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1
2008 Offsite & Interconnecting Piping Program Review
Presented by Tom Atkinson
The purpose of this program: To identify and repair piping that is clamped and/or impending minimum wall thickness
Safety and Environmental 2008 Budget and Committed Dock Road LPG Interconnecting Piping incident and path forward Clamp Removal Clamp prevention by identifying piping at or near retirement Future leak prevention Man Hours West Refinery Flare Lines Manpower efficiencies Post Outage Reports
2
2009 Safety & Environmental Record for the Offsite & Interconnecting Project
Safety & Environmental No Safety or NRC Recordable Incidents as of June 15th 2009.
Wyatt has worked 230 K man hours since inception of this program in May 2005 through June 15th 2009 with no Safety or NRC recordables.
3
2008 - Budget for the Base and Catch Up Programs through December 31st
Base Program $ 1,700,000
Committed $ 1,251,398
over/(under) budget $ (448,602)
Catch Up Program $ 4,500,000
Committed $ 4,410,787
over/(under) budget $ (89,213)
Overall Offsite & Interconnect Piping Program $ 6,200,000
Committed $ 5,662,185
over/(under) budget $ (537,815)
4
2008 – Base Program Budget Planned
Pulled out of scope Completed Lines Lines in progress Committed
Base Budget Lines - AFE H-28G01-077-240Line No.
No. of Clamps
Mitigated Leaks Budget SAP Committed
19-565-B-14" 0 $ 30,000 $ -
9010-842-B-8" 1 $ 35,300 $ 4,694
9065-20-B-3" 1 $ 35,000 $ 1,339
19-207-BB-6" 1 $ 75,000 $ -
19-5033-B-4" 1 $ 65,000 $ -
$ 250,000 $ -
9010-831-B-6" 1 $ 35,000 $ -
9025-187-B-24" 1 $ 124,000 $ -
19-202-B-30" 8 $ 1,519,200 $ 247,496
WFL Scaffolds WO 80037680 $ 9,903
Polaris DWG’s WFL WO 80035781 $ 30,800 $ 11,658
Polaris DWG’s WFL Tie Ins WO 80037700 $ 66,876
WFL Long Lead Hot Tap WO 80038286 $ 71,812
Structural repairs 1 & 2 SRU & Beavon 0 $ 125,747 $ -
Yearly Rental Equipment WO 80038440 0 $ $ 9,701
33-1140-C-2" 1 7 $ 38,000 $ 15,878
9030-39-B-12" $ 50,000 $ -
Subtotal Clamps 15 7 $ 2,413,047 $ 439,357
Total Base Program Committed $ 439,357
Total Unscheduled Committed $ 812,041
Total Committed $ 1,251,398
5
2008 –Base Program Unscheduled Repairs
Pulled out of scope Completed Lines Lines in progress Committed
Line No.No. of
ClampsMitigated
Leaks Base Budget SAP Committed 19-5116-BA-3" 1 1 $ - $ 23,918
9045-33-B-20" 1 23 $ - $ 165,827
19-547-C-4" 1 65 $ - $ 59,955
19-532-B-6" 1 1 $ - $ 17,792
WO 80037198 0 0 $ 1,860
9045-103-B-10" IST 0 2 $ 36,044
9045-105-B-12" IST 1 3 $ 82,611
9040-28-B-12" 1 3 $ 22,984
9045-107-B-14" 2 4 $ 20,535
9040-19-B-10" 1 4 $ 15,650
33-2003-B-16 0 4 $ 10,004
9045-104-B-12" 0 4 $ 5,208
9040-44-B-14" 0 4 $ 10,684
19-616-B-16"IH 0 4 $ 9,854
33-2304-B-6" 2 20 $ 133,771
9010-800-B-6" 0 4 $ 50,784
19-201-B-24” $ 4,465
9030-4-B-36” $ 16,678
33-2083–B-6” 0 6 $ 23,794
3308–2342- 24” $ 96,698
1604-4-B42” $ 2,925
33-1383-B-4” $
Subtotal Clamps 11 152
Total Clamps 26 159 Unscheduled Committed $ 812,041
6
Catch-Up Budget Lines AFE H-28K01-077-240
Pulled out of scope Completed Lines Lines in progress Committed
No. of Clamps
Mitigated Leaks
Paint Complete Budget SAP Actual
19-667-C-3" 0 $ 17,800 33-1145-A-3" 1 $ 32,300 $ 377 9040-43-B-24" & 9045-
13-B-24" 7 102 $ 152,900 $ 46,818 9015-100-B-10" 0 $ 33,700 9020-041-B-6" 2 $ 29,000 7907-D-2821-B-3" 0 $ 33,800 1604-03-B-36" / 9045-
11-B-36" 1 138 $ 258,200 $ 423,571 19-609-B-4 0 1 Yes $ 26,300 $ 17,824 9045-30-B-24" & 9045-
