Root Cause Analysis for Corrosion Induced Leak at Haldia Petrochemicals

Corrosion Induced Leak

• Materials
  • Material Degradation:
    • Poor quality coatings or protective layers
    • Chemical reactions between materials and process fluids
  • Material Quality:
    • Substandard material quality leading to faster degradation
  • Material Selection:
    • Use of improper materials not resistant to corrosion
• Environment
  • Temperature Fluctuations:
    • Extreme temperature changes causing material stress and weakening
  • External Environmental Factors:
    • Saltwater or chemical exposure from the surrounding environment
    • High humidity levels leading to accelerated corrosion
• Equipment
  • Design Flaws:
    • Inadequate design to handle the corrosive nature of the process fluids
  • Inadequate Maintenance:
    • Poor inspection procedures failing to detect early signs of corrosion
    • Irregular or insufficient maintenance schedules
  • Aging Equipment:
    • Lack of replacement of aging parts
    • Natural wear and tear of equipment over time
• Processes
  • Chemical Process Changes:
    • Introduction of new chemicals or processes without proper evaluation of corrosion risks
  • Operating Conditions:
    • Failure to adhere to recommended operating procedures
    • Harsh operating conditions exceeding design specifications
• Human Factors
  • Negligence:
    • Lack of attention to detail during inspections
    • Failure to follow standard operating procedures
  • Lack of Training:
    • Inadequate knowledge transfer among employees
    • Inadequate training on corrosion prevention and detection
• Management
  • Incident Response:
    • Delayed response to initial signs of corrosion
    • Lack of a proactive approach to corrosion management
  • Budget Constraints:
    • Insufficient budget allocation for corrosion control and equipment upgrades
  • Policy Issues:
    • Inadequate policies for regular inspection and maintenance