pox o2 spargers- report summary2 next step

POX 1 & 2 Improvements

Oxygen System Report Summary

Next Steps

September 2014

CJ Galeotti

POX 1&2 Oxygen Spargers – present state The Problem

2

The Problem:

• Oxygen sparger blockage leads to significant availability losses

• Inboard oxygen valve failures due to use of steam to clear blockages

• Pox vessels have a propensity to trip due to present manual oxygen addition

Contributing factors:

• Present sparger design

• Deviation from original installation

• Discharge point and style of pipe varies across compartments

• None appear to directly line up with Agitator centreline

• Allows entry and retention of solid materials

• Oxygen addition to the Pox Vessels in manual control state

• Present state of manual control stems from the ignition/fire risk potential of valves

style & materials and piping design and materials installed

• PPI reports identified that Valves and piping in O2 service were non compliant

against AIGA (Asian Industrial Gas Association) Standards

• No readily available means to clear blockages

• Steam is presently used but takes time to come on line, also steam

• Steam also represents ignition/fire risk


3

0

10

20

30

40

50

60

52

PV

00

8

A5

2P

O2

A5

2P

O1

A5

2P

O2

A5

2P

O1

A5

2P

O1

A5

2P

O2

A5

2P

O2

Jan Mar Apr Jun Aug Sep

2014

LXML Sepon POX Oxygen Sparger events

Internal work repairs on holedcomp1 oxygen sparger

Unblockd Oxygen sparge atCompt#1

Continued heating andunblocked all oxygen spargers

Inspection and work repair onholed oxygen sparge in Comp1vapour phase

Replaced worn oxygen spargein Comp-1, clean scales incomp3/4, replace comp1 AGgiblades;

Inspection and repair on holedoxygen sparge in Comp1vapour phase

0

10

20

30

40

50

60

52

PV

00

8

A5

2P

O2

A5

2P

O1

A5

2P

O2

A5

2P

O1

A5

2P

O1

A5

2P

O2

A5

2P

O2

Jan Mar Apr Jun Aug Sep

2014

Ho

urs

LXML POX - Oxygen Sparger Downtime restart after blocked oxygen sparge

Comp2 agitator frequently in protection mode& Comp3 oxygen sparge is partially blocked,thereby slowing down reaction rate

Unblockd Oxygen sparge at Compt#1

oxygen sparge block

oxygen sparge block

Heated up& unblocked oxygen sparges

Oxygensparges to POX2 compartment#1blocked

Continued heating and unblocked all oxygenspargers

Internal work repairs on holed comp1 oxygensparger

Inspection and repair on holed oxygen sparge inComp1 vapour phase

Continued heating up and unblocked all oxygensparges

Inspection and work repair on holed oxygensparge in Comp1 vapour phase

Replaced worn oxygen sparge in Comp-1, cleanscales in comp3/4, replace comp1 AGgi blades;

Replace worn oxygen sparges in compartment-1


4

0

50

100

150

200

250

Ho

urs

Unscheduled Availability Losses for POX area 2014 ytd (sept) by Cause

Availability - 52 POX2

Availability - 52 POX1


5

March 2013 – single biggest Oxygen sparger episode. Pox 2 blockages while

POX 1 offline for cluster flange repairs. Both POX units offline for ~90hours


6

0

20

40

60

80

100

120

140

160

Oxygen SpargerOxygen Sparger Agitator(thermal

overload) &Oxygen sparger

Oxygen SpargerOxygen Sparger Agi blades &Oxygen Sparger

Oxygen SpargerOxygen SpargerOxygen Sparger

Jan Mar Apr May Jun Aug Sep

2014

POX Downtime due to Oxygen Sprager blockages 2014

52 POX2

52 POX1

POX downtime due to Oxygen spargers continue to be a problem in a number of

events throughout 2014

POX 1&2 Oxygen Spargers Potential Solution

7

The Potential solution will most likely involve a number of actions on 3

broad fronts:

1. Return Oxygen control to automatic status to improve stability (operability)

and reduce process trips a) Requires upgrade of a number of valves to AIGA (Asian Industrial Gas

Association) compliant style, and material to prevent risk of fire (Detailed and

costed)

b) Program, enable and train operations in auto control

c) Cost estimates ~$840,000-$890,000 for each POX

2. Redesign the Oxygen Spargers to prevent retention of materials a) Fisher sparger design with downward discharge (Detailed, Designed and costed,

MOC raised)

b) Cost Estimate ~$87,000 for each POX

3. Provide a means to clear blockages a) Water injection system to readily available means to clear blockages (Conceptual

design only)