19-B-24" 3 $ 66,200 $ 8,752 33-1002-B-20" 0 $ - multiple lines 0 $ 100,000 $ 40,000 9045-56-B-14" 1 $ 61,900 9045-10-B-24" 1 $ 67,400 9045-165-B-30" 0 $ 79,100 33-1154-C-4" $ 51,400 31-57-B-6" 1 17 Yes $ 30,200 $ 51,801 Air Line on Docks $ 12,500 7904-0711-B-6" $ 35,000 $ 422
7
2008 Catch Up Program Budget Planned
No. of
ClampsMitigated
LeaksPaint
Complete Budget SAP Actual
9010-411-B-18" 2 $ 43,000 1605-04-B-24" 1 4 N/A $ - $ -
9030-2-B-36" 1 0 $ 198,600 $ 105,155 Punch List Items $ 50,000 $ 33-1007-B-4" 0 3 Yes $ 45,000 $ 13,927 9010-478-B-16 $ 50,000 $ 594
33-1255-C-6" & 33-1068-B-6" $ 24,400 $ 56,544
33-1069-BB-3" $ 35,000 7904-1519-BK1-8" $ 35,000 9055-7-B-4" 1 $ 40,000 $ 9,267 1605-14-B-8" 1 1 No $ 75,000 $ 33,392 9010-187-B-24 2 1 No $ 35,000 $ 46,248
9020-090-B-8" & 9020-009-B-6" 1 $ 50,000
33-1091-B-6" $ 24,000 19-604-B-6" 0 $ 40,000 $ 7,106 19-550-B-10" 1 $ 45,000
Pulled out of scope Completed Lines Lines in progress Committed
8
2008 Catch Up Program Budget Planned
Pulled out of scope Completed Lines Lines in progress Committed
No. of
ClampsMitigated
LeaksPaint
Complete Budget Committed
33-30-BA-2"-IH 16 $ 40,400 $ 15,785
SRU Cross Brace Demo $ 155,972 $ 25,816
Carry over from 2007 $ 207,845
Casing Seals TK-7408/9 0 N/A $ 8,328 $ 10,120
9030-1-B-42" 4 18 Yes $ 223,000 $ 354,393
9030-3-B-42" 2 0 $ 293,700 $ 67,525
Subtotal 33 301 $ 2,639,100 $ 1,503,282
Catch up Planned Program Committed $ 1,503,282 Unplanned Committed $ 2,907,505 Total Committed $ 4,410,787
9
2008 Catch Up Program Unscheduled Repairs
Pulled out of scope Completed Lines Lines in progress Committed
Line No.
No. of Clam
psMitigated
Leaks
Paint Complet
e Catch up Budget Committed12-17-B-8" 1 1 Yes $ 2,525 19-5058-BR-2" 2 2 Yes $ 95,205 9030-88-B-4" 4 9040-28-B-12" 0 1 Yes $ 7,448 19-5058-BR-2" 3 $ 246,711
60-110-B-24" 0
By Others??
?? $ 1,202 9040-33-B-36" 1 7 Yes $ 147,894 0 N/A $ 15,681 8700-1401-B-14" 1 7 No $ 56,998 9010-874-B-10" 1 1 Yes $ 30,076 33-1115-B-12" 2 22 $ 221,840 Deiso Btms Line South
ofArea 2 Control room 0 3 No $ 16,855 Deiso Btms Line TF13 0 43 No $ 22,889 Deiso Btms Line UOP
Corn 1 1 No $ 43,518 9045-105-B-12" IST N/A $ 842 9020-047-B-6 4 $ 28,472 9030-2-B-36" 0 242 $ 485,711 19-1047-C-4" 2 50 $ 926,432 LPG WO 90342519 $ 40,404 LPG 1 WO 90343981 $ 4,703
10
2008 Catch Up Program Unscheduled Repairs
LPG 32-206c-4”WO90344074 LPG Line $ 4,700 $ 4,703 LPG 33-1011c-4”WO-90343095 $ 33,300 $ 39,352 Benzene Line TF20Hurricane Emergency
leak $ 9,100 $ 9,029 33-2079-B-4" 3 $ 36,000 $ 25,629 33-2117-B-8" $ 272,000 $ 203,788 $ (900,000) 19-677-C-3“ LPG $ 275,000 EquipmentWO-80038441 $ 2,500 $ 2,500 Boiler Feed Water
Line WO 90342383 $ 65,506 $ 74,586 33-1161-C-4“ LPG 8 $ 175,000 $ 157,215
Subtotal 17 395 $ 2,349,857 $ 2,907,505
Total 50 696Unscheduled Committed $ 2,907,505
Pulled out of scope Completed Lines Lines in progress Committed
11
East–West LPG Interconnecting Line Incident at Dock road
LPG leak incident at Dock road lead us to multiple unknown LPG line repairs. East-West LPG Interconnecting Line 700’ of 4” at #6 Crude (Near miss that lead to the
shut down of #6 crude). Interconnecting spools at #6 Crude and the #2
LPG. 3” LPG Interconnecting lines in the West Plant that
tie into the 4” LPG East-West Interconnecting Line that run to the Tall Frac
12
Offsite and Interconnecting Root Cause and Operation and T/A Action
Inspection and Repairs of Interconnecting lines have been neglected.
