VATECH WABAG LIMITED Desalination Opens Challenges to Steel Industry K. Syed Amir Basha Chief Technology Officer VA Tech Wabag
Challenges to Steel Industry 2
Challenges to Steel Industry Factors driving the world towards seawater desalination: Limited Fresh water sources Increasing contamination of fresh water sources Increasing population Migration of people Disputes on ownership of sources 3
Challenges to Steel Industry Factors driving the world towards seawater desalination: About 50% of world s population livein cities along the coastline Reliable source of quality water Reducing cost of Desalinated Water Ocean is a draught proof Raw water Resource 4
Challenges to Steel Industry Desalination Plants contracted world wide 5
World Desalination Market Challenges to Steel Industry 6
Challenges to Steel Industry Pretreatment System RO System Post treatment System Outfall System Intake System 7
Challenge to Steel Industry The Desalination Plants are designed for a life of 25 to30years Proper material selection plays a vital role in restricting the physical and chemical deterioration of plant equipment to prolong their service life and efficiency while handling seawater in desalination plants. Early days seawater reverse osmosis (SWRO) plants were with SS 316 L components for high pressure application. Desalination plants were faced with failure of equipment/components due to corrosion. 8
Challenges to Steel Industry Seawater Reverse Osmosis OEMs were compelled to gradually switch over to superior grade metals for the pressure piping/fittings, pumps and valves to minimise the corrosion problems SS316L SS317L SS904L Duplex SS Ni-Resist Super Duplex SS Hastelloy 9
Challenges to Steel Industry Shifting to higher grade materials resulted in Non-Availability of materials/components/fasteners Limited expertise and facilities Long delivery period Prematured failure of fabricated/casted components High cost 10
Non-Availability of materials in India results: Challenges to Steel Industry Import of piping, valves, pumps, fasteners, etc. Long delivery period and sailing time increases project completion time Customs duty & associated clearance delays Increased price High stock level of spares to be maintained 11
Challenges to Steel Industry Limited expertise and facilities: Limited foundries to cast super duplex SS. High rejection rate of the castings Long lead time for components Failure of casting during operation. 12
Challenges to Steel Industry Prematured failure of fabricated/casted components: Crevice corrosion Stress cracking Pitting corrosion Galvanic corrosion 13
Challenge to Steel Industry Crevice corrosion in a tube victaulic coupling area MOC Duplex SS and Super Duplex SS 14
Pitting corrosion in a tube close to WAZ MOC Duplex SS Challenges to Steel Industry 15
Challenge to Steel Industry Fatigue failure in Valve spindle of Butterfly valve MOC: Super Duplex SS 16
Challenge to Steel Industry Stress fatigue failure in Brine recycle -Vertical pump column MOC: Ni Resist 17
Challenge to Steel Industry Pitting corrosion in tubes MOC: SS 316L 18
Challenge to Steel Industry Corrosion failure in Centrifugal pump wear ring MOC: Super duplex SS 19
Challenge to Steel Industry Crevice Pitting Crevice and pitting corrosion of the casing of a HP booster pump (cast duplex stainless steel UNS J93550, DIN 1.4468) 20
Challenge to Steel Industry Failure of swing arm of Swing Check valve Size 1000 mm MOC: Super Duplex SS 21
Challenge to Steel Industry Pitting corrosion in casing of Horizontal centrifugal pump MOC- Super Duplex SS Pitting corrosion in pipe weld MOC- Duplex SS 22
Challenge to Steel Industry Corrosion in Bell Mouth of Vertical pump MOC: Ni Resist 23
Challenge to Steel Industry Corrosion in Cartridge Filter tie rods and fasteners MOC: Duplex SS -2205 24
Challenge to Steel Industry Corrosion in 1000 mm swing check valve Disc and nut MOC: Super Duplex SS 25
Pitting Corrosion in Vertical pump impeller MOC: Super Duplex SS Challenge to Steel Industry 26
Challenge to Steel Industry Fatigue failure in Valve Spindle of 750 mm valve Material Super Duplex SS 27
Pitting corrosion in Vertical pump head MOC: Ni Resist Challenge to Steel Industry 28
Challenge to Steel Industry Casting crack in Vertical pump bowl MOC: Ni Resist 29
Challenges to Steel Industry Challenges Availability of materials/components/fasteners of Duplex SS & Super Duplex SS in India Development of expertise and facilities for casting and fabrication Short delivery period Eliminate prematuredfailure of fabricated/casted components of Super Duplex SS / Ni-resist Reduce cost Develop an alternate material to Super Duplex SS which is easy to cast, fabricate/repair. 30
Challenge to Steel Industry Thank you 31