Questar Pipeline Provides natural gas transportation and underground storage services in UT, WY and CO More than 2,500 miles of pipeline Key Facilities Clay Basin Storage Facility = Largest underground storage reservoir in the Rocky Mountains Overthrust Pipeline in Southwestern Wyoming Southern Trails Pipeline that runs from NM to CA 50% stakeholders of the White River Hub
Questar Core Service group performs preventive maintenance, minor overhauls, major overhauls, engine and compressor analysis, vibration analysis, portable emissions testing, troubleshooting & emergency repair on: 26 stand-by generators 12 Primary power generators 22 reciprocating Natural gas compressors 34 Turbine-fired Centrifugal natural gas compressors Also included in our duties are auxiliary equipment for 48 Questar Compressor stations, meter facilities, and natural gas processing plants. This equipment includes pumps, regulators, fans, and electric motors In addition to this equipment we also assist with maintenance, repair, and testing of 9 additional pieces of compression/power generation equipment for Questar Gas, which is the distribution side of our company This equals about 5800 horsepower in power generation, and 240,000 horsepower of natural gas compression
Management recognized a need for more complete maintenance strategy and implemented a Rotating Equipment Plan in 2009. This plan consisted of both a written maintenance plan and a record-keeping requirements. Although an improvement, it was evident that there were some lingering problems, especially with the record-keeping portion of the plan.
1. Mechanics would fill out paperwork days or weeks after coming in from the field. 2. Paperwork sometimes was incomplete. Missing data like hours and dates of maintenance causing admin to have to track information down Personnel were using the wrong forms to document the work 3. After the mechanics finished the forms, Admin personal entered the paperwork into the rotating machinery station files
If the paperwork was completed it was placed in the R.E.M.file for storage The task was completed and when the time came due to reissue the task we started the process again. Maintenance event triggered either by management or personal manually keeping records as to when the event was due. Assigned to a individual for completion The chain is easily broken, with no checks to confirm the maintenance event or maintenance paperwork was being completed. Hopefully personal finished the event and correctly completed the paperwork
Maintenance being complete without regular or organized frequency resulted in over maintenance, under maintenance, and missed maintenance events. Despite a serious commitment from management maintenance records were not consistently recorded.
It was difficult to compile usable information including: Date of last maintenance Trends Information about maintenance events Reoccurring problems not to mention the complete inability to readily submit maintenance records for NESHAP or other regulatory obligations. Questar needed a system where information within the stored records was accurate, and more usable.
Emergency Engines: Inspection interval is 500 hours or annually Engines < 500 HP: Inspection interval is 1440 hours or annually Engines > 500 HP: Inspection interval is 2160 hours or annually Alternatively, we can use an oil sample monitoring program in lieu of oil changes It was very apparent that record keeping was not adequate to ensure Quester's commitment to compliance with NESHAP maintenance regulations.
In 2012, We started researching maintenance record-keeping databases Management team employed the help of the Business System group to help select a process for streamlining the maintenance record keeping. The business system group had previously aided the Environmental group in successfully employing ACTS to help track GHG emissions requirements. They approached Ecocion about tracking and assisting in maintenance records. Initially the ACTS software didn t have the ability to generate tasks using engine hours as a trigger for a event. The folks at Ecocion demonstrated interest developing the ability within the ACTS software to generate an hour based trigger. In late 2012, Ecocion developed their software to where we could generate maintenance events based on a hourly requirement. We committed to using the ACTS Software to track and schedule our maintenance events.
2013 Activities ACTS Configuration (the database was mostly complete) Training SCADA Data Import (fully functional July 2013) ACTS Data Review and Validation, with communication with Environmental Resulted in a much more accurate and robust data base that will benefit all ACTS users. The corrected database also gives a very complete list of equipment that resides in the Questar system and will become the source for looking up a serial number or other information about a piece of equipment that Questar owns and operates.
We updated the maintenance forms to be NESHAP Compliant. This meant making changes to ensure that personnel were completing the NESHAP-mandated maintenance tasks at the required intervals. Since ultimately maintenance practices shouldn t be about feeding bureaucracies, we also modified most forms to ask that maintenance personal inspect certain events that were by definition reoccurring problems. The following are examples of inspection items from our maintenance forms based on the need for in-depth inspection rather than a regulatory mandated inspection. Belts visually inspect belts for cracked, loose, or frayed belts. (We ve had problems with belts breaking between maintenance intervals) Check Throttle Linkage for excessive wear. (Throttle linkage is often overlooked and worn linkages especially on generators will cause poor load response. Eventually resulting in shutdowns) Visually inspect ignition system for cracked, or loose wires. Spark plugs are changed often on our equipment but wires, Coils, and related primary wiring are often overlooked.