I contacted Bobby Loe in early November 2008 to identify all interconnecting lines that were associated with Unit outages in early 2009.
Bobby Loe provided a list of Interconnecting lines that were associated with Units that would be in T/As in early 2009.
Bobby Loe also separated the Interconnecting lines that could only be repaired during T/A’s.
Sent the prioritized list to Inspection in late November 2008 for the 2009 January, February, and March T/A’s.
Inspection started giving Maintenance inspection results according to the T/A order in 2009.
13
Paint failure areas caused lines to fail in 2nd half of 2008
These are lines that have been repaired before 12” Bunker Line on the Docks 4” LPG line in Area 1 16” #5 CDU Charge Suction in TF #13
14
Clamp Prevention by Identifying Piping At or Near Retirement
Total of Clamps Clamps Total Potential Actual Potential Potential areas that
to Remove Removed Clamps to Mitigate Clamps Mitigated could be spot painted
Base Program 15 1 7 7 50
Unscheduled Repairs 11 11 152 136 150
Sub-Total 26 12 159 143 200
Catch Up Program 33 13 301 183 75
Unscheduled Repairs 18 7 405 405 200Sub-Total 51 20 706 588 275
Base and Catch Up
Sub-Total 77 32 865 731 475
15
2008 Potential Savings from Mitigated Clamps
Clamp installation cost $5,000+ Cost to remove a clamp on a line $80,000+
Average cost to mechanical mitigate 1 clamp during a clamp removal $1,500 Delta installation and mitigation $83,500
731 Clamps mitigated – Credit 1/3 to Savings Potential savings from clamps mitigated 363 X $83,500 = $30,901,500
Potential savings from repaired failed paint 156 X $83,500 = $13,026,500
2008 Total potential savings from future clamp mitigation $43,928,000
Priority ActivityLead
Abatement Complete
Touch Up Paint Complete
Forecast or Schedule
Completion Date
Actual Completion
DateCrital Path and top Priority
1 24" Premium Base Suction 3308-2342-B-24"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
2 8" Regular Base R/D 3308-2117-B-8"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
3 42" Crude Line at Dock # 4 no no We need this lead abatement ASAP
4 36" Crude Line at Tk Field #59 no no We need this lead abatement ASAP
5 8" 2 Oil Line South of the UOP corner
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
6 36" #6 Oile Line East of Dike #4
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
7 6" Sour Naptha Line yes no We need to paint these repairs and touch up paint paint failure areas of the line.
8 8" Bunker Line to Dike #5 yes no We need to paint these repairs and touch up paint paint failure areas of the line.
9 Ole 2 Oil Suction South of Tank Field # 20
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
10 #1 Vac Line between TF 8 and 9
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
11 2" Caustic Line to # 1 Beavon Phase # 2
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
12 #1 Vac Make Up Line yes no We need to paint these repairs and touch up paint paint failure areas of the line.
13 Regular Base Suction Line in TK Field #7
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
14 # 5 & #6 CDU Slop Line yes no We need to paint these repairs and touch up paint paint failure areas of the line.
15 Deiso BTMS Line south of Area 2 Control Room
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
Priority ActivityLead
Abatement Complete
Touch Up Paint Complete
Forecast or Schedule
Completion Date
Actual Completion
DateCrital Path and top Priority
15 Deiso BTMS Line south of Area 2 Control Room
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
16 Deiso BTMS Line at TK Field 13
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
17 #2 V/B R/D Line @ 7413 Dike Wall Insulation
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
18 6" Header @ TK-6840 yes no We need to paint these repairs and touch up paint paint failure areas of the line.
