Automation Opportunities in LDAR

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Automation Opportunities in

LDAR(and the P&ID Data Conundrum)

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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.

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Audience Poll

What type of phone do you use?

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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

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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

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LDAR Automation Opportunities

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Why Automate Manual Processes?

1. Reduce opportunities for error

2. Eliminate inefficiencies and maximize labor force

3. Save costs by automating repetitive processes

4. Improve QA/QC between data systems

5. Create sustainable compliance processes

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Various LDAR Compliance Processes

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•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

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•What do all of these things have in common?• LDAR Applicability Determinations • LDAR Inventory/Retag• Management of Change• Fugitive Emissions Estimating• LDAR QA/QC

1.They are all manually-intensive processes2.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?

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Data Within P&IDs

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•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

Anatomy Of P&ID:Data, Data, Data

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The P&ID Data Conundrum

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• 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 YEARS prior to promulgation of NSPS GGGa and VVa (2008)

Best Opportunity to Automate?

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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

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• 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

Manual: LDAR Applicability Determinations

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Automated: LDAR Applicability Determinations

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• Use “smart” P&IDs to automate process

MANUAL: LDAR FLAGGING

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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

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MANUAL: LDAR TAGGING

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(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

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MANUAL: LDAR DOCUMENTATION

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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!

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DocumentationWorkflow

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Example LDAR MOC Workflow

Automated LDAR MOC Workflow

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MOC Data Shared Amongst Plant

Disciplines

HA-135Technician with “smart P&ID” loaded on tablet

Smart P&ID indicating MOC changes (pink cloud)

Component identified and updated in tablet

Automated LDAR MOC Tools

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HA-135

NAPHTHA FEED PUMP 1A4FWA-1A

LUBE OIL PUMP DISCHARGE 269-1

Novel Approach to IdentifyWhen MOCs are Put into Service

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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”

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Automated: Repair Scheduling and Data Exchange

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Maintenance work orders within smart

P&ID

Automated: Repair Scheduling and Data Exchange (cont.)

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• 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

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

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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

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LDAR Compliance Costs

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•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

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No. of P&IDs 1000

Frequency Every 5 Years

Labor Category Bill Rate Time w/o (hrs) Cost w/o

Engineer $100/hr 1 $100

- 1 P&ID per hour to markup by Efficiency Gain Time w/ Cost w/

hand, speciate, and scan into PDF 90% 0.1 $10

Net Savings $90

Total Savings $90,000

Return on Investment: LDAR Inventory/Retag

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Task LDAR Inventory/RetagNo. of P&IDs 1,000

No. of Components 50,000Labor Category Bill Rate Time w/o (hrs) Cost w/o

Flagging Technician $50/hr 2500 $125,000 - Flag 4 P&IDs per Day Efficiency Gain Time w/ Cost w/o

  50% 1250 $62,500   Bill Rate Time w/o (hrs) Cost w/o

Tagging Technician $30/hr 2000 $60,000 - Hang 250 Tags per Day Efficiency Gain Time w/ Cost w/

  0% 2000 $60,000   Bill Rate Time w/o (hrs) Cost w/o

Documenting Technician $40/hr 2000 $80,000 - Document 250 Comps per Day Efficiency Gain Time w/ Cost w/

  50% 1000 $40,000 Total Savings $102,500

Return on Investment: LDAR MOC

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Task MOC LDAR Updates

No. of MOCs/Year 500

Frequency Daily

Labor Category Bill Rate Time w/o (hrs) Cost w/o

MOC Technician $45/hr 4 $180

- 4 hours per P&ID Efficiency Gain Time w/ Cost w/

to inventory and monitor 33% 3 $135

Net Savings $45

Total Annual Savings $30,000

5-Year Return $150,000

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.

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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.

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Don’t Let These Compliance Processes Continue to Chase You

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LDAR Applicability

Management of Change

Fugitive Emissions Estimating

LDAR Inventory/

Retag

LDAR QA/QC

DataCompliance

Questions?