1. Low HP Generator Maintenance 2 week (meter run generator maintenance) 2. Low HP Generator Maintenance 8 week Addendum (meter run generator maintenance) 3. Generator Maintenance 750 hour (generator maintenance event for medium sized units) 4. *Generator Maintenance 2160 hour Addendum (additional quarterly maintenance for medium sized units) 5. High HP Generator 1000 hour (maintenance for high horsepower primary power) 6. High HP Generator 2160 hour Addendum (additional quarterly maintenance for high horsepower engines) 7. Caterpillar 3412 generator maintenance a form created for additional maintenance requirement for this this specific model of generators. 8. *Stand-By Generator Yearly Inspection (generators that don t exceed 25% utilization) 9. *Yearly Compressor Inspection form (for compressors that don t exceed 25% utilization. The primary driver for this inspection is NESHAP compliance) 10. *KVSR 2000 Hour Inspection (The primary driver is to stay in compliance with NESHAP records) 11. KVSR Yearly Inspection (off season maintenance for KVSR integral compressors) 12. GMV12 2000 Hour Inspection (required quarterly maintenance) 13. GMV 12 8000 Hour Addendum (required yearly maintenance on the GMVH-12, Coleman #1) 14. Caterpillar 2000 Hour Inspection (required quarterly maintenance) 15. Separable compressor maintenance form 16. Stand alone fan 8000 Hour Inspection *These forms were created or highly modified for NESHAP Compliance
Paper work is completed and submitted by personal. If responsible personal fails to submit the paperwork a reminder will be sent to the mechanic to submit paper work. If the paper work is still not completed management is notified that paperwork is not complete When the paperwork is submitted admin personal will close the task in ACTS. Upon Closure Acts will automatically schedule the task to be completed again. Acts Software triggers Maintenance event by either a engine hours or a time based requirement., or both ACTS provides a system of checks to ensure all events are being completed The maintenance event is either assigned to the Core service supervisor or to the personal in charge of an defined area Since maintenance is scheduled by ACTS, there will be no event that is missed or overlooked. The eventi s actually triggered slightly before it is due to allow maintenance to be scheduled.
The Maintenance event is triggered automatically each time, by equipment runtime or a calendar-based requirement, or both. ACTS ensures that all maintenance events are completed by sending out emails to ensure that the event is completed in a proper manner. The next maintenance event is automatically rescheduled when the job is closed and the paper work is submitted. The ACTS database stores equipment information and is readily available for all users to access. Our Environmental Department will have access to all maintenance records and will be able to produce records when needed for NESHAP or other regulatory inspections.
Maintenance events are being completed on the new forms. We ve introduced the upcoming changes to maintenance personnel. The priority is to have at least 1 NESHAP compliant maintenance record for each reciprocating engine by October 1 st, 2013. We ve introduced the Reciprocating Equipment Maintenance Forms at current time to ensure we would have adequate time be compliant with NESHAP by the due date.
Administrative Personnel have entered all maintenance forms as ACTS Inspections. This enables our ability to track information and readily produce records LOW HORSEPOWER GEN SERVICE, 2 WEEK This form is to be used for generators under 50hp, primarily Lister, small Onan packages. INTERVAL 2 weeks Form # 0101 UNIT ID Location / Station Name Engine Serial Number ENGINE HRS PRELIMINARY SERVICE REQUIREMENTS, sec 1 Review downtime and check with operations to identify ongoing problems. Check off. Review current Work Requests and Equipment Analysis Report to identify maintenance needs. Check off. ON-LINE INSPECTIONS, sec 2, Perform inspections while unit is running. Check oil pressure. Record oil pressure PSI Air filter, cleaner, and air Inlet piping. Inspect, replace, or repair as necessary. Check engine coolant temp. Record temp in degrees F. TEMP Check Catalyst pre and post temps. Record in Pre cat Post cat degrees F. temp temp Check Catalyst Differential Pressure. Record DP in "InH20" DP Check HZ. Hertz should be set at 60hz. Adjust as required. HZ Check and Record Amps. (Use gauges to check amps) Leg 1 Leg 2 Leg 3 Check and Record voltage. (Use gauges to check voltage) Leg 1 Leg 2 Leg 3 OFF-LINE INSPECTIONS, sec 3 Change oil and filter. Check oil level on REN barrel. Call operations, or fill tank. Belts visually inspect belts for cracked, loose, or frayed belts. Replace or repair as needed. Check Coolant Level. Check Throttle Linkage for excessive wear. Visually inspect ignition system for cracked, or loose wires. Replace as needed. General Condition of unit. Observe General condition of unit. Troubleshoot oil leaks. Identify what is needed for repair of problems. MAINTENANCE NOTES, sec 4 Record any repairs made. Compression Technician Signature Date
ACTS Regulations, Facility Associations, and Equipment Associations are being assigned, with a goal of having ACTS tracking all maintenance events by September 1 st, 2013
We will utilize ACTS for scheduling and all centrifugal compressors preventive maintenance and storing the appropriate records. Our goal is November but if the reciprocating process is moving smoothly we may be online with these forms even sooner.
The task was completed and when the time came due to reissue the task we started the process again. Maintenance event triggered either by management or personal manually keeping records as to when the event was due. If the paperwork was completed it was placed in the R.E.M. file for storage OLD PROCESS CONTAINED MULTIPLE WAYS FOR MAINTENANCE EVENTS TO GET LOST AND NOT FINISHED!!!!!!! Assigned to individual for completion Hopefully personal finished the event and correctly completed the paperwork
New process with ACTS eliminates a lot of problems with the previous workflow
Individual uses a tablet or Smart phone to record the maintenance events and closes the job their self. The event is automatically rescheduled and reset for when the equipment reaches the required interval. Maintenance event triggered by ACTS and automatically informs responsible party that he/she has a task due in ACTS Individual schedules the task and goes to the field to complete the inspection or maintenance event. Utilizing a tablet or smart phone simplifies the work flow and eliminates admin personal from having to close the event. The result is less paperwork and less man hours to complete the event.
Use ACTS to keep track of all Maintenance events including unscheduled maintenance with the use of the work order module that currently is in the software. Utilization of ACTS to create automated log sheets that would be utilized by operations instead of the paper log sheets currently utilized. This would eliminate paper record storage and make the daily logged data much more available for review. Utilize Acts to keep track of the large ticket inventory items such as fuel valves dry seals, and buffer seals. Possibly even utilize acts to maintain station inventory. Utilize ACTS to keep track of tooling inventory and the tools location within the system.
Questions?????