19 LPG Condensate Line West of 7416
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
20 20" #2 Oil Line under dock road
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
21 #2 CDU 6 Oil R/D line at TK - 6814
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
22 2 V/B R/D Line @ 7413 Dike Wall
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
23 #1 Vac R/D Line @ 7413 dike Wall
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
24 Coker Gas Oil Line @ 7413 Dike Wall
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
25 HVGO to #6 DD Line @ 7423 Dike Wall
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
26 MFP R/D Line Tank Field #6 yes no We need to paint these repairs and touch up paint paint failure areas of the line.
27 6" Old Water Line yes no We need to paint these repairs and touch up paint paint failure areas of the line.
28 East - West 4" LPG Transfer Line new tie-ins
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
29 East Plant #5 Crude Slow Down 4" LPG line
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
30 East Plant #1 LPG 4" LPG line Repairs
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
Priority ActivityLead
Abatement Complete
Touch Up Paint Complete
Forecast or Schedule
Completion Date
Actual Completion
DateCrital Path and top Priority
31 West Plant 4" LPG Transfer Line Replacement
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
32 West Plant 3" LPG line repairs yes no We need to paint these repairs and touch up paint paint failure areas of the line.
33 Deethanizer Off Gas Line #33-1184-B-4"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
34 OHD to 3 LPG Sweet LPG line #33-1155-C-4"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
35 # 4 Plat Cold Charge Line #33-2067-B-8"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
36 #2 Visb R/D Line #9045-105-B-12" IST
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
37 36" 6 Oil Line #9045-11-B-36" yes no We need to paint these repairs and touch up paint paint failure areas of the line.
38 6" R/D Header at Tk-6841 yes no We need to paint these repairs and touch up paint paint failure areas of the line.
38 36" Crude Line #9030-2-B-36" to DK 3/4
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
39 6" #5 CDU Kero R/D Line #33-1091-B-6" @ South Departure
Rack
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
40 8" #5 Jet T/D Line #31-130-B-8" to storage
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
41 4" Slurry Line #85-7064-BA-4" to DCU
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
42 TK-7412 header Spool 9040-37-B-30"
yes yes 4/23/09 We need to paint these repairs and touch up paint paint failure areas of the line.
43 TK-6841 3308-2374-B-12" yes no We need to paint these repairs and touch up paint paint failure areas of the line.
44 TK-6841 3308-2375-B-12" yes no We need to paint these repairs and touch up paint paint failure areas of the line.
45 TK-6841 3308-2379-B-12" yes no We need to paint these repairs and touch up paint paint failure areas of the line.
Priority ActivityLead
Abatement Complete
Touch Up Paint Complete
Forecast or Schedule
Completion Date
Actual Completion
DateCrital Path and top Priority
46 TK-6841 3308-2372-B-20"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
47 TK-6841 3308-2416-B-8"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
48 TK-6841 3308-2415-B-12"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
49 TK-6841 7907-0-0819-B-6"
yes no We need to paint these repairs and touch up paint paint failure areas of the line.
20
Man Hours – Base and Catch Up Program
TypeOriginal
Budget man- Hours
Man Hours Committed
Man Hours Under Reason
Base & Catch Up 83,650 69,345 14,305 We were under 14,305 Man Hours because of budget cuts.
