Automation Opportunities in LDAR and the P ID Data

Automation Opportunities in LDAR (and the P&ID Data Conundrum) Standards Certification Education & Training Publishing Conferences & Exhibits

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. 2

Audience Poll What type of phone do you use? or 3

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 4

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 Cal 3. 0™ software and Span. Box 3™ – LDAR Monitoring Robots, Puppies or Rainbows 5

LDAR Automation Opportunities LDAR Inventory LDAR Applicability Determinations and P&ID Markup Data Integration and Enhanced Technology Management of Change Leak Repair Scheduling and Tracking 6

Why Automate Manual Processes? 1. 2. 3. 4. 5. 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 7

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) 8

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 1. They are all manually-intensive processes 2. They all involve Piping and Instrumentation Diagrams (P&IDs) 9

The Compliance Foundation What in the world do P&IDs and foundations for houses have in common? 10

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 11

Anatomy Of P&ID: Data, Data 12

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 Auto. CAD 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) 13

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 14

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 15

Manual: LDAR Applicability Determinations 16

Automated: LDAR Applicability Determinations • Use “smart” P&IDs to automate process 17

MANUAL: LDAR FLAGGING Inefficient/Time. Consuming Error-Prone (flagging --> documenting) Housekeeping Issues 18

AUTOMATED: LDAR FLAGGING Smart P&ID Data Leak. DAS™ or Guide. Ware™ Integration • Engineering data is incorporated into smart P&ID™ • Single-click functionality to “push” inventory data into Guide. Ware™ (directly) or Leak. DAS™ database (indirectly) • Saves on inventory/retag technician labor-hours • More efficient data management/reduces potential for errors 19

MANUAL: LDAR TAGGING Tags, although not required by LDAR regulations, are commonly used together with database identification Tags are physically hung in the field according to SOPs Because tags are not accounted for in database, tracking tag inventory is difficult 20

(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 21

MANUAL: LDAR DOCUMENTATION Manually-intensive and onerous Error-prone: relies on LDAR inventory technicians to capture tens or hundreds of thousands of data records Mass-editing of data accomplished through LDAR database manually QA/QC limited to manual review (field and database) - not verifiable directly with P&IDs 22

AUTOMATED: LDAR DOCUMENTATION • Equipment, Stream, Service, Drawing No. etc. is stored in s. P&ID™ • Data is exported from s. P&IDs™ into Guide. Ware™ or Leak. DAS™ Increased Efficiency! s. P&ID ™ Pre-Population of LDAR Database Manual Data-Entry • Data is pre-populated into handhelds for technicians to field-verify 23

Documentation Workflow Smart P&ID LDAR Speciation Document in Tablet 24

Example LDAR MOC Workflow

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) 26

Automated LDAR MOC Tools HA-135 NAPHTHA FEED PUMP 1 A 4 FWA-1 A LUBE OIL PUMP DISCHARGE 269 -1 27

Novel Approach to Identify When MOCs are Put into Service PI tag near newly-added component may indicate if equipment is in hydrocarbon service 28

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” 29

Automated: Repair Scheduling and Data Exchange Maintenance work orders within smart P&ID 30 30

Automated: Repair Scheduling and Data Exchange (cont. ) • Integrating LDAR databases, such as Guide. Ware™ or Leak. DAS™ 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 32

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 33

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 34

Return on Investment: LDAR Applicability Determinations / P&ID Markups 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 35

Return on Investment: LDAR Inventory/Retag Task No. of P&IDs No. of Components Labor Category Flagging Technician - Flag 4 P&IDs per Day Tagging Technician - Hang 250 Tags per Day Documenting Technician - Document 250 Comps per Day LDAR Inventory/Retag 1, 000 50, 000 Bill Rate $50/hr Efficiency Gain 50% Bill Rate $30/hr Efficiency Gain 0% Bill Rate $40/hr Efficiency Gain 50% Time w/o (hrs) 2500 Time w/ 1250 Time w/o (hrs) 2000 Time w/ 1000 Total Savings Cost w/o $125, 000 Cost w/o $62, 500 Cost w/o $60, 000 Cost w/o $80, 000 Cost w/ $40, 000 $102, 500 36

Return on Investment: LDAR MOC 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 37

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. 38

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. 39

Questions? LDAR Inventory/ Retag Fugitive Emissions Estimating Management of Change LDAR Applicability Comp liance Data LDAR QA/QC Don’t Let These Compliance Processes Continue to Chase You 40