Modernization: Pump Seal System Upgrade

Configuring centralized seal plans for pumps at an oil and gas plant

Overview

A recent HAZOP audit identified safety deficiencies in the client’s pump systems, which handled critical flammable fluids. InnoTech implemented enhanced seal monitoring and safety standards, leveraging their expertise from previous projects. Challenges included prolonged timelines, changing project managers, and inconsistent documentation. Through meticulous communication and systematic use of commissioning tools, InnoTech overcame these hurdles. The upgraded systems now provide operators better control and troubleshooting capabilities, significantly boosting safety and reliability.

Situation

The HAZOP recently conducted at the client’s site revealed that their pumps did not meet the safety requirements. The technology was meant to monitor the pump seal integrity to prevent sizeable releases of fluid, but it was not performing adequately. The pumps in question pumped de-nuded lean oil and frac reflux which are highly flammable, so should they leak, the hazardous fluid could result in a safety risk to people, the environment and the client’s facility.

The client needed to bring these seals back up to the safety standard.

Why InnoTech?

Our previous help in creating standards and processes for similar projects made InnoTech the best choice for the job.

Actions Taken

The InnoTech team configured the PLC and DCS systems connected to the pumps to ensure that:

• If the seal fluid level dropped below a certain point, the operator would be notified to top it up. The fluid needs to be topped up regularly, so the team recommended a more common seal fluid that is less expensive and is more commonly available.
• The temperature does not exceed or drop below a certain level.
• The pressure does not exceed or drop below a certain level.
• The pump shutdown and alarm were functioning properly as per the shutdown keys and logic narratives.
• That the valves were opening and closing properly.

From this, they created and implemented a site PLC and DCS standard and configured the systems according to it. This standard was also adapted for five of the client’s other pump seal systems. Previous projects completed by InnoTech for the client helped in the development of these standards.

Challenges

The following are the challenges the team encountered throughout this project:

Engineering drawing inconsistencies

The prolonged timeline caused the drawings to be delivered at sporadic intervals, resulting in some inconsistencies in how the drawings were done.

	Timeline The project was completed over a prolonged period due to requests from the client to hold off on certain parts. The team kept comprehensive notes to minimize rework each time the project resumed.
	Change of PM The client’s Project Manager was replaced part way through the project. Being the remaining source of all project knowledge up to that point, InnoTech was relied upon to facilitate a smooth transition for the new PM.
	Engineering drawing inconsistencies The prolonged timeline caused the drawings to be delivered at sporadic intervals, resulting in some inconsistencies in how the drawings were done.
	No-notice site support When the project was on pause, the client sometimes reached out to the team for site support without notice. This created additional challenges as the same resources were not always available and substituting a resource can create greater inconsistency and cost inefficiencies.

To overcome these challenges the InnoTech team took great care in communicating thoroughly with all stakeholders, to ensure all were kept up to date. The commissioning tools also helped with this communication, as they acted as a road map, keeping track of what was complete and what had yet to be done.

Results

The new configuration improves the feedback the operators receive from the control system, increasing visibility and simplifying troubleshooting.

There is increased safety and reliability for the pumps. With accurate monitoring equipment and automations, the risk of leakage and liquid spills is reduced.

Lessons Learned

The implementation and commissioning schedule has significant impacts on cost efficiency and documentation consistency of a project. Ensuring that it is maintained can be the key to delivering the project within budget.
Unforeseen complications can arise on any project, so regardless of the project expectations, well-kept documentation acts as a reference at a minimum, and has the potential to be a vital resource in outlying circumstances. Notes can be kept in online notebooks, accessible to the whole team (like Microsoft OneNote on a shared drive) for input and keeping up to date with the project.

Discussion Questions

The old standards for ensuring that pump seals were well monitored and maintained, are not as extensive as the standards are now, have you recently reviewed your site pump seal standards?

Or, if you don’t have a seal standard in place, InnoTech can help!

Talk to one of our experts