSM ELEMENT IMPACTED OD IMPACTED OMS ELEMENTS

ELEMENT
Process Technology Procedures 5.3 Asset Operations

Mechanical Integrity 5.4 Inspection & Maintenance

Quality Assurance 5.2 Design & Construction

In case of any further clarification contact to undersign:

Name: Sujal Surendran

Mail ID: sujal.surendran@ril.com

ACHIEVE GOAL ZERO DTA-SAFETY

RIL CONFIDENTIAL Date : 26/05/2021

 LFI No. :LFI20210548
LEARNING FROM INCIDENT
During Field round, drop wise Naphtha leak observed from C05 Column OVHD line
F
Sr.No. 1 What went wrong Existing Dew point monitored only for Column Top
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Delta dew point calculations shall be dynamic and shall capture effects of
sulphates and amines. Any changes in these ingredients can disturb/
N
Learning from incident
elevate the dew point temperature in the overhead circuit which can
promote or accelerate corrosion.
A
Recommendation Type Technology L
Re-visit existing dew point calculations and implement necessary changes
Recommendation to current monitoring and sampling frequency to capture the dips in delta
dew point.
Sr.No. 2 What went wrong Localized Corrosion Observed at few locations
Inspection strategy for overhead piping shall cover thorough inspection
Learning from incident
(volumetric) of complete line in place of strategic or accessible locations.
Recommendation Type EAM
Comprehensive inspection of overhead piping in Crude units shall be
carried out. For on-stream inspection, grid thickness scan with conventional
UT shall be done or explore feasibility of high temperature LRUT (Long
Recommendation
Range Ultrasonic Testing). Turnaround inspection strategy for crude column
overhead lines shall include LRUT for identifying thickness loss and
carrying out preventive repairs.

RIL CONFIDENTIAL Date : 26/05/2021