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Experience in PSV Standards, Calculations, Headers, Flares

2015   Wheatstone LNG Plant
Part of his work as SME-Process Safety including validating that flare system calculations demonstrated the HP, LP and Marine systems could handle control valve failures without operator intervention being required.

2010 TurkmenGaz South Yoloten Gas Field
Bob coordinated flare-placement strategy between adjacent processing units to choose safest location in the event of a flare flameout from 4.5% H2S natural gas

2009 Borger Gasoline Benzene Reduction
As Systems Team Lead for distillation units Bob - together with the client - was responsible for the HAZOP action items that identified the PSV and CSO decisions, including validating the design case flaring scenarios. He reviewed the PSV calculations done in EPCON's software. In addition, he implemented all Emergency Isolation Valve and Safety Integrity Level design decisions into the final design.

2009   Ras Tanura Integrated Project
Part of his work as Project Interface Coordinator - between licensed units and infrastructure/offsites utilities - involved selection of which stream should go to which flare, and siting of the flares. This included identifying upset cases for streams with nitrogen-based compounds to be directed to a special ammonia flare.

2008 ExxonMobil Odoptu First Stage Processing
As HSE Lead, Bob was responsible for quantifying the loads to the flare for well-completion, startup, compressor upset, emergency and planned shutdowns. With sub-zero temperatures, sized a larger knockout pot to handle condensables. The design included specifying lower noise tip to enable workers to get some sleep during startup. This was complicated by - but resolved with added soundproofing in bunkrooms - the impracticality of using flare steam-assist at -40 C.

2007 ADMA-OpCo Habshan Alpha Platform
Bob validated PHAST and dispersion calculations for H2S-containing vent to flare. Implemented flow-switch based supplemental natural gas in the event of a sour gas release, to ensure mix was still combustible at the flare tip.

2007 Marathon Garyville Major Expansion
This was the first major refinery project to be impacted by Jan 2007 upgrade of API 521 from RP to Std - doubling in size plus became an international standard. Bob provided client with a cogent summary of these changes, reviewed unit plot plans for necessary rearrangement and reviewed the PSV calculation documentation - now 48 pages thick.

2006 Yorktown Refinery Low-Sulfur Gasoline
Bob ran FLARENET scenarios for the worst design case: loss of reflux to a debutanizer column on a cold winter's day. Together with bare-pipe radiant heat loss calculations, proved this release would not condense before reaching the flare knockout pot: avoiding the complication of a second unit-specific knockout pot.

2005 BP Cherry Point Canadian eXtra Heavy Oil
As part of debottlenecking study for processing alternate extra heavy crude, Bob developed scenarios around feasibility of tieing into the existing high-pressure or low-pressure flare. Determined conclusively that - even with HIPPS - the site would still need a new intermediate flare. This also meant the new flare could be tied-in as areas were shut down one at a time, rather than require a total refinery shutdown.