EQUIPMENT PROBLEM REPORT

Date : July 30, 2015

Subject: Hydrocarbon & Polymer Leaks From Y-5504 Gland Packing

1. Circumstance:

 Hydrocarbon & Polymer Leaks From Y-5504 Gland Packing

2. Chronology and Data Record

 26 August 2008 : Check leak and retighten bolts of gland packing

due to H/C leaks
 11 October 2008 : Replace gland packing and remove molten due to
H/C leaks.
 06 July 2015 : Mechanic conducted PM tasks as follow:
1. Re-tightening of gland packing bolts
2. Re-greasing of gland packing
 26 July 2015 at 10 pm LEL alarm gas detector appear due to H/C leak
form gland packing at bagging side. Mechanic could not conducted
tightening of gland packing bolts due to gland packing chamber full of
molten.

3. Immediate Action:
 1. Open hand hole
Finding: Molten melted in gland packing chamber
2. Put sealing in hand hole

4. Analysis and Root cause:

The function of Y-5504 Polymer Dryer to heating of wet resin (remain HC

which trapped in the resin) from reactor by using hot water (80 or 90 Celsius
degree) and polymer after drying is free of hydrocarbon.

Function of gland packing in the polymer dryer is to dynamic soft sealing, to

prevent leaks from internal dryer to the outside. There are 5 pcs of gland
packing (PTFE) each side, 3 pcs in inside and 2 pcs in outside (see drawing as
below). In between packing it was hole for injected grease as the additional
sealing agent and lubricant. Every 3 month, there is regular (PM)
maintenance to check the tightness and add some more grease to lubricate
the packing and avoid leakage of resin. Usually if we early know HC leaks
from gland packing we are conduct retighten of gland packing bolts.
HC analyzer (AI 5504) installed at near gland packing to detect HC leaks.
Operation conducted patrol routine of plant every 4 hours to check leaks of
HC by with open hand hole and inform to mechanic if any HC leakages
immediately.

Instrument team has PM plan in SAP to calibrate HC analyzer every 6 months

and result of last HC calibration (June 2015) was still normal.

Gland packing replacement can be done if plant in shutdown condition

because gland packing replacement is related with process side. It’s mean
dryer is main line for powder line so that cannot by pass

There are several symptom of gland packing problem which can created
excessive leaks of HC:

1. Gland packing worn out due to lack of lubrication

2. Gland packing bolts loose
3. Gland packing worn out due to life time

Re-greasing of gland packing conduct regularly every 3 months based on PM

plan schedule in SAP and the last of bolts retightening at 06 July 2015. Since
2008 we never replace gland packing complete set (5 EA), see SAP print
shoot as below:

Therefore most possible cause is gland packing worn out due to life time.
 5. Conclusion

Hydrocarbon & Polymer Leaks From Y-5504 Gland Packing due to

gland packing life time.

6. Preventive Action & recommendation

1. Replace complete set (5 EA) of gland packing every 3 years.

2. Tightening of gland packing bolts if any leaks.
3. Check HC leaks every shift by operation to early know if HC leakages
occur  Not waiting big leaks occur
4. Cleaning molten in chamber regularly