Reliability Enhancement

of
Analyzers and Detectors
Prepared by: SAIF UR REHMAN GTE I&E
Table of Contents

Install base of Analyzers and Detectors

Issues of pH Analyzers in Totality

• EDC/VCM pH Analyzer issues
• CA pH Analyzers issues
• Uty/PVC pH Analyzers issues
• Make Wise Analysis of pH Analyzers
• Way Forward

LEL/PPM Detectors
• Issues Summary
• Way Forward

2
Installed Base Analyzers
Analyzers - Plant Wise
Analyzers at Site S.NO Analyzers EDC/VCM PVC CA UTY/PP
1 pH 25 2 9 18
3 2 O2 9 -- 1 --
13 3%
3 Moisture 1 5 1 2
11%
4 Conductivity 2 -- 2 14
5 5 Ca/Mg -- -- 1 --
4%
7 6 Concentration -- -- -- 5
([PERCENTAGE])
54 7 Ethylene 3 -- -- --
([PERCENTAGE])
8 ORP -- -- 5 2
9 9 Others 4 1 2 6
([PERCENTAGE])
Total 44 8 21 47

10
([PERCENTAGE])

18
([PERCENTAGE])

3
Installed Base Analyzers
Detectors at Site
Detectors - Plant Wise
10
([PERCENTAGE])

S.no Detectors EDC/VCM PVC I PVC II UTY/PP CA

7 01 VCM (LEL) 20 12 16 -- --
([PERCENTAGE]) 02 VCM (ppm) -- -- 07 -- --
03 Chlorine(ppm) 02 -- -- -- 18
04 Others 02 -- -- 04 04
Total 24 12 23 04 22
48
20 ([PERCENTAGE])
([PERCENTAGE])

4
pH Analyzers Issues Summary

pH
50
Analyzers 2017 Jobs excluding PMs
Total CMs in 2017 of pH Analyzers : 119
Total PMs in 2017 of pH Analyzers: 648
40
Related to pH Analyzer Accessories
Related to Sample Flow Adjustments
PM plan for pH Analyzers
1 1 1 1

6
12
3
8

EDC/VCM UTY CA PVC

EDC/VCM UTY/PP CA Months

4
pH Analyzers Issues Summary - EDC/VCM

EDC/VCM
EDC/VCM CM JOBS
107
Sensor Probe Failures
90

Sample Cable problematic

Calibration Drift

Sample Flow Adjustment

2016 2017

300 PMs (13.9 %) in 2017 at EDC VCM 2160 PMs in total in 2017 at EDC VCM
6
pH Analyzers Issues Summary - ROP

ROP rop CM JOBS

24
Sensor Probe Failures
18
Sample Flow Adjustment 15
11
Calibration Drift

Salt build up on sensor results in erratic reading

216
2016 2017

CA UTY + PVC
PM 108

24 348 PMs in total in 2017 at ROP

CA UTY
PVC 7
 Make wise Analysis - pH Analyzers

CM Jobs Comparison of MT with Yokogawa, 2017

40 pH Analyzers Make

Make EDC/VCM PVC CA UTY/PP Total

Mettler Toledo 25 -- 09 09 44

DKK -- 02 -- 02 04
16
Yokogawa -- -- -- 06 06

Mettler Toledo Mettler Toledo Yokogawa

EDC/VCM UTY UTY

1.6 CM 1.78 CM 0.33 CM

Jobs/Analyzer Jobs/Analyzer Jobs/Analyzer [1] pH Analyzer Replacement Working 8
Mettler Toledo VS Yokogawa?
Mettler Toledo Yokogawa

Х Shorter sensor life - 12 Months (OEM)  Longer sensor life - 16 Months (OEM)
Х Comparatively lower KCL volume  Large internal KCL volume ensures longer life
Х Offers general purpose probe  Offers application specific probe

9
Yokogawa pH Sensor

10
Mettler Toledo VS Yokogawa?
Mettler Toledo Yokogawa

Х Shorter sensor life - 12 Months (OEM)  Longer sensor life - 16 Months (OEM)
Х Comparatively lower KCL volume  Large internal KCL volume ensures longer life
Х Number of salt build up issues in past at CA plant  Offers probe tailor-made for High conc. salts
Х Unit price: ~0.4 million PKR  Unit price: ~0.3 million PKR (~0.1M saving)

11
Way Forward- pH Analyzers
Replacement
Frequency - SAP
Mettler • Replacement Frequency to be
formulated in SAP
• Each sensor has a life cycle after
which it becomes problematic
Yokogawa
• 6 Analyzers already ordered in 2018
Cost: 2.25 M PKR

• 37 Analyzers to be replaced according

to 3 Year Phase Wise Replacement
Plan:
Cost: 4.5 M PKR/Year, Total: 13M PKR

20
Replacement Frequency - SAP
Going with Yokogawa + Replacement Plan will achieve following:
• Saving 0.75M PKR Annually
• *PM Frequency to be reduced to 3 months from 1 month: Sensor Life Cycle Sensor Life
(YOKOGAWA) : Cycle (Mettler):
528 18 Months 13 Months

pH Analyzer Replacement Price(PKR) Price(PKR)

