Compliance Verification Activity Report: CV1920-354 - Kinder Morgan Cochin ULC

Overview

Compliance verification activity type: Field Inspection

Activity #: CV1920-354
Start date: 2019-10-30
End date: 2019-10-31

Team:

Regulated company: Kinder Morgan Cochin ULC

Operating company: Kinder Morgan Canada Inc

Province(s) / Territory(s):

Discipline(s):

Related events:

Rationale and scope:

Integrity inspection of pump stations to verify compliance to the Onshore Pipeline Regulations and CSA Z662.

Compliance tool(s) used:

Facility details

Facilities:

Regulatory requirements

Regulatory requirements that apply to this activity:

Observations (no outstanding follow-up required)

Observation 1 - Estlin Pump Station

Date & time of visit: 2019-10-30 09:00

Discipline: Integrity Management

Categories:

Facility:

Observations:

CER inspectors met with the company representatives at their Regina office and then headed to the Estlin Pump Station for the inspection. The Cochin system transports condensate from the United States to Edmonton, Alberta.

The station is accessible by a well maintained road and is fenced with two egress gates in addition to the main site access. Signs with the company name, emergency phone numbers, non-smoking and warning of the presence of flammable products were posted at the site main entrance.
 
The pump station has a 3000 HP pump unit equipped with a Variable Frequency Drive (VFD) to control the speed of the pump. The pressure and flow rate is adjusted by controlling the speed of the pump.
 
Overpressure protection during operation is provided by a high pressure shutdown (pressure limiting system). The MOP is 1440 psi and the maximum pressure control set point is 1100 psi and the high pressure shutdown is set to 1150 psi. There is also a high pressure alarm set at 1080 psi. Cochin explained that the maximum pressure control set point was determine after a surge analysis was conducted on the line. Suction and discharge pressures are monitored at the pump unit and at the mainline just upstream and downstream of the pump station piping. Pressure transmitters and over pressure protection devices are tested on an annual basis.
 
To protect the station piping from thermal expansion over-pressures, the station piping has pop check valves which discharge into the mainline. The company explained that it has a system to ensure that all valves that need to remain open to keep the thermal relief system effective are kept open, including a “car seal” method involving a wire or tie wrap for preventing the unintended closure of the valves and a tag at each valve reminding the employees on the necessity to keep the valve open to prevent over pressure by thermal expansion.

The station is equipped with station Emergency Shut-Down (ESD) push buttons located throughout the station, including near the main entrance and the emergency exits. The ESD system is tested on an annual basis.
 
If communication is lost between the station and the control room in Houston for a period of 10 minutes, a station ESD is initiated.

Station isolation valves are equipped with position indicators and are inspected and tested semi-annually.

The station has an Uninterruptible Power System (UPS) and a propane fueled generator as alternate source of power. The generator is capable of operating the station ESD system, and provides power to operate all facilities at the station except the station pump unit.
  
The pump building is equipped with fire and gas detection. Fire detection triggers a station ESD and gas detection triggers a low level alarm at 10% of the lower explosive limit (LEL) and high level alarm and station ESD at 50% LEL. There is no forced ventilation in the pump building. The pump unit is equipped with a seal leak detection system, which consists of pressure switches between the primary and secondary seals of the pump. When the seal leak detection system is triggered, it stops the pump unit and isolates the station. The pump unit is also equipped with temperature, lube oil level, and vibration monitoring and protection devices.
   
The station has a Drag Reducing Agent (DRA) injection unit. The unit has two tanks and an injection system to inject the DRA in the mainline. There are check valves on the DRA injection line close to the mainline to prevent back flow of product in the DRA system.
 
The above ground piping coating observed was in fair to good condition. The piping also appeared to be properly supported. The piping had arrows for the direction of flow and labels to identify the product.
 
The company corrosion technician was onsite to explain the activities conducted to assess the Cathodic Protection (CP) system and the integrity of the station piping. He explained that yearly CP pipe-to-soil potential surveys and atmospheric corrosion inspections are conducted. Conditions of the above ground station piping coating and at the air-to-soil interface are assessed at that time. The station piping and the mainline are protected with the same CP system, which uses rectifiers to impress the current on the system. The rectifiers are equipped with remote monitoring units and the corrosion technician indicated that he reviews the rectifier readings on a monthly basis. He also explained that there are four stations in Canada equipped with coupons to monitor for internal corrosion. The Estlin Pump Station has an internal corrosion coupon.

