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Editorial
Peter Hunt Business Development Director ABB Consulting Maersk Curlew FPSO 04.
Maersk
BP
Looking ahead...
Welcome to the second edition of the new format Solutions newsletter. This edition includes articles from pharmaceutical, chemical and oil & gas companies with process safety, asset ageing and integrity being key themes. Two of our articles, PTT and Springfield Fuels, focus on technical training and competency where ABB Consulting continues to see a high demand from our customers. During 2011 well over 2000 delegates attended ABBs lunchtime talks, seminars, training courses, conferences and webinars. We also provided an increased amount of bespoke training at customer sites / offices. We continue to develop this offer with lunchtime talks now running in Yorkshire in addition to those in Humberside, the North East, the North West, Aberdeen and Grangemouth. We have also increased the number of our IChemE approved courses and our Pressure Relief training course is now running in Singapore and Australia. Best wishes for 2012 to all of our readers.
Shasun
Feature articles
4 Asset life extension Asset life studies on Maersk FPSOs 6 Retrospective HAZOPs HAZOP technique applied to existing facility at BP CATS Pressure systems training ABB deliver training for Springfield Fuels Ltd 8 Prestigious health and safety prize win Project team wins RoSPA Gold Award Ageing plant assessment Management of ageing assets at Shasun 12 Continued support to PTT Continued Technical Due Diligence training for PTT
9 Conferences Recent conferences ABB have sponsored, exhibited at or attended 10 Events / training Recent events or training courses ABB have attended
ABB solutions winter 2011 Customer magazine from ABB Consulting Copyright 2011 If you have any comments or feedback please contact Graeme Collings - graeme.collings@gb.abb.com ABB Consulting, Daresbury Park, Daresbury, Warrington, Cheshire, WA4 4BT, United Kingdom Tel: +44 (0)1925 741111 E-mail: contact@gb.abb.com Follow us on twitter: www.twitter.com/ABBCONSULTINGUK
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Feature articles
history, inspection reports and maintenance records. This allowed the multidiscipline ABB team to identify the life limiting issues, quantify the risk in terms of health, safety, environment, reputation and production as well as develop pragmatic recommendations to eliminate the issues or reduce the risks. The cost for individual recommendations was then estimated, together with proposed implementation dates. This facilitated the development of an expenditure profile for the asset through to the revised cessation of production date. The second project was also for the Curlew Field and involved undertaking an audit of the integrity management systems associated with ageing and life extension ahead of a forthcoming Key Programme 4 (KP4) audit by the Health & Safety Executive. This audit involved on site structured discussions with the main operations staff and main engineering disciplines together with a review of sample documentation across the five principal elements of the KP4 audit programme. The third project was for the North Sea Producer FPSO which is currently
Maersk Curlew FPSO.
located on the MacCulloch Field and is operated by ConocoPhillips. This project involved the design and facilitation of a one day workshop to identify potential gaps in the integrity management systems associated with ageing and life extension ahead of a forthcoming KP4 audit by the Health & Safety Executive. The output from this workshop was then used to develop an improvement roadmap. All three projects were completed in a short time frame to the overall satisfaction of the client.
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Feature articles
Maersk FPSOs
ABBs Asset Integrity Management team carried out an Asset Life Strategy Review and a KP4 gap analysis audit for our unit Maersk Curlew. Both studies were carried out on time and to the approved budget and we were satisfied with the reports produced as the final outcome of the studies.
Niels Poulsen, Mechanical Engineer, Maersk FPSOs.
Maersk FPSOs contributes to global energy supply by delivering safe and reliable floating oil and gas production services. Maersk FPSOs develop, build, install and operate FPSOs (Floating Production, Storage and Offloading units) tailored for oil production in demanding environments. FPSOs are among the most technically complex vessels in the world, and Maersk FPSOs is a proud supplier to some of worlds leading energy companies.
