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Asset Integrity ManagementSystems – Why you need this?       The Game Plan               December 10th 2012               ...
AIMS Projects on Legacy Assets Improvements • AIMS – Asset Integrity Management   System    - A plan to meet the minimum  ...
AIMS Projects on Legacy Assets Improvement                                •   Oil boom in early 1900’s                    ...
AIMS Project•   Background:     – Stations built in the 70’s.     – Drawings were incomplete.     – Modifications and addi...
Plant/Station Results• Project needs to be started at Any of the Existing Plant  Sites, where we attention needed.• Design...
Pressure Equipment Issues•   New Pressure relief valves.•   PRV pressure and capacities changed.•   Vessels were rerated f...
Car Seal Issues• Car seal additions:   – Blow down isolation valves.   – ESD bypasses.• Car seal procedures and training  ...
Shutdown Key Improvements• Shutdown Key Documented• Protection Standardization.• Block and hold concept:   – Reduces vente...
Emission Reduction Regulatory Requirements• Multi Million dollar project for the Oil and Gas Operators•Partial funding by ...
REMVue Air Fuel Ratio Control• Integrated engine and compressor controls• Air and fuel management   – Compensates for ambi...
Slipstreams•Feeds vented gas into the combustion air.•AFR reduces main fuel by the amount of added vent fuel.•Reduces our ...
Slipstreams•Various sources can be captured.   • Compressor packing   • Instrument gas vents   • Dehydrator flash gas•Util...
SlipStream•Control system shows current and totalized flow.•Currently saving $$ per month in fuel + credits.•Plan to colle...
Current operation Plant Procedure                   Improvements•   Documented safety system bypass procedure.•   Improved...
General Requirements• Plants working in North American continent are  over 60+ years, require an audit of the As-Built  dr...
General Requirements…..Contd.• The final part of the AIMS process is a review of  the HAZOP recommendations and correction...
Phase 1. As Build• The general scope of the project involves obtaining the  latest drawings and documents of the subject  ...
Phase 1 As Build……Contd• A mechanical field trip occurs to as build the  equipment and piping associated with the facility...
Phase 1 As Build……Contd• Following the field trip the drawings are again modified  by the mark-ups made by the instrumenta...
Phase 1 As Build……Contd• PFD Drawings and Material & Energy Balance• PFD drawings will be as-built based on the site findi...
A Plant PFD(Typical Drawing)                               21
Phase 1 As Build……Contd•   Heat and Material Balance Calculations, Line Lists.•   This is required for detailed process en...
Phase 1 As Build……Contd•   A new site PSV valve list will be created and deficiencies identified with    respect to their ...
Phase 1 As Build……Contd• Control Valves• Control valves affecting PSV sizing will be checked for  fail open flow rates.• L...
Phase 1 As Build……Contd• Drain System• A schematic of the existing drain system will be  developed.• The drain system will...
Phase 2 HAZOP• The HAZOP technique provides a means of  systematically reviewing the design and operability of a  system t...
Phase 2 HAZOP…..Contd.•   Although HAZOP is a problem identification technique, a solution to    an identified potential p...
Phase 2 HAZOP…..Contd.• A Risk Matrix is utilized to allow for  consistent judgment of the consequences  (Severity and Lik...
29
Risk Ranking Example                       30
HAZOP Report Findings Based on assumedsafeguards, A Typical Example on PHA Study)                                         ...
HAZOP Phase 2…..Contd.• Typically, project HAZOPs are completed  prior to any construction, therefore, risk  rankings woul...
Phase 3: Review of       Recommendations and Corrections• This Phase of the project consists of reviewing the  recommendat...
Phase 3: Review of Recommendations and Corrections…..Contd.• Following the completion of the bidding process,  a set of Is...
Phase 4. Final Drawings• Following completion of the HAZOP  recommendation work, A User must make a  decision to proceed w...
Why we need Asset Integrity Management Systems?Compliance with following:•Labour Code•Occupational Health and Safety Regul...
