PETROLEUM PROCESSING PLANTS—TECHNICAL SURVEILLANCE PROGRAM

Abstract

On behalf of itself and BHP-B, Esso operates offshore production platforms in Bass Strait, a crude stabilisation and gas processing plant at Longford and a LPG fractionation plant at Long Island Point, Victoria. The Technical Surveillance Program for these facilities is implemented at both the Operator and Engineering levels. The program has been enhanced by building on existing DCS process control and process information (PI) systems and through development of a more structured engineering monitoring system. The enhanced program continues to register tangible benefits in integrity, product quality, recovery, efficiency and reliability and capacity.

At the operator level, the process is monitored continuously, assisted by process alarms to maintain the plant within the normal desirable operating zone. Safe operating limits define the outside boundary of the safe operating envelope which is secured with shutdown and other automatic protective devices. Alarm and limit conditions associated with these parameters have been incorporated into the DCS control system with pre-defined operator responses appearing automatically on the screen if the condition is reached.

At the engineering level, the surveillance program is a systematic periodic monitoring process focussing on optimum performance and continuous improvement. It is structured using the elements of a management system. Within this framework, engineering spreadsheets have been developed with direct links to process data via process information system software. The spreadsheets assist plant engineers to efficiently monitor the key performance variables; they also pre-define the acceptable operating range, calculate statistical performance, highlight deviations and hyperlink back to the PI system for more detailed troubleshooting. Day-today deviations and performance improvements are fed back and reviewed at the working level, more significant issues are formally investigated and reviewed with management. Key data and overall performance is summarised monthly, and formally reviewed by plant and engineering management.