Compliance tool used: No compliance tool used

Observation 2 - Creelman Pump Station

Date & time of visit: 2019-10-30 14:15

Discipline: Integrity Management

Categories:

Facility:

Observations:

The station is accessible by a well maintained road and is fenced with two egress gates in addition to the main site access. Signs with the company name, emergency phone numbers, non-smoking and warning of the presence of flammable products were posted at the site main entrance.

The pump station has a 3000 HP pump unit equipped with a Variable Frequency Drive (VFD) to control the speed of the pump. The pressure and flow rate is adjusted by controlling the speed of the pump.

Overpressure protection during operation is provided by a high pressure shutdown (pressure limiting system). The MOP is 1440 psi and the maximum pressure control set point is 1100 psi and the high pressure shutdown is set 1150 psi. There is also a high pressure alarm set at 1080 psi. Cochin explained that the maximum pressure control set point was determine after a surge analysis was conducted on the line. Suction and discharge pressures are monitored at the pump unit and at the mainline just upstream and downstream of the pump station piping. Pressure transmitters and over pressure protection devices are tested on an annual basis.

To protect the station piping from thermal expansion overpressures, the station piping has pop check valves which discharge into the mainline. The company explained that it has a system to ensure that all valves that need to remain open to keep the thermal relief system effective are kept open, including a “car seal” method involving a wire or tie wrap for preventing the unintended closure of the valves and a tag at each valve reminding the employees on the necessity to keep the valve open to prevent over pressure by thermal expansion.

The station is equipped with station Emergency Shut-Down (ESD) push buttons located throughout the station, including near the main entrance and the emergency exits. The ESD system is tested on an annual basis.

If communication is lost between the station and the control room in Houston for a period of 10 minutes, a station ESD is initiated.

Station isolation valves are equipped with position indicators and are inspected and tested semi-annually.
 
The station has an Uninterruptible Power System (UPS) and a propane fueled generator as alternate source of power. The generator is capable of operating the station ESD system, and provides power to operate all facilities at the station except the station pump unit.
  
The pump building is equipped with fire and gas detection. Fire detection triggers a station ESD and gas detection triggers a low level alarm at 10% LEL and high level alarm and station ESD at 50% LEL. There is no forced ventilation in the pump building. The pump unit is equipped with a seal leak detection system, which consist of pressure switches between the primary and secondary seals of the pump. When the seal leak detection system is triggered, it stops the pump unit and isolates the station. The pump unit is also equipped with temperature, lube oil level, and vibration monitoring and protection devices.
   
The station has a Drag Reducing Agent (DRA) injection unit. The unit has two tanks and an injection system to inject the DRA in the mainline. There are check valves on the DRA injection line close to the mainline to prevent back flow of product in the DRA system.

The above ground piping coating observed was in fair to good condition. The piping also appeared to be properly supported. The piping had arrows for the direction of flow and labels to identify the product.

Compliance tool used: No compliance tool used

Observation 3 - Findlater Pump Station

Date & time of visit: 2019-10-31 09:00

Discipline: Integrity Management

Categories:

Facility:

Observations:

The station is accessible by a well maintained road and is fenced with two egress gates in addition to the main site access. Signs with the company name, emergency phone numbers, non-smoking and warning of the presence of flammable products were posted at the site main entrance.

The pump station has a 3000 HP pump unit equipped with a Variable Frequency Drive (VFD) to control the speed of the pump. The pressure and flow rate is adjusted by controlling the speed of the pump.

Overpressure protection during operation is provided by a high pressure shutdown (pressure limiting system). The MOP is 1440 psi and the maximum pressure control set point is 1100 psi and the high pressure shutdown is set 1150 psi. There is also a high pressure alarm set at 1080 psi. Cochin explained that the maximum pressure control set point was determine after a surge analysis was conducted on the line. Suction and discharge pressures are monitored at the pump unit and at the mainline just upstream and downstream of the pump station piping. Pressure transmitters and over pressure protection devices are tested on an annual basis.

To protect the station piping from thermal expansion overpressures, the station piping has pop check valves which discharge into the mainline. The company explained that it has a system to ensure that all valves that need to remain open to keep the thermal relief system effective are kept open, including a “car seal” method involving a wire or tie wrap for preventing the unintended closure of the valves and a tag at each valve reminding the employees on the necessity to keep the valve open to prevent over pressure by thermal expansion.

The station is equipped with station Emergency Shut-Down (ESD) push buttons located throughout the station, including near the main entrance and the emergency exits. The ESD system is tested on an annual basis.