• 352 PM saved per year Frequency /unit /44 Sensors

PMs Mettler 12 months 70K ~3.0 M annually

352 Man Hrs per year ~2.25 M
Yokogawa 16 months 50K
annually
176

1 Month Plan 3 Month Plan

* PM Frequency will vary from case to case. 13

Way Forward- pH Analyzers

Replacement
Frequency - SAP
Mettler • Replacement Frequency to be
formulated in SAP
• Each sensor has a life cycle after
Yokogawa which it becomes problematic

• 6 Analyzers already ordered in 2018

Cost: 2.25 M PKR Warehouse Inventory
• 37 Analyzers to be replaced according • Min and Max of
to 3 Year Phase Wise Replacement inventory to be
Plan: redefined according to
Cost: 4.5 M PKR/Year, Total: 13M PKR replacement plan

20
LEL/PPM Detectors Issues: Summary

Detector Jobs 2017 excluding PMs

CA: CL2 (ppm): AT-1517, AT-1503

4 Faulty Sensors
Replaced:
VCM: VCM(LEL): AT-12, CL2(ppm): AT-351
14
12
11
AT-36,AT-35,AT-37
False Alarm Generation:

Calibration Requirement

Total Jobs in 2017= 37

Total PMs in 2017= 240 EDC VCM CA PVC

15
LEL/PPM Detectors Issues: Causes

• Failures occur due to life cycle completion and high exposure

• Unavailability of Sensor Replacement Plan causes:

1.Repetitive Failures
2.Increased no. of CM Jobs

• VCM and CL2 (ppm) detectors are prone to interference from Motorola

• VCM and CL2 (PPM) Detectors are Obsolete

CL2(ppm) Sensor Life Cycle : 12-18 Months VCM(LEL) Sensor Life Cycle : 14-18 Months

16
Way Forward- Detectors

Replacement
Detectors Frequency
Upgradation SAP
• Replacement
• 8 Cl2 and 4 VCM Frequency to be
(ppm) detectors will formulated in SAP
be upgraded from RAE • Each sensor has a life
to Honeywell in 2018 cycle after which it
becomes problematic

I II III

17
Replacement Frequency - Detectors

Replacement Price(PKR)
Detector
Frequency /unit
Price(PKR) * CL2 Sensor Life Cycle :12-18 Months
~0.8 M annually for 18 VCM Sensor Life Cycle : 14-18 Months
CL2 (ppm) 16 months 50K
sensors

VCM(LEL) 18 months 55K ~1.55 M annually for 55

sensors
VCM(PPM) 12 months ~55K ~0.18 million for 3 sensors PM Plan
6
 PM Frequency of VCM detectors(boundary wall) to be reduced to 3 months from 1 month
36 4

PMs 1
12 • 24 PM saved per year VCM VCM CL2
(LEL) (PPM) (PPM)
24 Man Hrs per year
Months
1 Month Plan 3 Month Plan
18
Way Forward- Detectors

Replacement Warehouse
Frequency Inventory
Detectors
Upgradation SAP
• Replacement • Min and Max of
Frequency to be inventory to be
• 8 Cl2 and 4 VCM formulated in SAP redefined in SAP
(ppm) detectors will • Each sensor has a life according to
be upgraded from RAE cycle after which it replacement plan
to Honeywell in 2018 becomes problematic

I II III

19
The End
Annexure

1. pH Analyzer Replacement Working

2. Life Cycle Yokogawa
3. Life Cycle Mettler
4. Recommended PM strategy by OEM
SCD and NON-SCD Division

pH Analyzers EDC/VC PVC CA UTY/P Total

M P
SCD 20 -- -- 02 22
NSCD 05 02 09 16 32
Total 25 02 09 18 54

Mettler Model Yokogawa Model

• Transmitter: PH2100E / M420/M400 • Transmitter: FLXA21
• Sensor:INPRO4800/120/PT100 • Sensor: FU20-05-T1-NPT

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Update on O2 Analyzers at EDC VCM
LTC/OXY O2 Analyzers
SIEMENS OXYMAT-6
Issues:
- Bulk liquid carry over issue results in
frequent measuring chamber cleaning and
deposition on electronics
- Frequent sampling system choking and
shift-wise purging of KO bottles
Availability:
- 01 new analyzer available in stock
- Spares available in stock
Furnace O2 Analyzers
Rosemount OXYMITTER 4000
Issues
- Sensor cell requires replacement every 1 –
1.5 years
Availability and way forward
- ZERO availability in stock after recent issue;
re-ordering to be expedited (Cost: 1.6MRs)
- Old Analyzer to be refurbished
- Oxy recommends to install Yokogawa O2
analyzer
Incinerator O2 Analyzers
Rosemount World Class 3000
Issues:
- Current model is obsolete by OEM
- Vulnerable condition due to ZERO
maintenance spare
Way Forward:
- 01 New analyzer (5MRs) ordered as per
funds approved in IP-2017. Delivery in
August. Analyzer is being made part of
stock and 2nd will be ordered from
inventory as backup .
23