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
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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.
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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
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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.
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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
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7. Car Seal Issues
• Car seal additions:
– Blow down isolation valves.
– ESD bypasses.
• Car seal procedures and training
was improved.
• Improved Car seal documentation
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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
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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.
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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)
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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.
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12. Slipstreams
•Various sources can be captured.
• Compressor packing
• Instrument gas vents
• Dehydrator flash gas
•Utilizing station and unit
outages to install equipment.
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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
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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 Valves
o 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.
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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.
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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.
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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
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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.
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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.
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31. HAZOP Report Findings Based on assumed
safeguards, A Typical Example on PHA Study)
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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.
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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.
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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.
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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.
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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 and
Piping code)
•Manufacturers Standardization Society-Standard Practices
•CSA B149.3 Code for field approval of fuel related components on
appliances and equipment
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