Questions?             37
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Aims presentation on Western Region NACE Conference at Victoria 2013

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Facility Management Systems(Asset Integrity Management Systems) Why you need this? by Gobind Khiani

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Aims presentation on Western Region NACE Conference at Victoria 2013

  1. 1. Asset Integrity ManagementSystems – Why you need this? The Game Plan December 10th 2012 Gobind Khiani Staff Facilities Engineer
  2. 2. AIMS Projects on Legacy Assets Improvements • AIMS – Asset Integrity Management System - A plan to meet the minimum standards required to show due North American diligence. Practices on Improvements - Ensures that a professional engineer to legacy/ has certified our Facilities. existing Plants, • Meeting Code requirements. Facilities. • Provides the required information to proceed with future plant improvements 2
  3. 3. AIMS Projects on Legacy Assets Improvement • Oil boom in early 1900’s made owner/operators build plants, pipelines, facilities and this has made them continuously improve to meet Updates on the Regulatory, Codes, Health, Safety and Environments in Natural Resource Rich Areas such as Prairies in Canada.Map is to show position only. 3
  4. 4. AIMS Project• Background: – Stations built in the 70’s. – Drawings were incomplete. – Modifications and additions were made.• Solution: – As-Built Drawings – Design Review – HAZOP Station- Hazard and Operability study – Shutdown Key Review – Management of Change 4
  5. 5. Plant/Station Results• Project needs to be started at Any of the Existing Plant Sites, where we attention needed.• Design review, HAZOP and Action items are complete.• Plant safety, reliability and emissions were improved. 5
  6. 6. Pressure Equipment Issues• New Pressure relief valves.• PRV pressure and capacities changed.• Vessels were rerated for temperature.• Piping spec breaks were protected.• 2 inlet scrubbers were added 6
  7. 7. Car Seal Issues• Car seal additions: – Blow down isolation valves. – ESD bypasses.• Car seal procedures and training was improved.• Improved Car seal documentation 7
  8. 8. Shutdown Key Improvements• Shutdown Key Documented• Protection Standardization.• Block and hold concept: – Reduces vented gas – Faster restart• Plant still blows down on: – ESD – Fire Detection – 40% LEL 8
  9. 9. Emission Reduction Regulatory Requirements• Multi Million dollar project for the Oil and Gas Operators•Partial funding by the Canadian government•Reducing fuel and vented gas in our compressor stations•Utilizes Air Fuel Ratio Control and Slipstream•Project Plan•25 units upgraded to AFR/slipstream•15 slipstream systems added to current AFR units.•7 AFR+SS and 5 SS to be installed.•Currently have 28 operating AFR units. 9
  10. 10. REMVue Air Fuel Ratio Control• Integrated engine and compressor controls• Air and fuel management – Compensates for ambient conditions and changes in fuel• Reduces fuel consumption (~ 6%)• Reduces NOX emissions• Can use vented gas as Fuel (Slipstream) 10
  11. 11. Slipstreams•Feeds vented gas into the combustion air.•AFR reduces main fuel by the amount of added vent fuel.•Reduces our greenhouse gas emissions. 11
  12. 12. Slipstreams•Various sources can be captured. • Compressor packing • Instrument gas vents • Dehydrator flash gas•Utilizing station and unitoutages to install equipment. 12
  13. 13. SlipStream•Control system shows current and totalized flow.•Currently saving $$ per month in fuel + credits.•Plan to collect dehy flash gas as well.~$$ per month 13
  14. 14. Current operation Plant Procedure Improvements• Documented safety system bypass procedure.• Improved Lock out tag out systems.• Various improved operating procedures.• Shut Down Keys.• Plot Plan.• Slip Stream/Energy Efficiency.• Regulatory and current code compliance.• BMS requirement/s• De-bottlenecking project/upgrade. 14
  15. 15. General Requirements• Plants working in North American continent are over 60+ years, require an audit of the As-Built drawings for various plant stations. In order to determine if the existing drawings and documents reflect the actual conditions, equipment and instrumentation as shown on the drawings.• Following the as-build Phase of the project, a HAZOP is undertaken to identify any potential hazards and/or operability problems. 15
  16. 16. General Requirements…..Contd.• The final part of the AIMS process is a review of the HAZOP recommendations and correction of those items that pose a significant threat to the health and safety and/or operability of the facility being reviewed.• Phase 1 – As-Build drawings• Phase 2 – HAZOP Drawings• Phase 3 – Review HAZOP Recommendations and correct deficiencies• Phase 4 – Final As Build 16
