How can you design oil and gas facilities for maximum safety and efficiency?

The effect of carbon dioxide (CO2) in liquefied natural gas (LNG) feed gas: High levels of CO2 in LNG feed gas can lead to foaming issues during LNG production. Foaming can result in operational problems, reduced product quality, and even safety hazards. The following strategies can be used to control these concerns: - Using amine-based Acid Gas Removal systems is effective in reducing CO2 content to acceptable levels. - Antifoaming agents: These chemicals help break down foam and reduce its formation. - Temperature and pressure are critical parameters in various separation processes and adsorption technologies used to remove or reduce CO2 in LNG feed gas - Reducing residence time can help decrease the likelihood of foaming.

An important thing to keep in mind, already from the early days of concept development, is the system engineering thinking and how technical trade-offs can affect each other. Most serious companies nowadays have a set of process safety requirements that get embedded into the design however having a real understanding of how the system works together, how each components, sub-assembly and sub-system effect each other is crucial in being able to identify potential areas of weakness where a major accident hazard can occur.

The industry has many thousands of years of operating experience and we have to learn from what went well and what didn’t, in order to build and operate facilities safely and optimally. Rigorous research of accidents that have happened and understanding the true root causes of failures are fundamental to implementing robust designs and subsequently safely operating and maintaining the equipment. With existing equipment, ensure that all lessons are incorporated but prioritise on the basis of safety, then reliability and environmental impact.

For sure oil & gas is not a safety company, it is a business activity to create value/profit. And process safety is essential element to the business to sustain for the long run. Various past major incidents teach us in the hard way that poor process safety performance can wipe the business entity out of business. Good process safety performance has strong relation to good corporate governance (GCG) that is capable to balance between safety and business goal. Company with good GCG will “do what they talk” which is key element in process safety. Company with good process safety should have good GCG that finally will affect their financial balance sheet to ensure they can sustain in the business.

Comprehensive QA: Oil & Gas Regulatory Adherence: Embeds compliance seamlessly into operations, ensuring accountability and safeguards against legal implications. Proactive Safety Design: Incorporates HAZOP, FMEA, and design reviews. Empowered Workforce: Equips teams with tailored training and assessments. Efficient Maintenance Strategies: RCM for proactive upkeep, reducing downtime and critical failures. Emergency Readiness: Response teams and simulations ensure swift, effective reaction to unforeseen events. Informed Decision-Making: Real-time monitoring and KPI tracking enables agile interventions for enhanced efficiency. Dynamic Improvement Culture: Workforce adaptability implementing change management and transparent reporting

Process safety is the bedrock of responsible oil and gas operations, where preventing major accidents is paramount. It's the embodiment of lessons learned and technological advancements, ensuring our industry operates at the highest standards of safety and efficiency. Elements like hazard identification, risk assessment, automation, and incident investigation weave a tapestry that safeguards people, property, and the environment. In a world of evolving technology, our commitment to process safety remains unwavering. #ProcessSafety #OilAndGas #SafetyFirst

Build it inside the prison, no rights, no free choice no free will. Happy management happy business. More security more concrete walls, non stop work shift, no salary, no insurance. Accident without investigation.

You need a database to gather your safety inspections. Cenezon can help you here. I would still love to work there, if they would give me another chance. .

If we know process, we can use from well integrity management system for 6 phase and according to knowledge about each phase, we can do job very safely.

Including the 'human factor' as early as possible into designs, can make a huge difference in the operability and maintainability of facilities. So the earlier Operations is involved in contributing to the functional specs of a design, the better. Follow-through in the design phases with a solid OR&A framework, does the rest.

In the oil and gas industry, the marriage of technology and human factors is paramount. Human factors, encompassing psychological, social, and physical dynamics, wield profound influence over safety and efficiency. As we advance, technology and data analytics help us harness this potential. Human factors engineering is our tool to shape ergonomic, data-centric facilities, optimizing usability and interface design. The right training programs are data-rich, and a culture of data-driven safety emerges. This blend of technology and human insight propels us towards higher standards in facility design and operations. As an SME, I'm thrilled to spotlight how this fusion elevates information-centric safety and efficiency in our industry.

There is no doubt that human is the most valued resource of every organization. However, several accidents have been traced to human factors. It is therefore necessary that efforts must be channeled towards the development of the human resources to ensure that those managing our assets are the best in their workplace behavior, safety culture and behavior, team players, technically and morally sound. Do not mortgage your human resources for excessive profits and short-term gains. Else you might encure more loss on the long run. Invest in your human resources and you will have less human factors related incidents and losses 📉

if we believe that Human being make more mistakes than machines, we should design our safety control and emergency system to make it utmost automated, sophisticated but still simplified and comprehensive for operators on site. From another aspect, Human factor impact during the facilities design for maximum safety Lies within the selection of experts who would contribute during the safety case and others tools deployment and would influence the safety system design finally adopted. A mixture of Senior and Junior experts with specific skills (from different disciplines) in the team is recommended.

From a design perspective, Human Factors is contracted to a Specialist Consultancy, the key to success is in their detailed scope of work. Feedback from the client is paramount to achieving this goal.

