Zero Incident Start-up

Zero Incident Start-up Techniques for Oil and Gas Instrumentation and Flow Meter Services

Achieving a "Zero Incident" start-up in the oil and gas industry

Achieving a "Zero Incident" start-up in the oil and gas industry is paramount for safety, operational efficiency, and environmental protection. This document outlines key techniques and best practices for instrumentation and flow meter services to ensure a smooth, incident-free commissioning phase.

1. Pre-Commissioning Planning and Preparation

Thorough planning is the foundation of a successful start-up. This phase involves meticulous preparation and verification of all instruments and systems before they are brought online.

1.1 Design Review and Verification

P&ID Review: A detailed review of Process and Instrumentation Diagrams (P&IDs) to ensure all instrumentation and flow meters are correctly represented and integrated into the system design. Verify tag numbers, line numbers, and instrument specifications.
Specification Alignment: Confirm that installed instruments and flow meters match the design specifications and are suitable for the operating conditions (pressure, temperature, fluid type, hazardous area classification).
Loop Diagrams: Validate all control loop diagrams to confirm correct wiring, signal paths, and interlocks.

1.2 Vendor Documentation and Training

Documentation Review: Ensure all vendor manuals, data sheets, calibration certificates, and maintenance procedures are readily available and understood by the commissioning team.
Specialized Training: Provide specific training for personnel on critical or new instrumentation and flow meter technologies. This can be conducted by vendor specialists or in-house experts.

1.3 Site Readiness and Installation Verification

Mechanical Completion: Verify that all mechanical installations related to instrumentation, such as impulse lines, thermowells, and mounting brackets, are complete and meet design standards.
Electrical and Wiring Checks: Conduct thorough electrical continuity checks, insulation resistance tests, and ensure proper grounding and shielding of instrument wiring.
Pneumatic and Hydraulic Connections: Verify correct and leak-free installation of pneumatic and hydraulic lines to control valves, actuators, and other instruments.
Physical Inspection: Visually inspect all instruments and flow meters for damage, correct orientation, proper labeling, and accessibility for maintenance.

2. Calibration and Configuration

Accurate calibration and correct configuration are crucial for reliable performance and safety.

2.1 Bench Calibration

Primary Standard Calibration: All critical instruments should be calibrated against certified primary standards in a controlled environment before installation.
Documentation: Maintain detailed records of all calibration results, including "as found" and "as left" data.

2.2 Field Calibration and Loop Checks

Wet Calibration (Flow Meters): Where feasible, conduct wet calibrations for flow meters using the actual process fluid or a suitable substitute to verify accuracy under operating conditions.
Loop Checks: Perform comprehensive loop checks for all control loops, from the field instrument to the control system (DCS/PLC) and back to the final control element. This includes signal simulation, alarm testing, and interlock verification.
HART/Foundation Fieldbus Configuration: Verify correct configuration of intelligent instruments using appropriate communication protocols.

2.3 Safety Instrumented System (SIS) Testing

FAT/SAT for SIS: Conduct thorough Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for all Safety Instrumented Systems, ensuring safety functions operate as designed and meet required Safety Integrity Levels (SIL).
Functional Testing: Perform functional tests on all safety interlocks, emergency shutdown (ESD) systems, and safety valves to confirm their fail-safe operation.

3. Pre-Start-up Safety Review (PSSR)

The PSSR is a critical step to ensure that all safety, operational, maintenance, and emergency procedures are in place and understood before introducing hydrocarbons or hazardous materials into the system.

Checklist Completion: Utilize a comprehensive PSSR checklist covering all aspects of instrumentation, controls, safety systems, and operational readiness.
Multi-Disciplinary Team: Conduct the PSSR with a team comprising representatives from operations, maintenance, engineering, and safety.
Action Item Resolution: Ensure all identified deficiencies or outstanding actions from the PSSR are addressed and closed out before start-up.

4. Start-up and Commissioning Procedures

Detailed and well-executed start-up procedures minimize risks and ensure a controlled transition to operational status.

4.1 Step-by-Step Procedures

Clear and Concise Procedures: Develop step-by-step start-up procedures for each instrument, loop, and system. These procedures should be clear, concise, and easily understood by all personnel.
Permit to Work (PTW) System: Strictly adhere to the PTW system for all start-up activities, ensuring proper authorization and hazard control measures are in place.

4.2 Controlled Introduction of Process Fluids

Gradual Pressurization: Introduce process fluids gradually, monitoring for leaks, pressure anomalies, and instrument responses.
Vent and Drain Management: Ensure proper venting of air and draining of condensate to prevent cavitation or hydraulic shock.

4.3 Performance Monitoring and Tuning

Live Data Monitoring: Continuously monitor instrument readings, control loop performance, and process parameters during start-up.
Control Loop Tuning: Optimize PID control loop tuning parameters to achieve stable and responsive process control.
Alarm Management: Verify alarm setpoints, priorities, and functions, ensuring they are appropriate for operational conditions.

5. Post-Start-up Verification and Handover

Even after initial start-up, ongoing verification and a formal handover are essential.

5.1 Post-Start-up Performance Checks

Baseline Data Collection: Collect baseline performance data for all critical instruments and flow meters to serve as a reference for future maintenance and troubleshooting.
Trending and Analysis: Trend key process variables and instrument outputs to identify any anomalies or drift.

5.2 Documentation Updates

"As-Built" Drawings: Update all P&IDs, loop diagrams, and instrument lists to reflect "as-built" conditions.
Maintenance Records: Ensure all calibration, configuration, and maintenance records are accurately updated and stored in the Computerized Maintenance Management System (CMMS).

5.3 Formal Handover

Operations and Maintenance Training: Conduct a formal handover to operations and maintenance personnel, providing comprehensive training on the new or modified systems.
Maintenance Strategy: Develop and implement a robust preventive maintenance strategy for all instrumentation and flow meters.

Conclusion

A Zero Incident start-up for oil and gas instrumentation and flow meter services requires a holistic approach, encompassing rigorous planning, meticulous preparation, thorough testing, and a strong safety culture. By adhering to these techniques, organizations can significantly reduce risks, optimize performance, and ensure the long-term reliability and safety of their operations.