  17. 17. Phase 1. As Build• The general scope of the project involves obtaining the latest drawings and documents of the subject Plant/Station from the Drawing Management Systems and performing site visits to compare the drawings to the actual situation in the field.• The field trip is conducted in two parts. Following the receipt of the P&IDs, PFDs, Plot Plan, Electrical Single Line, Area Classification and Shut-down Key, a review of the drawings for content is made. A scoping field trip of approximately four days duration is made to verify the drawings compared to the actual conditions. 17
  18. 18. Phase 1 As Build……Contd• A mechanical field trip occurs to as build the equipment and piping associated with the facility. Following the field trip, the redline as-built mark- ups are transferred to the project drawing files and the second part of the field trip can proceed.• During the second part of the field trip study the instrumentation and process departments review the site and obtain instrument and process information required to assess suitability of the installed equipment. 18
  19. 19. Phase 1 As Build……Contd• Following the field trip the drawings are again modified by the mark-ups made by the instrumentation and process groups.Further to the scoping field trip, the Consultant will evaluate the following list of items:• P&ID Drawings• P&IDs will be as-built up to vendor skid limit and out of vendor skid limit.• Vendor skid packages will not be part of this as-built drawings scope, if no drawings exist.• If Vendor P&IDs are available they will be put in CAD Format and included in the scope. 19
  20. 20. Phase 1 As Build……Contd• PFD Drawings and Material & Energy Balance• PFD drawings will be as-built based on the site findings.• Material Balance will be completed based on the site readings. The normal/min/max operating conditions will be taken from the operation history and reflected in the Material & Energy Balance.• This is a good point at which to review a typical set of marked up redline drawings to show you the scope of the mark-ups and see the changes required from the field reviews. 20
  21. 21. A Plant PFD(Typical Drawing) 21
  22. 22. Phase 1 As Build……Contd• Heat and Material Balance Calculations, Line Lists.• This is required for detailed process engineering on the existing plant/s.• For HAZOP purposes partial line numbers will be added where none exist. The line specification is not always available and cannot be included in the line number.• Existing line lists will not be altered and all existing line numbers will remain the same.• Shut-down Keys• As-built Shut-down key will be reviewed with the client after HAZOP. (S/D key as-built by Cenovus)• Changes from the S/D key review meeting and HAZOP will be added where necessary for safety reasons and they will be shown in red.• Site Plans• Site plan is completely as-built. 22
  23. 23. Phase 1 As Build……Contd• A new site PSV valve list will be created and deficiencies identified with respect to their rated capacity for the existing condition.• Pressure Relief Valveso The relief valves will be checked for various sizing scenarios. Recommendations will be made where necessary.o Most of the compressors do not have compressor curves. As per the instruction from Cenovus, the maximum sizing flow rate will be 10% above the maximum operating flow rate or 25% above the normal operating flow rate whichever is higher. For the compressors which have compressor curves, the maximum compressor design capacity will be used.o For PSV’s in vendor packages, the final decision on safety recommendations must be reviewed and accepted by vendor(s), where possible.o New PSV’s where found necessary will be designed and implemented. 23
  24. 24. Phase 1 As Build……Contd• Control Valves• Control valves affecting PSV sizing will be checked for fail open flow rates.• Level valves will be sized for fail open gas breakthrough rates for the tank vent sizing• No other control valves will be checked.• Vent System• All individual blow down valves will be checked for the existing condition to ensure they meet the industry standards. And checked for venting rates and blow down time. 24
  25. 25. Phase 1 As Build……Contd• Drain System• A schematic of the existing drain system will be developed.• The drain system will be checked for the worst case vapor break through to the produced water tanks.• Produced water tank vents will be checked for this worst case scenario.• All level control valves that dump into the produced water tanks will be checked for their fail open flow rates.• Incorporation of restricted orifice/check valves where found necessary will be implemented. 25
