Value Awards Winner Case Studies
MTI Value awards were created to recognize member organizations that have best translated MTI resources into real solutions. These outstanding winners have used crucial MTI information to increase their safety, reliability, sustainability and profitability.
2017 Winner: The Dow chemical company & TITAN Metal Fabricators
The Dow Chemical Company and TITAN Metal Fabricators used Radiographic Testing (RT) techniques and acceptance criteria to evaluate Tantalum liner welds before insertion into the steel. A failure of the Tantalum lining often results in total loss of the spool and can lead to significant plant down time. The lost margin per hour was estimated in the $10’s of thousands. According to previous work processes for the fabrication of Tantalum pipe, these indications would not have been found until the liner had been inserted into the steel, making repair much more difficult.
The MTI Solution:
Through their participation in MTI Project #212, Dow Chemical and TITAN were able to collaborate to develop and use RT techniques acceptance criteria to evaluate a Tantalum liner before insertion into the steel. The evaluations provided Dow Chemical with results that allowed them to identify potential problems before insertion into the steel housing. Through the use of RT, Dow Chemical recognized results in higher reliability, improving on-line time, lowering maintenance expenses and extending the life of equipment and improving plant safety by reducing the potential release of harmful chemicals. Being able to identify issues faster meant savings in the form of not having to replace expensive spools and decreasing plant downtime, potentially saving millions of dollars over time. These innovative techniques can continue to be used over time.
- Significant Savings in Downtime and Costs of an Estimated $10’s of Thousands in Lost Margin
- Improved Processes and Procedures Leading to Reduced Maintenance Costs
- Improved Plant Safety by Reducing Potential Release of Harmful Chemicals
- Collaborative Efforts in Form of MTI Project
- Access to MTI Members and Experts
2016 Winner: The DOW Chemical Company & Electro chemical
An Existing FRP scrubber was installed in the early 1970’s, and the lower section was exhibiting end of life characteristics such as a deteriorating corrosion barrier, repeated repairs needed and operation interruptions. Replacement would have costed an estimated $2,000,000 and was not a practical solution due to the location of the installation. Repair costs added up quickly over time: every 3 years, approximately $50,000 were spent in coating repairs, and every 6 years, approximately $100,000 were spent in in coating and sleeve repairs.
The MTI Solution:
Using MTI connections, The Dow Chemical Company approached Electro Chemical to find a safer, less costly way solution. Electro Chemical evaluated the feasibility of applying a thermoplastic liner in the section of the scrubber experiencing the most deterioration from age and chemical exposure. The option of installing a PVDF thermoplastic liner was evaluated using MTI publications 165-05 and 166-05. Experts concluded that this option would provide the protection needed, would be easily installed and would have a service life in the environment much better than replacing the corrosion barrier.
This option provided an estimated savings of over $2,000,000 in NPV for Dow Chemical by avoiding the costs of a replacement vessel, the need for an extended shut down to install a replacement and the associated costs of piping and foundation modifications. The PVDF liner option also eliminated the need for the costly recurring repairs. These practices opened up additional opportunities between the two companies, and created a new strategy that could be applied across the industry.
- Improved Processes and Procedures
- Improved Plant Safety, Reliability and Integrity
- Assistance from Crucial MTI Resources
- Significantly Reduced Costs and Downtime
2015 Winner: AkzoNobel & Ellett Industries
One of AkzoNobel’s businesses was replacing a catalyst chamber that became problematic because of its limited throughput and the difficulty in changing the unit out. The site wanted to increase the capacity of the new unit while minimizing installation costs. The increased size of the redesigned unit brought the top head too close to the roof, making the potential catalyst exchange even more complicated and dangerous for maintenance personnel.
The MTI Solution:
Through MTI meetings, activities and networking, AkzoNobel found and worked with Ellet Industries to find a solution to their problem. Similar to other MTI member fabricators, AkzoNobel found that Ellett had demonstrated high-quality expertise and attention to detail along with the ability to work with the customer to optimize a design. Ellet Industries found a cost-effective solution for AkzoNobel that increased worker safety during the catalyst change, reduced overall exposures, decreased downtime and maintenance costs and allowed future catalyst changes to become much more efficient.
- Reduced Downtime from 4 Hours to 30 Minutes
- Reduced Maintenance Costs by 20%
- Redesign of Vessel Improved Plant Safety by Reducing Exposure to Heat, Dust and Personal Injury
- Improved Process and Procedures
- Collaboration with MTI Members