Total Lindsey Oil Refinery
Project details
Client challenge
The existing compressor system was not fully integrated, relying on two hired trailer mounted diesel driven compressor units, separate Breathing Air Purification units and back-up cylinders. It was also reported that the existing compressor units required significant ongoing rental and service maintenance costs with servicing required every 210 running hours. This was an issue because the Client required a system to provide continuous duty.
In addition, the system included bottled medical breathing air as a back-up but this system was cumbersome and partly fallen into disrepair. The Client justified the project on economic grounds but there was also a need for a more integrated approach to assure safety integrity and reliability and the risks were controlled to ALARP.
Safewell has a track record in providing fully integrated compressed air systems in accordance with BS EN012021:2014 offering high safety integrity, reliability and long-term return of investment.
The Client approached Safewell to design a solution based on their user requirements. Safewell discussed the requirements in detail with the client representatives to discover and diagnose the precise requirements and design a fully integrated turnkey solution.
Diagnosis and Design
The Solution consisted of a Skid Mounted Compressed Breathing Air System complete with a modern, compact and energy efficient electric compressor and the proven ALARP Guaranteed ALG Breathing Air Purification System.
The project scope also included the design and manufacture of the Compressed Air Intake Inlet Spool Piece complete with state of the art Gas Detectors for Hydrogen Fluoride, Hydrogen Sulphide and Methane. The design included a safety instrumented function with a validated Safety Integrity Level (SIL IEC 60508) to automatically shutdown the compressor when gas is detected at the inlet. In addition, a GRP Building was designed and manufactured to house the Breathing Air Skid offering full protection from harsh environments. A 3880 Litre Breathing Air Storage Receiver was also manufactured and installed on site.
Safewell worked with the client right from the start, providing detailed involvement in the Factory Acceptance Test and site commissioning.
Lifecycle Value
Safewell continues to work with the Client to provide the quarterly lifecycle safety service and 24/7 support. The Client now has a fully integrated on demand Breathing Air System with a high margin of safety. The risk of exposure to dangerous gases in the ambient air (H2S, H2F, CH4) has been mitigated and the service requirements and costs have been reduced. The system now requires a service every 2000 hours as opposed to every 210 hours allowing this system to be operating 365 days a year with a lower lifecycle cost.
Breathing Air Compressor
We offered a bespoke solution to TLOR integrating our Standard ATEX Breathing Air Compressor Design. If this is of interest to you, please do not hesitate to contact us.
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