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Feature articles
BP
Retrospective HAZOPs
The HAZOP technique has been in use for many years and has proven to be an excellent tool to help identify process hazards, allow companies to control major accident risks and prevent operability issues.
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Feature articles
The technique has traditionally been applied during projects and modifications. However, an increasing use of the HAZOP technique is to apply it in a retrospective manner to existing facilities and not only on new projects or for modifications. BP require HAZOPs to be conducted on their existing assets in order to ensure that they are operated to the highest safety standards. ABB Consulting were approached by personnel at the BP CATS gas terminal to conduct a retrospective HAZOP. This involved utilising an experienced HAZOP leader and scribe from ABB, BP process and mechanical engineers, senior operators and other specialist disciplines. The study was conducted over a number of months utilising a highly structured approach to HAZOPs. BP have set new, higher standards for conducting HAZOPs. HAZOP is a rigorous, searching technique and when applied utilising a multi-disciplined team can help identify many issues that the original designers may have overlooked. Similarly, personnel who have operated and maintained such processes can highlight problems they have faced during day to day operations. Many recommendations are generated from such an in depth, critical review of production facilities. The recommendations are aimed at continually reducing risks to as low as reasonably practicable levels such that incidents are prevented and companies continue to operate successfully. The partnership between ABB skilled HAZOP resources and BPs experienced operations personnel can yield significant business benefits for successful continued operation. A retrospective HAZOP provides BP with a new baseline study which can further be used and kept evergreen, as future process improvements are identified and subjected to the HAZOP methodology. The HAZOP report thereby becomes a living document that reflects current understanding of hazards and risks. ABB is now supporting BP CATS in the close out of the actions. This is a prioritised programme of work to ensure that the risk reduction benefits of the HAZOPs are fully realised in a timely manner.
BP is one of the worlds leading international oil and gas companies, providing its customers with fuel for transportation, energy for heat and light, retail services and petrochemicals products for everyday items. CATS is the Central Area Transmission System, which delivers 20% of the UKs gas through a 404 kilometre (223 mile) pipeline from the Central North Sea to the CATS processing Terminal in Teesside on the North East coast of England, UK.
expertise and long-standing experience of developing and delivering technical training. SFL commissioned a series of three two-day training courses covering pressure equipment integrity. This tailored training programme will be followed by appropriate hands-on experience, coaching and mentoring to support and embed the learning. This training will also form the basis of development of new engineers.
SFL
By working with the consultants at ABB we were able to tailor the course content to meet the specific needs of our business. I have received many positive comments from the engineers who attended the three two day courses, and as an engineering community we have benefited greatly from the training.
Mark Britt, Inspection Group Manager, SFL
Springfields, near Preston, has provided nuclear fuel fabrication services since the mid1940s in fact it was the first plant in the world to produce fuel for a commercial power station. On 1 April 2010 Westinghouse entered into an agreement with the Nuclear Decommissioning Authority (NDA) for a long-term lease of the Springfields site, which transferred responsibility for the commercial fuel manufacturing business and Springfields Fuels Limited to Westinghouse.
Feature articles
The Team members of the ABB, Esso and suppliers senior managers.
RoSPA firmly believes that organisations that have demonstrated their commitment to continuous improvement in accident and ill health prevention deserve recognition. ABB / Esso demolition and remediation projects has shown that it is committed to striving for such continuous improvement and we are delighted to honour it through the presentation of an award.
David Rawlins, RoSPA Awards Manager
any potential historical legacy issues. In delivering the project, ABB has overall responsibility for decommissioning, CDM coordination, land remediation
and project management. ABB applied their five stage demolition methodology to the project to offer Esso a safe, cost effective and complete solution.
plant. Opportunities for improvement were also identified. These opportunities were prioritised by means of the criticality assessment and corrective actions recommended. Shasun Pharma Solutions found the health check to be a value adding process and plan to use the output of the study to optimise their integrity management programs.