  26. 26. Phase 2 HAZOP• The HAZOP technique provides a means of systematically reviewing the design and operability of a system to identify potential hazards and/or operability problems. The technique involves structured brainstorming, using guidewords describing the appropriate parameters of various pieces of equipment and lines, to find deviations from design intent and normal process conditions.• HAZOP is a hazards identification process. It is not intended to be a problem solving technique. The results of a HAZOP are usually a list of potential hazardous scenarios. Often, when there is insufficient information to determine if situations represent hazards, the results of a HAZOP include recommendations for additional study 26
  27. 27. Phase 2 HAZOP…..Contd.• Although HAZOP is a problem identification technique, a solution to an identified potential problem often is obvious to the HAZOP team. In such a case, the study results may include specific recommendations for design and/or operational improvements.• The HAZOP is performed by a team of specialists in the field being studied, led by a person knowledgeable in the HAZOP technique. A typical HAZOP team consists of a PHA (Process Hazards Analysis) Facilitator and representatives from the Design Contractor and the Client with expertise in: Process Engineering, Instrumentation, Electrical, Maintenance. Operations, Inspection/Materials, Safety/Loss Prevention, Environment, and Controls. Some of the team members may be on an “on call” basis. One member may represent more than one specialty, with the PHA Facilitator sometimes acting as the Scribe, recording information as well as leading the study. 27
  28. 28. Phase 2 HAZOP…..Contd.• A Risk Matrix is utilized to allow for consistent judgment of the consequences (Severity and Likelihood). The Risk Matrix used for the HAZOPs is produced by Owner/Operator and is a standard that is to be followed with respect to EH&S/Operations Risk assessment. 28
  29. 29. 29
  30. 30. Risk Ranking Example 30
  31. 31. HAZOP Report Findings Based on assumedsafeguards, A Typical Example on PHA Study) 31
  32. 32. HAZOP Phase 2…..Contd.• Typically, project HAZOPs are completed prior to any construction, therefore, risk rankings would not be an issue because identified risks would be resolved prior to construction. These HAZOPs occurred after the system were operational, therefore, risks had to be reported as after known safeguards. 32
  33. 33. Phase 3: Review of Recommendations and Corrections• This Phase of the project consists of reviewing the recommendations that have been made during the HAZOP and deciding which of those recommendations require implementation. The review of the HAZOP recommendations is done by the Engineering Consultant and the Client with each party presenting views and finally signing off on the recommendation.• When it is decided that corrective action is required to satisfy a recommendation and the review has been completed. The consultant prepares a set of Issued for Bid drawings, to allow the client to send for tender, the drawing package, to selected construction contractors, to obtain prices for completion of the required works. 33
  34. 34. Phase 3: Review of Recommendations and Corrections…..Contd.• Following the completion of the bidding process, a set of Issued for Construction drawings are completed and issued to the successful contractor for use in completing the construction phase of the work.• Completion of the HAZOP recommendations generally completes the project. The Client, at their option, may require the consultant to produce a final As-Built set of drawings to reflect the site conditions at completion of the HAZOP recommendations. 34
  35. 35. Phase 4. Final Drawings• Following completion of the HAZOP recommendation work, A User must make a decision to proceed with a final as building of the construction work that was undertaken as a result of the HAZOP.• This final drawing modification is generally undertaken by the consultant of record during the HAZOP. 35
  36. 36. Why we need Asset Integrity Management Systems?Compliance with following:•Labour Code•Occupational Health and Safety Regulation•American Petroleum Institute Codes and Practices•ASME Boiler and Pressure Vessel Codes.•ASME Code for Pressure Piping(B31.3)•Pressure Equipment Safety Regulations(ABSA in Alberta, Canada)•Canadian Standards Association Standards(e.g. Electrical code andPiping code)•Manufacturers Standardization Society-Standard Practices•CSA B149.3 Code for field approval of fuel related components onappliances and equipment 36
  37. 37. Questions? 37

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