If communication is lost between the station and the control room in Houston for a period of 10 minutes, a station ESD is initiated.

Station isolation valves are equipped with position indicators and are inspected and tested semi-annually.
 
The station has an Uninterruptible Power System (UPS) and a propane fueled generator as alternate source of power. The generator is capable of operating the station ESD system, and provides power to operate all facilities at the station except the station pump unit.
  
The pump building is equipped with fire and gas detection. Fire detection triggers a station ESD and gas detection triggers a low level alarm at 10% LEL and high level alarm and station ESD at 50% LEL. There is no forced ventilation in the pump building. The pump unit is equipped with a seal leak detection system, which consist of pressure switches between the primary and secondary seals of the pump. When the seal leak detection system is triggered, it stops the pump unit and isolates the station. The pump unit is also equipped with temperature, lube oil level, and vibration monitoring and protection devices.
   
The station has a Drag Reducing Agent (DRA) injection unit. The unit has two tanks and an injection system to inject the DRA in the mainline. There are check valves on the DRA injection line close to the mainline to prevent back flow of product in the DRA system.

The above ground piping coating observed was in fair to good condition. The piping also appeared to be properly supported. The piping had arrows for the direction of flow and labels to identify the product.

Compliance tool used: No compliance tool used

Observation 4 - Elbow Pump Station

Date & time of visit: 2019-10-31 12:30

Discipline: Integrity Management

Categories:

Facility:

Observations:

The station is accessible by a well maintained road and is fenced with two egress gates in addition to the main site access. Signs with the company name, emergency phone numbers, non-smoking and warning of the presence of flammable products were posted at the site main entrance.

The pump station has a 3000 HP pump unit equipped with a Variable Frequency Drive (VFD) to control the speed of the pump. The pressure and flow rate is adjusted by controlling the speed of the pump.

Overpressure protection during operation is provided by a high pressure shutdown (pressure limiting system). The MOP is 1440 psi and the maximum pressure control set point is 1100 psi and the high pressure shutdown is set 1150 psi. There is also a high pressure alarm set at 1080 psi. Cochin explained that the maximum pressure control set point was determine after a surge analysis was conducted on the line. Suction and discharge pressures are monitored at the pump unit and at the mainline just upstream and downstream of the pump station piping. Pressure transmitters and over pressure protection devices are tested on an annual basis.

To protect the station piping from thermal expansion overpressures, the station piping has pop check valves which discharge into the mainline. The company explained that it has a system to ensure that all valves that need to remain open to keep the thermal relief system effective are kept open, including a “car seal” method involving a wire or tie wrap for preventing the unintended closure of the valves and a tag at each valve reminding the employees on the necessity to keep the valve open to prevent over pressure by thermal expansion.

The station is equipped with station Emergency Shut-Down (ESD) push buttons located throughout the station, including near the main entrance and the emergency exits. The ESD system is tested on an annual basis.

If communication is lost between the station and the control room in Houston for a period of 10 minutes, a station ESD is initiated.

Station isolation valves are equipped with position indicators and are inspected and tested semi-annually.
 
The station has an Uninterruptible Power System (UPS) and a propane fueled generator as alternate source of power. The generator is capable of operating the station ESD system, and provides power to operate all facilities at the station except the station pump unit.
  
The pump building is equipped with fire and gas detection. Fire detection triggers a station ESD and gas detection triggers a low level alarm at 10% LEL and high level alarm and station ESD at 50% LEL. There is no forced ventilation in the pump building. The pump unit is equipped with a seal leak detection system, which consist of pressure switches between the primary and secondary seals of the pump. When the seal leak detection system is triggered, it stops the pump unit and isolates the station. The pump unit is also equipped with temperature, lube oil level, and vibration monitoring and protection devices.
   
The station has a Drag Reducing Agent (DRA) injection unit. The unit has two tanks and an injection system to inject the DRA in the mainline. There are check valves on the DRA injection line close to the mainline to prevent back flow of product in the DRA system.

The above ground piping coating observed was in fair to good condition. The piping also appeared to be properly supported. The piping had arrows for the direction of flow and labels to identify the product.

Compliance tool used: No compliance tool used

Observations (company follow-up required)

Identified non-compliances to company plans or procedures are non-compliances either to:

- the condition of an authorization document that requires the implementation of that plan or procedure; or

- the relevant section of the regulations that requires implementation of that plan or procedure including those sections that require implementation of plans or procedures as a part of a Program