Shasun
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Conference delegates - Asif Raza, ABB; Andy Plant, Lucite; Malcolm Pass, ABB; Zac Meadows, FujiFilm Imaging; Bill Brown, Syngenta; Liz Thomas, ABB; Phyllida Sumner, FujiFilm Diosynths; Roger Bours, Fike; Neil Roberts, Dow Corning; Colin Deddes, BP; Gaynor Woodford and John Walkington, ABB.
ABB hosted its second conference and exhibition on Pressure relief in Edinburgh. There were 80 delegates with guest speakers from Lucite, FujiFilm, Syngenta, Fike, SABIC, Dow Corning and BP. Malcolm Pass, ABB, also held a PEL Software introduction session. The event was very well received and preparation for the 2012 conference is under way. Please contact Debby Law - deborah.law@gb.abb.com if you would be interested in presenting at the 2012 conference.
The ABB exhibition stand at the conference. From left: John Walkington, Ken Bell, Peter Hunt and Jon Cook of ABB.
ABB Consulting were the headline sponsor of the first HAZARDS AP symposium in Kuala Lumpur. It was jointly organised by the Chemical Industries Council of Malaysia (CICM) and the IChemE. During the event, ABB presented four technical papers by Ken Bell, Allen Ormond and Jon Cook. With over 230 attendees, the symposium was very well attended with delegates from companies such as Petronas, Syngenta, Shell, BASF, DuPont, Talisman, Huntsman, ConocoPhillips and Orica.
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PEL goes back to school! A new initiative has been undertaken to provide undergraduates access to PEL for their final year projects. The universities of Cambridge, Heriot Watt, Newcastle have so far joined the scheme. PEL training In response to the overwhelming requests from users, two physical properties masterclasses and two Open PEL training courses have been presented in ABBs offices at Belasis and Daresbury. Users from INEOS Chlor, Mexichem, Lucite, Sabic, Fujifilm, Urenco, Worley Parsons, Teijin Films, Huntsman Tioxide, Invista, Johnson Matthey, and ABB attended. Such was the excellent feedback that these courses have now been scheduled for 2012. www.tinyurl.com/es-seminars ProvueDB.net grows in popularity This new product extends the successful desktop system for creating and controlling datasheets with the ability to access them from anywhere in the world - through your normal browser. Create your datasheets in China, check them in the UK, and approve them in Houston! There is nothing to download or install, and you get the latest updates automatically. Add to this the ability to transfer your existing databases from the desktop, instant access to all previous revisions, and an audit trail for each field on each datasheet and the package becomes pretty irresistible. CAPRE This is a new development designed to help engineers with pressure relief calculations. It is a suite of important, commonly-used pressure relief calculations for flexible use within Excel. CAPRE (pronounced CAPR-i) stands for CAlculations for Pressure Relief in Excel. It will deliver a set of validated, documented, and secure calculations all with the same user interface making them easy-to-use and readily accessible. Initially CAPRE will be accessed from Microsoft Excel. In the longer term CAPRE would also be accessible from PEL Relief and possibly the internet and other systems such as MathCAD and Python. This is a short term development project and we plan to release CAPRE at the next PEL Roadshow targeted for early 2012. If you would like to get involved in the development for this exciting new product please do not hesitate to contact us. We couldnt have designed this project in France so effectively without ProvueDB.net Carolyn Potter, Senior Process Engineer, Croda, UK For further information about PEL please visit: www.pelsoftware.com PEL Support Services +44 (0)1925 741126
Peter Hunt, ABB, (left) and Steve Elliott, CIA (right) with award winner Ian Williamson, Syngenta.
ABB were the Chemical Industry Association (CIA) awards headline sponsor and also sponsored the prestigious Manufacturing and Resource Efficiency Award. This years winner was Syngenta, based in Grangemouth.
