How to Handle Failure of PTFE Lined Pipes and Fittings.

How to handle failure of PTFE lined pipes and fittings

Billions of dollars Loss of pharma and chemical plant due to failure of equipment

Effects of failure, production loss, accidents, fire, and environmental damage

Piping failure can be internal leakage, external leakage, failed lining, or failed metal piping itself.

Reasons for failure: defective pump, reactor, process malfunction, chemical reaction, sudden rise in temperature or pressure. Human error, valve failure, sensor defect, or maintenance error.

Lined piping failure detection: early detection of lining failure can be seen in the vent holes given to pipes and fittings. In the case of early detection, there are chances that the batch or material under process can be saved from the mixing of corrosion with process fluid or spillage of material on the floor.

During the inspection, the first step is to stop the process or plant so failed-lined pipes or fittings can be replaced. It is also recommended for inspection of all the nearby connected lined pipes and fittings since there are chances that if failure was due to the pump or any external reasons, then there are also chances that other piping would also be damaged and need to be replaced.

Once the lined product is uninstalled, it is mandatory to check first what process is used and how hazardous that chemical is for human contact, or it may have material that creates gas, and that’s harmful. After checking if it's safe to check, and if possible, cleaning it for surface inspection. ?

In some cases of failure, due to high pressure or high vacuum lining damage, we see a change in the shape of the lining, so during cleaning or inspection, it would be better not to change for further evaluation if required because maintaining the same condition will be helpful to understand the engineer's reason for failure.

?While doing inspection, it is better to note operating parameters exactly and also process fluids and the properties of materials.

?In case of a failure of welding or metal portion, there are chances that the quality of welding was poor or that, due to the highly corrosive nature of the fluid, after lining failure, the weld joint got weaker and the metal part got damaged.

?Depending on the situation, it's better to take pictures of the failure even before uninstalling and after removal from the piping.

?Common types of lined pipe and fitting failure

• Cracked flaring of the PTFE tube on the flange area
• Bulging of PTFE tubes due to vacuum
• Pin hole in the lining
• Cracked tubes of lined pipes
• Cracked-lined surface of PFA/FEP lining
• The metal joint cracked from welding.
• Cast part failure in lined tee, lined cross, or lined reducer
• Gasket failure in the joint
• Shrink lining inside metal
• Lining lifted from the metal surface
• Pieces of PTFE fiber inside the pipe
• Pieces of lined material inside the process
• Burned material of lining
• Shrinkage of the lining
• Cracked from drilling area of flange
• Lined valve failure
• Leakage due to loose bolting
• Leakage due to failure of the PTFE bellow/PTFE expansion joint?
• Spillage due to a cracked-lined bend

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