Human factors encompass the psychological, social, and physical elements shaping how individuals engage with oil and gas facilities and execute tasks. These factors significantly impact safety and efficiency by influencing behavior, performance, communication, teamwork, decision-making, and error prevention. Human factors engineering tailors facility design to accommodate human capabilities and limitations. Key aspects include ergonomics, usability, interface design, training, and fostering a safety-oriented culture. Through such considerations, human factors engineering enhances both operational effectiveness and safety within oil and gas facilities.

Asset integrity is non-negotiable in oil and gas. Leveraging technology for inspection, testing, and maintenance is our gateway to data-driven, lifelong performance. It adds efficiency, speed, accuracy, and depth to information, bolstering confident decision-making. This transparency and consistency resonate across the organization, ensuring safety and effectiveness in every facet of our operations. #AssetIntegrity #OilAndGas #Technology

Asset Integrity in my view require system thinking. We need to create and acceptable balance where Health, Safety of personell, and Environment are not sacrificed, as a minimum. Maintenance and inspection, even evaluation of results should come from the design of the system functions and their understanding of degradation mechanisms, and in my experience efficiency then is a byproduct.

AIM's ultimate goal for securing system integrity, avoiding loss on HES, asset loss on damage, interruption, production losses. AIM shall have the proper programs: 1. Inspections (visual, UT, IR, on tank / vessel, pipeline, structure both above water & underwater); 2. Monitoring (corrosion, chem injection); 3. Certification (press vessel, tank, PSV); 4. Maintenance (cleaning, repair, modification, replacement). However integrity failure could be happened from other process' failure, which deteriorate the integrity. Example my project was an offshore waterflood's leakages due to the oxygen knockout for the water injection. High oxygen created internal corrosion, it then stopped the secondary recovery injection & dropped the production.

Proactive maintenance and inspection activities to ensure that equipment remains in optimal condition and to identify and rectify safety issues.

The reliability and functionality of an asset depends on the integrity. The integrity of an oil and gas asset is a factor of time, usage, monitoring, maintenance and the operating environment. Managing an asset in offshore or Deepwater environment is different from onshore. Due to high exposure to corrosion and other environmental factors, more investment is required to maintain asset integrity in such environment. Also, the tendency for failure of an oil and gas asset and the environmental, socio-economic impact of lost of containment of hazardous substances in a marine ecosystem are some of the factors that asset managers must consider in their operations.

Asset integrity is vital for oil and gas facilities to function effectively and safely, preserving the environment. It entails maintaining equipment, structures, and systems to ensure continuous performance and reliability. Asset integrity management involves planning, implementing, and monitoring activities such as inspection, testing, maintenance, and repair. By prioritizing these measures throughout the asset lifecycle, asset integrity management safeguards against potential hazards, ensuring operational efficiency and environmental protection.

Energy is life. Therefore it cannot be wasted. The possibility of use and exchange is what create flow in the process. Finding the areas where the design can facilitate this exchange also create normally positive economics. The trick is to not increase unmanageable risk in the process.

Energy is the largest cost in the industry and needs managed appropriately. A senior manager must be made accountable for all aspects of current energy performance and future strategies. Energy can only be managed if it can be measured and costs must be understood. Where appropriate, a cost of greenhouse gases should also be included in energy management programmes

Energy efficiency is pivotal in enhancing the safety and profitability of oil and gas facilities. By optimizing design, operation, and maintenance, facilities can reduce energy consumption, emissions, costs, and waste. Strategies like energy auditing, benchmarking, monitoring, heat integration, cogeneration, waste heat recovery, and renewable sources are instrumental. Prioritizing energy efficiency not only drives sustainability but also bolsters competitiveness in the industry, ensuring long-term viability and resilience.

In the pursuit of operational excellence, digital transformation emerges as a cornerstone of the oil and gas industry. The critical role of technology in ensuring safety, efficiency, and asset integrity. It's evident that integrating digital technologies and data-driven solutions is not a choice; it's a necessity. This journey enables our facilities to optimize processes, monitor performance, manage assets, assess risks, and prevent incidents more effectively than ever before. The data-driven decisions it supports ensure that our operations are both transparent and consistent. In a world where safety and efficiency are non-negotiable, digital transformation becomes our compass for achieving operational excellence.

Any succesfull use of a technology (including digital) needs to address three topics: people - process - technology. Integration of these three to support the clear business objectives, will make or break the benefits from new technology deployment.

People have already found ways to bypass every technology known to man. Why would these technologies succeed where all others have failed?

In-plant workers should carry a location beacon to allow for a quick response to their location or evacuation notification if needed. Even within very noisy areas.

Digital transformation revolutionizes oil and gas facilities, merging digital technologies and data to bolster safety and efficiency. Through automation, AI, IoT, cloud computing, big data analytics, and digital twins, facilities optimize processes, monitor performance, manage assets, assess risks, prevent incidents, and achieve operational excellence. Embracing digital transformation not only enhances productivity but also ensures a competitive edge in an evolving industry landscape, driving sustainable growth and resilience.

