SIMOPS For Common Cooling Seawater System Phase-3

SIMOPS - Seawater cooling system

The main objective of SIMOPS study is to ensure that all potential hazards and risks pertaining to production and construction activities pertaining to the scope of the project are identified and scheduled properly and the safety of personnel and protection of equipment and the environment is ensured. The risks associated with simultaneous operations can be eliminated, minimized or managed through proper planning, communication and supervision

The Objective of Common Cooling Seawater System Phase-3 Project is to extend the seawater supply and return headers for NFE Project common RO Plant by installing main cooling water pumps at existing Pump House and other associated facilities. The project is also required to make suitable provisions for end users. The scope of the project essentially includes the design, supply, procurement, construction, installation and commissioning of the following components, but not limited to:

  • New Main Sea Water Pumps
  • New Rotary Drum Screens
  • Interconnection of Existing Pump House manifold
  • Supply Headers from the existing main seawater supply headers to the end user, battery limit.
  • Return Headers from the end user at battery limit to the existing main seawater Return Headers.
  • Minimum flow bypass lines at Corridor A between proposed NFE supply headers and return headers.
  • Minimum flow bypass lines at Corridor E between existing QSGTL & Barzan supply headers and return headers.
  • Discharge piping including anchors, rubber Bellows, combined Check Valves and Isolation valves from New CW pumps to the existing Pump House manifold.
  • New Electro Chlorination package to be installed at the existing chlorination building near  Pump House.
  • New seawater filter for the Electro Chlorination package and coarse filter
  • Extension of existing Electro Chlorination dosing system for the proposed facilities at Pump House.
  • New Variable Speed Drive System (VSDS) transformers, VSDS drive and Electric motor for the proposed pumps at Pump House.
  • New Rectifier Transformer unit and DC bus ducts for the proposed Electro Chlorination package
  • All the required field and control room instrumentation for the proposed facilities and integration of the same with the proposed / and existing control system.
  • New Local Lot Control Center (LLCC) building for the proposed facilities to monitor the facilities at the end user battery limits and the piping corridor.
  • All civil and structural works including grading, excavation, back filling, compaction, foundations, fencing, gates, RCC and asphalt paving and other miscellaneous works pertaining to roads, road crossings (RC), pipe bridges, above ground pipe corridors, drainage system and maintenance tracks.
  • Extension of existing Pump House EOT crane track and provision of new maintenance platform.
  • New Analyzer House at Pump House and Analyzer Room
  • Provision of 44 Nos. of manholes on existing CW pipelines at Valve pits

SIMOPS is mainly concerned with “manned operations”. ‘Automated’ systems do not need to be considered normally.In order to determine if the “hazard” from one operation that impacts another concurrent operation is a source of an “Unacceptable Risk”, the Frequency (F) of the hazard’s occurrence and the Severity (S) of its impact are to be concluded from the project specific Hazard Matrix.

When the hazard is concluded to be a source of “Risk”; i.e. falling outside the ALARP and within the “Unacceptable Region” of the Matrix, Risk Management for the purpose of a SIMOPS exercise could be achieved by either one of the following two courses of action:

  • Hazardous Activities impacting each other could be avoided if either one of the concurrent activities is “staggered”; i.e. carried out at different timings. This approach implies rescheduling of the SIMOPS plan; or
  • If ‘staggering’ of SIMOPS is unachievable or uneconomical, provide the necessary Safety Controls; i.e. ‘Layers-of-Protection’ and/or ‘Barriers’ that will ensure having the risks to fall within their ALARP region.

Simultaneous Operations (SIMOPS) refers to the concurrent execution of multiple tasks by multiple functional groups at a shared location. In the Oil & Gas and Petrochemical sectors, the concept of SIMOPS is employed when various activities, including construction, commissioning, start-up, and production operations, are conducted concurrently.

In this context, alongside the inherent dangers associated with each individual task, there is a potential for additional risks to arise as a result of concurrent execution within the same vicinity. 

  • To identify any additional hazards that may be introduced as a result of the SIMOPS.
  • Assessing the relevant level of risk
  • Verify the adequacy of the planned control measure
  • Identifying additional risk reduction measures; and
  • Contribute insights to enhance the Permit to Work process by incorporating supplementary control measures.

During SIMOPS Workshop, the participants were guided by a SIMOPS facilitator to undertake the following steps. The designation of an accountable individual for the execution of identified counter measures Furthermore, as an additional component, the workshop provided propaedeutic documentation in the following manner:

  • The revised timetable for construction, pre-commissioning, commissioning, and start-up operations is provided.
  • Process Flow Diagrams (PFD) and Piping & Instrumentation Diagrams (PID) are included.
  • Plant layouts and equipment layouts;
  • Material Safety Datasheet (MSD) of handled substance;
  • Hazardous area classification drawings;
  • This section provides an in-depth analysis of manning level and worker distribution in areas where simultaneous operations (SIMOPS) are being conducted.
  • Layout showing Permit to Work areas;
  • Layouts showing location of temporary construction devices such as crane, diesel generator, welding machines, scaffolding, etc.; and
  • Quantitative Risk Assessment (QRA) and consequence analysis developed during detailed design (if available).

First step of the SIMOPS workshop is the identification of SIMOPS scenario, type and schedule of activities to be performed simultaneously. According to starting date of energy source (hydrocarbon, pressure, power) introduction in a certain unit, specialists from construction and commissioning pointed out the activities planned to be executed in the same area involved by introduction of energy source.

A thorough hazard identification process was conducted for each simultaneous operations (SIMOPS) scenario. The discipline specialists furnished comprehensive details pertaining to the scheduled activities in conjunction with the establishment of a connection to the power source for the feed.

This information encompassed the commencement date, the specific tools required, the manpower allocation, the impacted area, and the anticipated duration, among other relevant factors.

The implementation of the structured guidewords approach facilitated a comprehensive analysis, leading to the accurate identification of hazards linked to each SIMOPS scenario. Particular attention was given to the additional hazards coming from the contemporary execution of the two activities.

SIMOPS workshop concluded that all project activities will be permissible under existing QP work permit protocols taking necessary safety measures as per WP requirements. No SIMOPS activities required any additional risk assessment and no SIMOPS activities were identified which are not permitted.

The high-risk category entails a level of risk that poses significant potential for unacceptable losses to individuals, assets, the environment, or reputation. In order to mitigate this risk, it is imperative to either eliminate the hazard entirely or promptly reduce the risk to a tolerable level.

The risk level is classified as medium, which means it is deemed acceptable but requires effective management to ensure it is kept as low as reasonably practicable (ALARP). This entails implementing measures to reduce the frequency and/or severity of hazardous events to a level that is reasonably achievable. The term “reasonably practicable” indicates that the proposed solution should be feasible to implement and that the benefits should outweigh any associated drawbacks and costs.

Low risk refers to a situation that is deemed acceptable and does not necessitate immediate action. However, it is acknowledged that corrections may still be made as resources become available. Two different risk levels will be assessed. The first one is known as “Initial Risk” was set without considering any risk reduction measures, and the second one known as “Residual Risk”, taking credits from control measures and operating procedures existing or planned to be carried out during the execution of the concerted activity.