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
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
