Global Challenges/Trusted Solutions

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.


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2017 Winner: The Dow chemical company & 
TITAN Metal Fabricators

The Problem:
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.

Key Benefits:

  1. Significant Savings in Downtime and Costs of an Estimated $10’s of Thousands in Lost Margin
  2. Improved Processes and Procedures Leading to Reduced Maintenance Costs
  3. Improved Plant Safety by Reducing Potential Release of Harmful Chemicals
  4. Collaborative Efforts in Form of MTI Project
  5. Access to MTI Members and Experts

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2016 Winner: The DOW Chemical Company & 
Electro chemical

The Problem:
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. 

Key Benefits:

  1. Improved Processes and Procedures
  2. Improved Plant Safety, Reliability and Integrity
  3. Assistance from Crucial MTI Resources 
  4. Significantly Reduced Costs and Downtime




2015 Winner: 
AkzoNobel & Ellett Industries

The Problem:
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.  

Key Benefits:

  1. Reduced Downtime from 4 Hours to 30 Minutes
  2. Reduced Maintenance Costs by 20%
  3. Redesign of Vessel Improved Plant Safety by Reducing Exposure to Heat, Dust and Personal Injury
  4. Improved Process and Procedures
  5. Collaboration with MTI Members

Approved by Members

MTI’s numerous benefits are best spoken by our members who engage with MTI resources and networking power on a day-to-day basis. 

 

“MTI’s value comes in several different forms. One is the instant access we have to experts in the CPI corrosion world and the other is having access to MTI publications, so between the publications and the ability to speak to experts, we can get answers to some of the questions we’re facing.”

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Eileen Chant, Becht Engineering 

 

The added benefit for a refiner in MTI is that chemical processing companies have a different approach and application of materials technologies (like FRP, chemical resistant masonry, nonmetallics, etc.) that has little penetration in refineries. Seeing how chemical processing industries deal differently with materials issues gives new options to consider for refining materials issues.”

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Kevin Ganschow, Chevron



“We’re in the midst of dynamic change within the engineering workforce. New engineers work very differently than older engineers. Long reports are passé; immediate response and focussed knowledge transfer are the new norm. The amount of time spent crafting a recommendation or making a judgment is decreasing, while the regulatory ramifications of poor decisions are rapidly increasing. MTI and its repository of knowledge helps bridge the gap between being both responsive and thorough.”

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Ed Naylor, AkzoNobel


“I work with nonmetallics, and MTI provides technical information and training, and they do a lot of research. This has been an organization that has helped me immensely to get all kinds of information that is not normally available with other national organizations… Personally, I have found working on projects, going to the actual meetings and participating in training has been invaluable. I have also appreciated the networking with other colleagues from companies and being able to sit and brainstorm on common problems in our industry.”

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Deb McCauley, 
Chemours


“One of the benefits we have as a supplier to the industry is to have direct communication with producers. It’s helpful for us and beneficial to them before they make material decisions...Even the short time that I’ve been a member, I’ve found MTI is a family. I can speak with anyone in the group, even outside of meetings. It’s great networking.”

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Wendy McGowan, 
Neotiss