Integrating Chemical Understanding and Continuous Improvement (Kaizen/PDCA) to Eliminate Sulphuric Acid Pipeline Leakage

Abstract

Failure analysis and reliability improvement in a water treatment plant were studied for leak failures [12] occurring due to corrosion and material selection problems of the supply line carrying 98% sulphuric acid [6]. A Kaizen approach with the support of root cause analysis by the Fishbone Diagram, 5 Whys, and FMEA identified the main contributors: material incompatibility, infrequent inspection, and inadequate corrosion monitoring [21]. Utilizing the Kaizen approach [9], an acid-resistant breather with a silica gel desiccant installed at the storage tank vent reduced leakage incidents by approximately 80% within six months.