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Conferences
Leeds Manchester Manchester London Manchester
Improving Business Performance Integrity Management Pressure Relief Process Safety Management Shutdowns and Turnarounds
27th June 27th November 11th - 12th December Seminars 21st February 28 th February 7th March 8th March 15th March Lunchtime forums 12th January 13th January 19th January 20th January 27th January 2nd February 3 February
rd
Conferences are major industry forums focusing on key topic areas. Please contact us if you would be interested in presenting at any of our 2012 conferences.
Delivering Projects in a Live Operating Plant Learning from Buncefield Hot Topics for Power Generation Asset Closure Alarm Management in Practice
Seminars
Seminars are focused on industry hot topics and include inputs from external speakers.
Alarm Management - ISA 18.2 vs EEMUA 191 Human Factors in Maintenance Risk Based Inspection - Quantitative or Qualitative Living with Corrosion Automation Legacy Migration - How to Start After the Energy Audit - Where Next? HAZOPs Only Reduce Risks When the Actions are Done! Inspection is More than PSSR Assessing Your Human Factors SMART Decommissioning
Grangemouth Teesside Aberdeen Grimsby Daresbury Grangemouth Teesside Hull Huddersfield Daresbury
Lunchtime forums
Lunchtime forums provide an update on key industry topics and share best practice.
17th February 23rd February 24th February Webinars 18th January 22nd February 21st March 18 th April 16th May Training courses 11th January 19th January 31st January 8 th February 8 February
th
Webinars
Webinars are focused on industry hot topics and are accessed over the web. A full list of all the above events is available at: www.tinyurl.com/es-seminars
Growing Old Gracefully! - Challenge of Ageing Assets Making Change Work Is Your Electrical System Discriminating? HAZOPs Only Reduce Risks When the Actions are Done! Human Factors in Maintenance
An Engineers Guide to DSEAR Human Factors Incident Investigation Hazard Study Awareness* Electrostatics Ignition Hazards* Mechanical Legislation Awareness SIL Awareness for Control / Electrical Technicians Essentials of Pressure Systems* IEC 61508 / 61511 SIL Determination* Achieved SIL Maintenance and Reliability Improvement Pressure Relief* Risk Based Inspection Project Management in the Process Industries Pressure Relief* Pressure Relief* Human Factors in the Workplace
Manchester Manchester Manchester Grimsby Edinburgh Cardiff York Frodsham Manchester Aberdeen Bristol Manchester Teesside Australia Singapore Manchester
Technical training
Training courses provide in-depth knowledge on key subjects as part of an engineers professional development. A full list of training courses is available at: www.tinyurl.com/es-courses
16th February 21st - 22nd February 7th - 8th March 13th - 14th March 13th - 14th March 13th - 15th March 20th - 21st March 21 - 22
st nd
March
All of these events are organised and delivered by ABB Consulting. For more information on: Seminars please contact Deborah Law Tel: +44 (0)1642 372029 E-Mail: deborah.law@gb.abb.com Training courses please contact Jackie Kendall Tel: +44 (0)1642 372121 E-Mail: jackie.kendall@gb.abb.com * IChemE approved training course
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Further news
Ken Bell and Brian Hudson, ABB, (centre) with delegates from the TDD awareness training.
PTT Public Company Limited (PTT PCL) or just (PTT), is a Thai state-owned SET-listed oil and gas company. Formerly known as the Petroleum Authority of Thailand (PTT), it owns extensive submarine gas pipelines in the Gulf of Thailand, a network of LPG terminals throughout the Kingdom, and is involved in electricity generation, petrochemical products, oil and gas exploration and production, and gasoline retailing businesses.
Technical Consultancy.
ABB Consulting provides technical consulting and engineering services to improve performance in the areas of compliance, operations and engineering to customers in the chemical, petrochemical, oil & gas, power, pharmaceuticals, metals and consumer industries worldwide. We offer expertise in the following areas: Environmental services Functional engineering Industrial energy efficiency Inspection Integrity management Operations improvement Process safety Project services Technical software Technical training
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ABB Consulting Tel: +44 (0)1925 741111 E-Mail: contact@gb.abb.com
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