Virtualization through simulation & BIM software and IoT sensors. Design Phase: Virtualization allows for iterative design processes, optimizing layouts for maximum safety and efficiency. It also provides a platform for multidisciplinary collaboration, leading to well-informed technical decisions, cost estimation and budgeting. Construction Phase: Virtualization empowers precise control over time, materials, and costs; minimizing delays and cost overruns, crucial in reducing risks associated with construction. Operation Phase: Real-time data from sensors enables proactive issue resolution, enhancing safety. Performance monitoring through digital twins allows for predictive maintenance, facility management and seamless operations.

Ensure site management have skin in the game when it comes to safety performance with sufficient audits to confirm compliance with contractual requirements.

Communication between engineering, operations, inspection and the construction contractor are key to a successful project and provides the end user with a safe and functional facility.

We also need to be aware of the financial pressure on the design team. Optimisation is actually a three legged stool between safety, efficiency and the cost of building the installation. As the cost of an installation increases so does the financial risk and there is a balance to be struck between a potential future loss of integrity or efficiency and a real current cost. All Engineers need to have an understanding of the world of finance so that we can produce effective arguments that non Engineers can understand.

How can you design oil and gas facilities for maximum safety and efficiency? You can’t. Maximum safety you can reach by simply not building them. No impact, no risk. But that’s not the point right? And what is maximum efficiency? Uptime? Throughput? Energy efficiency? Lowest carbon footprint? All possible, all in part in conflict. To answer the question you must first realise what your objectives are. All of them, not just safety and efficiency (not easy). And then define the trade-offs you are willing to make (even more difficult). Only then you are in a position to start creating a design that suits you.

Make sure the Project Team is led by someone with a very strong track record in Production Operations. The worst outcomes are achieved by adding Operations personnel after the FEED has been completed.

Major operational problems on a facility are frequently the result of missing maintenance and operability considerations during design. The inclusion of a Maintenance and Production Specialist on the design review team can address issues such as : - Fork lift, crane, mechanical handling access for removing valve stems, rotating equipment components. - Proximity of large equipment to other items/pipe racks. Does major dismantling of one equipment item require removal of adjacent equipment and pipework? - Is routine inspection and minor repair possible without the use of temporary access facilities - scaffolding, man-lifts. Issues that can be identified and addressed easily during design but are costly and time consuming in operation

Modular and repeatable design in oil and gas facilities enhances safety and efficiency by standardizing operations, enabling consistent performance, and allowing for iterative improvements. This approach offers operational familiarity, reducing errors and training time. Modular components can be customized for specific wells, avoiding unnecessary costs and facilitating easy maintenance. Mass-produced modules reduce costs and construction time, while ensuring quality and adherence to safety standards. This design strategy supports continuous improvement and adaptability in the face of evolving industry demands.

In an ideal world there is infinite time and resources to cover all aspects of human, system and available technology to cover all fields of risk, efficiency and operability. We definitely aim for that. But unfortunately this has been proven not positive since resources and time to perform are not limitless. Therefore, a full spectrum and systematic understanding of the intended production is our best option. All barriers and their relationship must be understood in purpose, functionality and interaction. And trying to find the sweet spot where one can pull a balance trick is the key in my view.

Conduct well thought out mock drills frequently to ensure responses are adequate. Targeted scenarios that are in-field and relevant to the workers. Should not take more than 10 minutes. I suggest selecting random workers or work groups to take a few minute mock emergency response quiz that focuses on a situation that may occur within their work area. Read the script and record the answers. Determine if the response is reasonable and identify shortfalls that require further training. Actually complete the training! In-plant work is dangerous and frequent verification that workers understand and follow emergency procedures is crucial. This would also compel all workers to understand the process as they may be the chosen participant.

Overall a concise description of what is a very complex problem. I agree that maximum safety and maximum efficiency are not compatible as Jaen Paul say so neatly. However up to a point both are complimentary, any safety incident also involves a loss of efficiency, ranging from a minor "lost time" injury through to catastrophic destruction of the installation. As long as you understand the concept of As Low As Reasonably Practicable and set a sensible level for tolerable risk assuring integrity also assures efficiency.

Thorough subsurface studies for the entire life of the field should be the basis for facilities initial design to take into consideration the impact of change in reservoir and fluids behavior with time on the process and storage facilities performances and thus efficiency. In this respect, well test design and data analysis in addition to consistent fluids laboratory analysis are paramount. this will also ensure facilities cost (CAPEX) efficiency since any facility to be re-designed-replaced-added with time is planned for from the initially selected and optimized facilities design.

This is the point where I tell people that none of the above will exclusively enable an Oil & Gas facility to be designed for maximum safety and efficiencly. The answer is ALL of the above ... and MORE. Using a proper, robust OR&A system will ensure that ALL of these things are taken into account, at the right time, by the right people to deliver the project RIGHT - FIRST TIME.

Everyone involved in a construction project has their own skillset, knowledge base, and experience. Each position looks at a project through a unique lens. Designers and architects look at what is being built, construction managers look at how to build it, and Environmental, Health, and Safety (EHS) professionals look at how to build it safely. When companies wanted something built, one team designed it and another team built it. There was only as much cross-communication as was needed to get the job done