21
2008 Phase #1 Jumper Design Engineering Chronology
Activity Completion Date
Preliminary red line Plot Plan, P&ID & ISO’s 30 Aug 08
Request MOC approval 15 Sep 08
Detail design of the P&ID & ISO DWG’s 30 Nov 08
22
Phase # 1 Jumper Execution Status
Scaffolds are erected to take thickness readings for all hot taps and stopples
Wyatt is currently laying out all the hot tap and stopple areas in the field so the Inspectors can document the thickness readings for the hot tap and stopple approval – Projected completion 2 Feb 09
Inspection will start taking thickness readings on 26 Jan 09 – Projected completion 16 Feb 09
Engineering will review the inspection thickness findings for hot taps and stopples starting 2 Feb 09 – Projected completion 23 Feb 09
Wyatt will start fabricating the pipe jumpers on 9 Feb 09 – Projected completion 17 Apr 09
Triangle will start installing all the hot tap and stopple fittings on 16 Feb 09 – Projected completion 30 Mar 09 TISI will start cutting all hot taps 9 Mar 09 – Projected completion 20 Apr 09
TISI will install stopples according to the future flare repair schedule
Wyatt will start installing the Jumpers on 23 Mar 09 – Projected completion 29 May 09
23
Phase #1 Jumper Installation
24
Phase #1 Jumper Resources
25
Phase #1 Jumper Preliminary Estimate
HOVENSA L.L.C. St. Croix USVITurnaround Estimate Summary
West Flare Jumper/Hot TapsBy : L. Chappell H-29K01-077Date :Jan. 16, 2008AFE No: : H-29K01-077 ESTIMATE SUMMARY REV 1Estimate:
WBS Non-Wyatt Wyatt Non-Wyatt Wyatt Wyatt Total Detail Description M/Hrs. M/Hrs. M / L / E $ Labor $ Mat'l $ Dollars
240 Piping 5,042 11,471 255,816 1,349,916 41,296 1,647,028250 Valves - Replace 0 0 0 0 0 0
Above The Line ==> Directs 5,042 11,471 255,816 1,349,916 41,296 1,647,028
Field Supervision 0 2,519 0 90,684 4,534 95,218 Field Support 119 320 4,653 11,520 0 16,173 Consumables 0 0 13,752 0 14,310 28,062
Logistics 1,715 0 72,000 0 0 72,000 Major Equipment 0 0 0 0 0 0 Equipment Rentals 0 0 85,600 0 0 85,600 Environmental - Waste Disposal 0 0 0 0 0 0
Indirects 1,834 2,839 176,005 102,204 18,844 297,053
SUB-TOTAL 6,876 14,310 431,821 1,452,120 60,140 1,944,081
999 Contingency ............ 0.0% -$
TOTAL BASE AMOUNT $1,944,000
26
West Flare Repair/Replacement Schedule Status
24” High pressure line 75% complete – Projected completion 02 Mar 09
Waiting on the subcontractors to supply estimates and timelines for the 24” Hydro-chem – Line Mole and Chemical Clean Veolia - Line Mole and Chemical Clean TISI – Drill, Hot Tap, and Set Stopples Triangle – Weld all Hot Tap and Stopple Fittings
30” Low pressure line 0% complete – Projected completion 04 Sept 09 (This repair will be included in the 2010 budget)
27
Material Status
TISI Hot Tap/Stopple fittings are on site. $107,975 08 Budget
Material for the hot tap jumper fabrication are on $288,500 08 Budget site.
Long lead material for Phase # 2 repairs on the $84,100 09 Budget high pressure flare line to be purchased no later than 13 Apr 09.
Long lead material for Phase # 3 repairs on the $160,600 09 Budget low pressure flare line to be purchased by 28 Sep 09
28
Environmental MOC Concerns
Environmental Department is in possession of the MOC.
MOC has not been approved because of Subpart JA regulation concerns.
Next slide shows the typical red line P&ID tie-in Subpart JA regulation concern. The environmental concern is the area we plan to tie the jumper into the flare header inside the battery limits valve. Our P&ID’s show the flare header starts at the discharge side of the relief valve. Environmental and Legal say we need clarification on this issue before moving forward because EPA could interpret the flare header starting inside the battery limits valve.
29
30” Low Pressure Flare Header
30” Low Pressure Flare Header
24” High Pressure Flare Header
24” Existing Jumper
8” Existing Jumper
Proposed Jumper
V-1 V-2
Battery Limits
Legend
=24” High Pressure Flare
=30” Low Pressure Flare
=30” Low Pressure Flare (Area #1)
=Unit Example
=Proposed Jumper
30
RR&E for Offsite/Interconnecting Manager, Planners and Schedulers
Receive marked up DWG’s from Inspection Receive marked up P&ID, blind list, de-inventory plan and Champ or
MOC from Operation Walk down the job and draw up a detailed repair plan Order all materials Build time line Schedule and Estimate Fabricate in the shop and execute the job in the field
The Offsite/Interconnecting group is not using Engineering and they generate their own replacement in kind DWG’s directly from Operation/Inspection. Operation/Inspection is working closely with us to make sure repairs on all these lines are executed according to the current standards and specification!
31
Equipment Plan Efficiencies
Lease to Own Delivery by October 2008 Received in 2009
Vacuum Truck Transfer Pump Wench truck Water truck Trailer and Piggy back Forklift
32
2008 Post Outage Report for Offsite and Interconnecting Piping Repairs
Files are located in the T/A Building.
All pertinant files are being downloaded into “Live Link” by the Planners.