POX O2 Spargers- Report Summary2 Next STEP
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The document summarizes issues with the oxygen spargers in POX 1 & 2, including frequent blockages that cause availability losses. It presents potential solutions, including: 1) Upgrading valves and piping to prevent fires and allow automatic oxygen control for $844,756-$889,039 per unit. 2) Redesigning the oxygen spargers using a "Fisher sparger" design for $87,000 per unit to prevent material retention causing blockages. 3) Conceptually designing a water injection system for readily clearing blockages. The recommendations are to deploy the redesigned spargers immediately and include oxygen control automation and upgrades in 2015, holding the blockage clearance system
POX O2 Spargers- Report Summary2 Next STEP
- 1. POX 1 & 2 Improvements Oxygen System Report Summary Next Steps September 2014 CJ Galeotti
- 2. 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. POX 1&2 Oxygen Spargers – present state The Problem 3 0 10 20 30 40 50 60 52PV008 A52PO2 A52PO1 A52PO2 A52PO1 A52PO1 A52PO2 A52PO2 Jan Mar Apr Jun Aug Sep 2014 LXML Sepon POX Oxygen Sparger events Internal work repairs on holed comp1 oxygen sparger Unblockd Oxygen sparge at Compt#1 Continued heating and unblocked all oxygen spargers Inspection and work repair on holed oxygen sparge in Comp1 vapour phase Replaced worn oxygen sparge in Comp-1, clean scales in comp3/4, replace comp1 AGgi blades; Inspection and repair on holed oxygen sparge in Comp1 vapour phase 0 10 20 30 40 50 60 52PV008 A52PO2 A52PO1 A52PO2 A52PO1 A52PO1 A52PO2 A52PO2 Jan Mar Apr Jun Aug Sep 2014 Hours 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#1 blocked Continued heating and unblocked all oxygen spargers Internal work repairs on holed comp1 oxygen sparger Inspection and repair on holed oxygen sparge in Comp1 vapour phase Continued heating up and unblocked all oxygen sparges Inspection and work repair on holed oxygen sparge in Comp1 vapour phase Replaced worn oxygen sparge in Comp-1, clean scales in comp3/4, replace comp1 AGgi blades; Replace worn oxygen sparges in compartment- 1
- 4. POX 1&2 Oxygen Spargers – present state The Problem 4 0 50 100 150 200 250 Hours Unscheduled Availability Losses for POX area 2014 ytd (sept) by Cause Availability - 52 POX2 Availability - 52 POX1
- 5. POX 1&2 Oxygen Spargers – present state The Problem 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. POX 1&2 Oxygen Spargers – present state The Problem 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
- 7. 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)
- 8. 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
- 9. 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
- 10. Potential Solution – 2) Redesign Oxygen Sparger 10
- 11. 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 1ea $ 10,663 $ 10,663 5% $ 11,196 SAP WO 200010295 Compartment 1 10020085 NOZZLE,COMPARTMENT 1 1ea $ 7,990 $ 7,990 10% $ 8,789 Modified end piece Compartment 1 10004817 FLANGE,STUB END,SDUP,100NB,SCH80S,BW 1ea $ 525 $ 525 5% $ 551 SAP WO 200010295 Compartment 1 10026108 FLANGE,LAPJOINT,SDUP,100NB SCH80S,CL600 1ea $ 690 $ 690 5% $ 725 SAP WO 200010295 Compartment 1 10004765 PIPE,SDUP,DN100,SCH80S,GR2507,5-7M VAR 1ea $ 4,097 $ 4,097 5% $ 4,302 SAP WO 200010295 Compartment 1 Fabrication 1ea $ 1,000 $ 1,000 5% $ 1,050 est Compartment 1 Installation 1ea $ 5,000 $ 5,000 5% $ 5,250 $ 31,863 est Compartment 2 10020106 PIPE,TI,DN100MSCH80,GR12,PE,3M 1.5ea $ 5,741 $ 8,612 5% $ 9,042 SAP WO 200010304 Compartment 2 10004806 NOZZLE,COMPARTMENT 2 1ea $ 4,382 $ 4,382 10% $ 4,820 Modified end piece Compartment 2 10004738 FLANGE,STUB END,SDUP,80NB,SCH80S,BW 1ea $ 333 $ 333 5% $ 350 SAP WO 200010304 Compartment 2 10026255 PIPE,SDUP,DN80,SCH80S,GR2507,6M 1ea $ 4,523 $ 4,523 5% $ 4,749 SAP WO 200010304 Compartment 2 10016149 FLANGE,SDUP,80NB,RF,NPT,CL600 1ea $ 434 $ 434 5% $ 456 SAP WO 200010304 Compartment 2 Fabrication 1ea $ 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 2ea $ 4,381 $ 8,762 5% $ 9,200 SAP WO 200010266 Compartment 3 & 4 10019805 NOZZLE,COMPARTMENT 3-4 2ea $ 2,775 $ 5,550 10% $ 6,105 Modified end piece Compartment 3 & 4 10004585 PIPE,SDUP,DN50,SCH80S,GR2507,6M 2ea $ 1,382 $ 2,764 5% $ 2,902 SAP WO 200010266 Compartment 3 & 4 10007684 FLANGE,STUB END,SDUP,50NB,SCH80S,BW 2ea $ 303 $ 606 5% $ 636 SAP WO 200010266 Compartment 3 & 4 10025969 FLANGE,LAPJOINT,SDUP,50NB SCH80S,CL600 2ea $ 180 $ 360 5% $ 378 SAP WO 200010266 Compartment 3 & 4 Fabrication 2ea $ 1,000 $ 2,000 5% $ 2,100 est Compartment 3 & 4 Installation 2ea $ 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.
- 12. 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