Collaboration and innovation have been key to the success of Gibson’s Natural Gas Liquids (NGL) plant in Moose Jaw. Teams across Engineering, Projects, Operations, Commercial and Lab came together to address challenges, enhance safety and bring the plant into safe, on-spec and reliable production. The result is a true example of what can be accomplished when we all work it out and do it together!
The primary goals of the project were to enhance safety and ensure reliable operations year-round. Several upgrades were completed to meet this goal, including:
- Installing a Safety Instrumented System (SIS)
- Upgrading heater safety systems and instrumentation
- Improving heat tracing and insulation to address winterization issues experienced last year, which had required significant expenditure on hoarding and heating
These upgrades have made the plant safer and better prepared for future winters, reducing risks and improving operational efficiency.
Innovation and Problem-Solving
This project also highlighted the importance of creative problem-solving and teamwork. When faced with a challenge in flow measurement, Gibson partnered with Spartan Controls to integrate mass flow meters into the system. Tight timelines required quick action, and collaboration across locations made it possible. Moose Jaw, Edmonton and Hardisty worked together, with Hardisty supplying spare Coriolis flow meters to ensure deadlines were met.
Additionally, Engineering, Projects, Operations, Spartan and Commercial worked on a first-ever heater characterization procedure for Moose Jaw. This innovative approach defined safe operating ranges and was only possible through the collective efforts of everyone involved.
NGL Plant Start-Up and Adjustments
After a shorter test run last summer that provided valuable data but produced off-spec product, the team adjusted its approach. Operations focused on reducing H₂S in the product, while Commercial found a customer for the off-spec material.
A second start-up this fall achieved on-spec production right away. Since then, the NGL plant has been operating safely and reliably. The effort involved:
- Operator training to ensure the team was equipped to manage the plant effectively.
- Maintenance work to troubleshoot and address issues such as instrumentation and control.
- Project team support to make necessary modifications.
- Commercial’s flexible approach to scheduling trucking and managing customer relationships as product rates fluctuated.
- Engineering’s ongoing work to troubleshoot and optimize plant operations, aiming to stabilize flows and improve yields.
Coordinated Communication and Effort
Throughout the project, communication and organization kept the teams aligned. Daily updates, action trackers, and regular meetings brought departments together to address risks and meet timelines. This project demonstrates how teamwork, problem-solving and commitment can lead to outstanding results.
