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Automation Opportunities in LDAR. (and the P&ID Data Conundrum). Presenter.
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Automation Opportunities in LDAR (and the P&ID Data Conundrum)
Presenter • Shane Kling is CEO and Co-Founder of Environmental intellect (Ei) and has approximately 9 years of LDAR compliance experience. During his career, he has supported more than 100 facilities spanning petroleum refining, chemicals, upstream oil and gas, and other manufacturing industries. He recently transitioned from Sage Environmental Consulting to support Ei’s mission on a full-time basis, which is to improve industry standards by introducing industry best available technology and integrating existing data systems to achieve the highest level of compliance.
Audience Poll What type of phone do you use? or
Topics to be Covered • LDAR Compliance Processes and Management Systems • Description of Various LDAR Compliance Processes • P&IDs: The Compliance Foundation • Automating Manual Compliance Processes • Reducing Costs Associated With Manual Processes • Question and Answer
Topics *Not* Covered • Automating LDAR Monitoring Data Collection • Bluetooth transmitters in combination with LDAR databases is already industry best practice • Automating LDAR Calibration Process • LDAR Tools as already addressed this area with its Cal3.0™ software and SpanBox3™ • LDAR Monitoring Robots, Puppies or Rainbows
Why Automate Manual Processes? • Reduce opportunities for error • Eliminate inefficiencies and maximize labor force • Save costs by automating repetitive processes • Improve QA/QC between data systems • Create sustainable compliance processes
Various LDAR Compliance Processes • LDAR Applicability Determinations: (review and highlighting of P&IDs to indicate LDAR / non-LDAR) • LDAR Inventory/Retag (transcribing P&IDs markups through flagging, then tagging and documentation) • Management of Change (managing impacts to LDAR program from engineering changes) • Fugitive Emissions Estimating (heavy liquid equipment counts) • LDAR QA/QC (cross-referencing P&IDs vs. LDAR database to verify accuracy)
Common Link Within Compliance Processes • What do all of these things have in common? • LDAR Applicability Determinations • LDAR Inventory/Retag • Management of Change • Fugitive Emissions Estimating • LDAR QA/QC • They are all manually-intensive processes • They all involve Piping and Instrumentation Diagrams (P&IDs)
The Compliance Foundation What in the world do P&IDs and foundations for houses have in common?
Data Within P&IDs • The following data can be present in P&IDs: • Equipment counts/inventory • Equipment types • Stream speciation • Equipment design specifications • Directional flow • From/to information • PI tag references • Line lists, including piping IDs • MOCs, redlines, and revision numbers • Process unit, drawing number, and facility name
The P&ID Data Conundrum • Industry standard CAD programs were not designed to meet the needs of compliance programs • Purpose was to provide an "electronic drawing board" to draftspersons • In fact, the first commercial version of AutoCAD was released in 1982: • Shortly after the promulgation of NSPS VV (1981) but before NSPS GGG (1983) • 10 YEARS prior to the promulgation of the Process Safety Management standards in 1992, which requires P&ID updates every 5 years as part of PHA revalidation • 32 YEARSprior to promulgation of NSPS GGGa and VVa (2008)
Best Opportunity to Automate? Sure, “automation” sounds like a nice concept, but… …how do we justify the costs? • The answer for most plants: capital projects, turnarounds, or LDAR inventory/retag projects
LDAR Inventory/Retag Projects • Let’s now examine the various steps in a retag project and explore opportunities for automation: • Applicability determinations and P&ID markup • Flagging • Tagging • Documentation
Automated: LDAR Applicability Determinations • Use “smart” P&IDs to automate process
Automated: LDAR Flagging • Engineering data is incorporated into smart P&ID™ • Single-click functionality to “push” inventory data into GuideWare™ (directly) or LeakDAS™ database (indirectly) • Saves on inventory/retag technician labor-hours • More efficient data management/reduces potential for errors
(Semi)Automated: LDAR tagging • Physical hanging of tags is unchanged; however you can: • Track that all tags hung for valves, pumps, and other tagged equipment match LDAR applicability in smart P&ID • Audit LDAR database and smart P&ID to identify tagging gaps • Incorporate LDAR tag numbers into P&IDs for future MOC tracking
Automated: LDAR Documentation • Equipment, Stream, Service, Drawing No. etc. is stored in sP&ID™ • Data is exported from sP&IDs™ into GuideWare™ or LeakDAS™ • Data is pre-populated into handhelds for technicians to field-verify Increased Efficiency!
Automated LDAR MOC Workflow HA-135 Technician with “smart P&ID” loaded on tablet MOC Data Shared Amongst Plant Disciplines Component identified and updated in tablet Smart P&ID indicating MOC changes (pink cloud)
Automated LDAR MOC Tools HA-135 NAPHTHA FEED PUMP 1A 4FWA-1A LUBE OIL PUMP DISCHARGE 269-1
Novel Approach to IdentifyWhen MOCs are Put into Service PI tag near newly-added component may indicate if equipment is in hydrocarbon service
Manual: Leak Repair Scheduling • Question: When a leak is identified, how is the repair scheduled, tracked, and ultimately logged into database for compliance records? • Answer: The LDAR Coordinator or Database Admin generates Leak Repair Work Order, and this is distributed to Maintenance • Maintenance then logs the repair into its maintenance management system (e.g., SAP) • Closure of leak relies on a lot of communication, manual processes, and data “silos”
Automated: Repair Scheduling and Data Exchange Maintenance work orders within smart P&ID 30
Automated: Repair Scheduling and Data Exchange (cont.) • Integrating LDAR databases, such as GuideWare™ or LeakDAS™ with SAP or Maximo offers: compliance improvements, reduced labor, and seamless communication • Some companies have integrated their LDAR database with SAP, but there are others with limited I.T. resources that have this need 31
Costs Associated with P&IDs • Many operating facilities spend millions of dollars each year in activities that directly/indirectly involve P&IDs: • Engineering/CAD • MOC Updates and Redlines, Troubleshooting • CAD Updates • Safety • PHA Revalidation • Process Safety Information (PSI) Updates
Costs Associated with P&IDs (cont.) • Operations and Maintenance • Identification of equipment • Environmental • Applicability determinations • P&ID-based compliance reviews (e.g., LDAR, BWON, NSPS Ja) • MOC updates
LDAR Compliance Costs • There are several LDAR-related costs that can be reduced with automation, including but not limited to: • LDAR Applicability Determinations • LDAR Inventory/Retag • Management of Change • LDAR QA/QC • Fugitive Emissions Estimating
Return on Investment: LDAR Applicability Determinations / P&ID Markups
Concluding Thoughts 1. Shift from Analog to Digital: The need exists to begin process of converting your facility P&IDs into "smart P&IDs" that can fulfill the company's needs. 2. Technology Integration Reduces Operational Costs: Automating repetitive processes allows professionals to focus on solving problems computers cannot 3. Management Buy-in: There are several opportunities to gain Management buy-in, such as capital projects, P&ID revalidation, LDAR inventory/retag, etc.
Concluding Thoughts (cont.) 4. Leading the Effort: As professionals, your knowledge is more valuable to the company than repetitive job tasks 5. Ask Questions, Learn More: The information presented today should provide a good introductory conversation with CAD, engineering and your Management on opportunities for automation.
Don’t Let These Compliance Processes Continue to Chase You Questions? Fugitive Emissions Estimating LDAR Applicability LDAR Inventory/ Retag Management of Change Data Compliance LDAR QA/QC
