Introduction to SIMOPS in Seawater Cooling Systems
Simultaneous Operations (SIMOPS) involve executing multiple tasks concurrently at a shared location, particularly in the Oil & Gas and Petrochemical sectors. The primary objective of a SIMOPS study is to identify, assess, and mitigate risks associated with simultaneous production and construction activities. By implementing proper planning, communication, and supervision, SIMOPS ensures personnel safety, equipment protection, and environmental security.
Project Overview: Common Cooling Seawater System Phase-3
The Common Cooling Seawater System Phase-3 Project aims to extend the seawater supply and return headers for the North Field Expansion (NFE) Project’s common Reverse Osmosis (RO) Plant by installing main cooling water pumps at the existing Pump House. The project scope includes:
- New Infrastructure:
- Installation of new main seawater pumps
- Integration of new rotary drum screens
- Interconnection of the existing Pump House manifold
- Supply & Return Headers:
- Supply headers connecting existing main seawater supply to end users
- Return headers linking end users to existing seawater return headers
- Minimum flow bypass lines at Corridor A (NFE supply & return headers) and Corridor E (QSGTL & Barzan headers)
- Piping & Valves:
- Discharge piping, anchors, rubber bellows, check valves, and isolation valves from new cooling water pumps to Pump House manifold
- Electro-Chlorination System:
- New electro-chlorination package at the existing chlorination building
- New seawater filter and coarse filter for electro-chlorination
- Extension of existing electro-chlorination dosing system
- Power & Control Systems:
- New Variable Speed Drive System (VSDS) transformers, drives, and electric motors for proposed pumps
- New rectifier transformer unit and DC bus ducts for electro-chlorination
- New field & control room instrumentation, integrated with the existing system
- New Local Lot Control Center (LLCC) building to monitor facilities at end-user battery limits
- Civil & Structural Work:
- Grading, excavation, compaction, foundations, fencing, road crossings, pipe bridges, drainage systems
- Pump House EOT crane track extension and new maintenance platform
- New Analyzer House & Room at Pump House
- 44 new manholes on existing CW pipelines at valve pits
SIMOPS Risk Assessment and Management
Key SIMOPS Considerations
SIMOPS primarily focuses on manned operations, assessing hazards where multiple tasks are executed concurrently. A Hazard Matrix evaluates risk levels based on Frequency (F) and Severity (S). The approach ensures:
- Identification of additional hazards from concurrent operations
- Risk assessment and classification (High, Medium, or Low Risk)
- Verification of control measures’ adequacy
- Identification of risk reduction measures
- Enhancement of the Permit to Work (PTW) process
Risk Management Strategies in SIMOPS
If hazards fall within the Unacceptable Region of the risk matrix, the following mitigation strategies are employed:
- Activity Staggering: Rescheduling activities to eliminate risk.
- Safety Controls & Barriers: Implementing necessary Layers-of-Protection (LOP) to bring risks within As Low As Reasonably Practicable (ALARP) limits.
SIMOPS Workshop & Risk Evaluation
A structured SIMOPS workshop was conducted, where specialists reviewed potential hazards using guideword analysis. The process included:
- Hazard identification for each SIMOPS scenario
- Risk assessment before and after control measures (Initial Risk vs. Residual Risk)
- Evaluation of:
- Process Flow Diagrams (PFD) & Piping & Instrumentation Diagrams (PID)
- Plant layouts & equipment placements
- Material Safety Data Sheets (MSD)
- Hazardous area classification
- Permit to Work (PTW) areas
- Construction layout (temporary devices like cranes, generators, welding machines, scaffolding, etc.)
- Quantitative Risk Assessment (QRA) & consequence analysis
SIMOPS Risk Classification
- High Risk: Immediate mitigation required to prevent unacceptable consequences.
- Medium Risk: Managed effectively under ALARP principles.
- Low Risk: Acceptable but subject to continuous monitoring and potential improvement.
Conclusion
The SIMOPS workshop concluded that all project activities comply with QP work permit protocols with necessary safety measures in place. No additional risk assessments were required, and all identified SIMOPS activities were permissible.
By adopting structured risk assessment methodologies, implementing effective risk control measures, and ensuring seamless integration of construction and operational activities, the Common Cooling Seawater System Phase-3 project successfully adheres to safety, reliability, and operational excellence in the oil & gas industry.