Potential Solution – 1) Oxygen Auto Control and AIGA Compliance

8

PPI Report 2013 – typical 90O

sockets

POX 2 Compartment 1 -typical

90O sockets

Inconsistent valve specs in field

(same service) 316 body and

trim

Same service different location

316 Stainless body and monel

trim

Potential Solution – 1) Oxygen Auto Control and AIGA Compliance

9

Cost Estimate

Items POX 1 POX 2

Valves $ 397,680 $ 407,280

Piping $ 81,792 $ 81,456

Installation $ 40,320 $ 41,920

Design $ 34,500 $ 32,500

Ammendment of stock details $ 16,200 $ 16,800

Freight $ 35,120 $ 35,120

Welding QA/QC $ 24,000

WQR development

Supervision (days) before & during

installation $ 28,000 $ 28,000

Programming/valve $ 16,200 $ 16,800

Subtotal $ 649,812 $ 683,876

Contingency @30% $ 194,944 $ 205,163

Total $ 844,756 $ 889,039

Typical Valve locations requiring upgrade

Potential Solution – 2) Redesign Oxygen Sparger

10

Potential Solution – 2) Redesign Oxygen Sparger

11

Oxygen Sparger Stock No Description Qty Unit Unit price

Extended Price

Accuracy Total Price by Compartment

Comment

Compartment 1 10004350 PIPE,TI,DN150,SCH80S,GR12,PE,3M 1 ea $ 10,663 $ 10,663 5% $ 11,196 SAP WO 200010295

Compartment 1 10020085 NOZZLE,COMPARTMENT 1 1 ea $ 7,990 $ 7,990 10% $ 8,789 Modified end piece

Compartment 1 10004817 FLANGE,STUB END,SDUP,100NB,SCH80S,BW 1 ea $ 525 $ 525 5% $ 551 SAP WO 200010295

Compartment 1 10026108 FLANGE,LAPJOINT,SDUP,100NB SCH80S,CL600 1 ea $ 690 $ 690 5% $ 725 SAP WO 200010295

Compartment 1 10004765 PIPE,SDUP,DN100,SCH80S,GR2507,5-7M VAR 1 ea $ 4,097 $ 4,097 5% $ 4,302 SAP WO 200010295

Compartment 1 Fabrication 1 ea $ 1,000 $ 1,000 5% $ 1,050 est

Compartment 1 Installation 1 ea $ 5,000 $ 5,000 5% $ 5,250 $ 31,863 est

Compartment 2 10020106 PIPE,TI,DN100MSCH80,GR12,PE,3M 1.5 ea $ 5,741 $ 8,612 5% $ 9,042 SAP WO 200010304

Compartment 2 10004806 NOZZLE,COMPARTMENT 2 1 ea $ 4,382 $ 4,382 10% $ 4,820 Modified end piece

Compartment 2 10004738 FLANGE,STUB END,SDUP,80NB,SCH80S,BW 1 ea $ 333 $ 333 5% $ 350 SAP WO 200010304

Compartment 2 10026255 PIPE,SDUP,DN80,SCH80S,GR2507,6M 1 ea $ 4,523 $ 4,523 5% $ 4,749 SAP WO 200010304

Compartment 2 10016149 FLANGE,SDUP,80NB,RF,NPT,CL600 1 ea $ 434 $ 434 5% $ 456 SAP WO 200010304

Compartment 2 Fabrication 1 ea $ 1,000 $ 1,000 5% $ 1,050 est

Compartment 2 Installation 1 $ 3,000 $ 3,000 5% $ 3,150 $ 23,617 est

Compartment 3 & 4 10018823 PIPE,TI,DN80,SCH40S,GR12,SEAMESS,3M 2 ea $ 4,381 $ 8,762 5% $ 9,200 SAP WO 200010266

Compartment 3 & 4 10019805 NOZZLE,COMPARTMENT 3-4 2 ea $ 2,775 $ 5,550 10% $ 6,105 Modified end piece

Compartment 3 & 4 10004585 PIPE,SDUP,DN50,SCH80S,GR2507,6M 2 ea $ 1,382 $ 2,764 5% $ 2,902 SAP WO 200010266

Compartment 3 & 4 10007684 FLANGE,STUB END,SDUP,50NB,SCH80S,BW 2 ea $ 303 $ 606 5% $ 636 SAP WO 200010266

Compartment 3 & 4 10025969 FLANGE,LAPJOINT,SDUP,50NB SCH80S,CL600 2 ea $ 180 $ 360 5% $ 378 SAP WO 200010266

Compartment 3 & 4 Fabrication 2 ea $ 1,000 $ 2,000 5% $ 2,100 est

Compartment 3 & 4 Installation 2 ea $ 1,500 $ 3,000 5% $ 3,150 $ 24,472 est 2 spargers

Subtotal $ 79,951

Contingency 10% $ 7,995

Budget Total $ 87,946

New “Fisher” Sparger design- ~$87,000 for 1 set of sparger pipes and

nozzles to be fabricated in house,…MOC required.

POX 1&2 Oxygen System

12

Recommendations:

• Adopted and deploy sparger redesign option (Fisher Sparger) as immediate

improvement

• MOC raised for POX 2 November shut

• Include provision for Oxygen control automation including valve/pipe upgrades to

AIGA in 2015

• Capex pre-submissions completed

• Risk review of present Non-AIGA compliant state of equipment

• Place blockage clearance system on hold pending effectiveness of above options

pox o2 spargers- report summary2 next step

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