Field Operations

1. Field Operations

2. Field Operations (Real World) Applicable technology courses, core and non-core facilities operations, safety courses are the main thrust of most training program. At the end of those training program, we feel confident that we are ready to run the plant and cope with operational upsets and emergencies. Once out there in the field, some got lost in dealing with day to day events and failed to demonstrate workplace competency expected. So many views were offered regarding that issue. Some nasty, some polite or politically correct criticism, most experts says it is system failure, etc. Probably it is a bit of everything. One global company has this unwritten culture. They expect their people [specifically Experts key staff] to “know what to know and what to look for” on their own. Simple enough, but the problem is sometimes people hired were not prepared for that. Some do not even have a clue.

3. Field Operations Somesimply insisted in practices they learned in their previous workplace which may differ from present workplace practices. But because of difference in workplace environment what we considered acceptable practices may not be the right thing to do elsewhere. Even in the industry we are in, some practices differ due to many reasons. Fortunately in APC, all or most of “ what we should know and what to look for ” are made available for our perusal. They were prepared either as SI or WOI.

4. Field Operations In addition to our ability to operate the plant efficiently and safely, putting into practice those SI and WOI we are expected to practice certain work place behaviors. Problem is nobody tells us. This module attempts to give you some hints of those expectations by way of compiling some work practices and behaviors which are part of the work culture in most manufacturing plant. Module also includes simplified basic aspects [or fundamentals] of some specialized field prepared by a non specialist so that we will not be intimidated by technical jargon during formal trainings. Because we should have reasonable ideas about field operation, this module can also help us prompt course facilitators to teach what we more on what is needed in our job [as process technician].

5. Field Operation Process Technicians Process technicians are the equivalent of plant or process operators in the old days. Common misconception from outsiders is that process technician job is similar to what a TV technician or the repair man Sony send you to fix your electronic appliances. In a manufacturing plant, process technicians are the man and women who run [operate] the plant. Their main task as a group is to manufacture/produce product required of them. To illustrate what process technicians do, let us talk about lube oil refining which is a multi-product plant with similar operating scheme like ours.

6. Field Operation Process Technicians (con’t) Normally corporate tells manufacturing volume of each products they want for that year based on forecast. TSD planner prepare a ‘running plan” based on figures supplied by corporate. [Running plan includes scheduling of raw material, chemical, and everything needed to produce what the want]. Plant operation, of course, is programmed based on facilities available/capabilities. Main thrust is to prepare a running plan sequence that would minimize slope [transition product]. Our job as process technician is to produce the volume of product with the spec they want safely and efficiently on time.

7. Field Operation Process Technicians (con’t) Plants are usually divided into two main areas. Main plant which is usually referred as ISBL or Core plant and OSBL or Non Core area. Each areas are further subdivided into several sections. These sections are divided among the process technicians based on some criterias. In most plant, the process technicians is considered the owner of assigned sections. Hence he/she is responsible for ensuring that all applicable rules and regulation were followed by everybody entering/working in his area. Ensure that all facilities/equipments under him were in good running condition including housekeeping in his workplace. Of course process technician main key results area is to come up with whatever is expected/needed from his area to manufacture product.

8. Field Operation Process Technicians (con’t) To illustrate, let’s say you are assigned in the utilities and among your responsibilities is steam production and cooling water. - You should be able to treat raw water at required spec and volume to support your demin and cooling water system make needs. - You should be able to produce enough demin water to support your boilers - You should be able to produce enough steam with the right spec required at the core plant

9. What They Don’t Teach You (And Tell You) Common perceptions about Process Operator Heard from a Refinery Manager during an induction course Early one Sunday morning his wife decided that she wants to join his daily morning round of the plant. The man obliged. No problem after all he is the boss. While in the middle of the plant, his wife told him that she wanted to go the toilet. “We do not have women toilet here, just do what you want right here”, he replied. “But dear, there are some chaps walking around ”, his wife argued. “Don’t worry about them”, he replied. “Those are my operators, they don’t see, they don’t hear, they don’t smell.

10. What They Don’t Teach You (And Tell You) Common perceptions about Process Operator (con’t) Heard from a Refinery Manager during an induction course This story was an old, recycled joke about our profession repeated in an audience of about 300 cross-posted operating staff from about 6 countries. Some of us might feel insulted hearing that joke in an induction course, but not that crowd. We asked for more after a big applause. But the refinery manager replied that he got to get back to business. He started his talk with something like this: I think what you want to hear is something about pay. When is pay day, holiday and night premium rates etc, etc, but my job is to orient you gents about the project. Bear with me guys. Free lunch will be served……….

11. What They Don’t Teach You (And Tell You) Types of Operator Elsewhere, plant operators classify their co workers according to work style. Here are few I had chosen from a newsletter, I found inserted in one training material used in preparing this training module. Probably, most of the type of operators named no longer exist in present day workplace culture, but let us look at them just the same.

12. What They Don’t Teach You (And Tell You) Types of Operator • Smart Operator Walk around his area first hour. Sleeps most of the night, wake up once to take his snack and back to bed again. Morning comes he produces his readings (because he is smart unlike some who had readings at all times, he writes S/D on the reading sheets whenever his facilities are on S/D). He performs housekeeping (water flushing) minutes before the boss comes, ensuring that he is in a place he can be seen when the boss arrive. Oh, yes, he always have a friend who knows where his bed is, in case he is needed or the boss decided to walk around.

13. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 2. The Professor Loves to lecture on trainees and plant visitors. Keeps correcting junior operators on the pretext that the later is not doing his job according to SOP, [what ever SOP meant to him] At the same time, he lecture the guys theories [learned from University of Hard Knock] he thinks applicable to the job. To him there is only one way to do the job right. Do it according to “his SOP”. Because he is the professor whenever trainees join the plant, people throw him those guys for on the job shadowing. Whenever, a trainee fumbles during assessment, he learned to reason out that, that is what the professor taught them, They usually got away with it. Good laugh for all, when assessors spread the story at the CCR the next day.

14. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 3. Monkey Operator He can run all equipments in the plant. Usually he got what is called a “bible” [they call it capitulo siete in the Phil] where peculiar procedures were written. In addition, he got so many markings out in the field to assist him. It is something similar to this: Push the top bottom on the left, next push the bottom below, a bulb will light, then push the green bottom and the machine will run etc. If equipment failed to runs, he request maintenance assistance. He satisfactory performs all routine, but hopeless when task deviates from normal. He never fails to do his readings. Even when plant is on shutdown, he got one.

15. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 3. Monkey Operator Sometimes, others even call him for help in starting up machine which made him think he is the best. So during yearly assessment he complains to the boss during assessment about his “grade” and talk about his promotion claiming he knows all, but was left out for more than ten years. Once he even threaten

16. What They Don’t Teach You (And Tell You) Types of Operator 4. Mr Credit Grabber He is always around in all activities. You can be sure that he is holding his handy talkie’s mouth piece all the time to makes sure he communicates with CCR before the man on the job do it. Here is a typical example – While area operator is trying to run a turbine driven pump, Mr. C.G. would start communicating with CCR informing the DCS operator [and for the bosses to hear] the progress of the job. “The lube oil system is now circulating”, later “Governor is now latch and steam valve is now being open”. Then “Pump is now fully commissioned, it is all your mate”. “Thanks, Raymond (Mr. C. G), excellent job”, CCR would acknowledge.

17. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 4. Mr Credit Grabber Man on the job? Entirely left out of the picture as they say. He usually just throw their valve wrench to the ground out of prostration, walk away looking for someone to complain about Mr C.G.

18. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) He got the sense of urgency. He is already at the CCR while the rest of the gang are still halfway the “premonade”. He go straight to main CCR after getting his “props” from his locker, and look for the guy he is to relieve for handover. He checks the DCS and discuss status of his area with the DCS operator. Before going to the plant he pass by the Permits Office to orient himself of works to be carried in his area that day. Unlike some, he does not return to the locker room and waste time “looking around the place” for 10 minutes or pass by the pantry to “inspect”, read bulletins he had been reading daily for the past 3 months nor to gather the latest gossip.

19. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) He knows what to know and what to look for He performs his routines with meticulous attention to details. Note down concerns, rectify what he can immediately and discuss with his supervisor any issue that needs higher up attention. He performs housekeeping and do what he can immediately to eliminate hazard he noticed instead of just logging them and waits for someone to action. What is “bad” about him is he never come up with some idiotic report to please his boss whose expertise is to blew up non sense out of proportion.

20. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) He often review engineering principles associated with his facilities referring to technical book to checks. Mentally review emergency procedures normally referring to SI/OI for confirmation. He always try to do his best to excel not necessarily for promotion but for the sake of learning. This type would be happy to be promoted but being an intelligent and realistic person, he do not expect it, because he knew he lack the “real world core competencies” whatever that mean. He will eventually make it [if he decides to stay] in a couple of years, and in time he will be the big boss running the organization.

21. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) Off course, he knew the location of all F/G props in his area, their functions and design, particularly the characteristic of detection element, because he knew that is the key to proper management of the system. He never forget to perform routine checks/tests on safety equipment, Prepare WOR as required.

22. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) He have the sense of ownership He ensure that he is aware of every activities in his area. Check all ongoing work. He satisfy himself that work permits issued are in order, stipulations correct even though they were signed by the boss. Ensures workers complied with PPE and requirements of the permit. He stops work if warranted. He repeatedly checks on his equipments several times during the shift to satisfy himself that everything are ok while ensuring that all routines are done and all request from CCR are complied with.

23. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) No butterfly in his tummy Because he works hard and fully aware of what is going on, he does not leave CCR when the boss enters nor change direction to avoid meeting big guys walking around the plant. During emergencies he emerged as the leader directing the show while his boss keeps tailing him or no where to be found. During simulated safety drill he knows exactly what to do, problem is sometimes he shout at people doing idiotic actions and on occasion can not refrain from laughing seeing stupid things people are doing.

24. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) Bad Guy on the Block He does not mind being tagged as “bad guy” by some people as long as he is doing what are expected of him. He would not allow people not wearing the prescribed PPE in his area, would not tolerate unsafe acts, police his area to ensure people are following company regulations no matter who they are. He would even sent you back to CCR to sign the visitor log book if you forget to do so. He would not allow maintenance to close completed work permits if housekeeping is not done reasonably well.

25. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) He does not hesitate to challenge anyone when he thinks best efforts/options were not being carried out while performing activities in his facilities.

26. What They Don’t Teach You (And Tell You) Types of Operator (con’t) 5. Operator (Typical) Model Operator How come? He is the bad guy on the block, do not support some boss’ idiosyncrasies, challenge people, insist that everybody follows rules, checks even his boss’ job, stops ongoing work if he feels necessary, act as if he own the plant, and at the same a model operator.

27. What They Don’t Teach You (And Tell You) Types of Operator (con’t) In the former BPC [forerunner of APC], there were about 80 process technicians And probably 50 maintenance tech. I like to think that all of them developed a work culture attributed to the last type I called operator (typical). [In the newsletter they are called “mga krus”- why ?, you might be asking your self]. Now almost all of them are doing good elsewhere. Despite their relatively shorter work experience, they were able to compete with others with 10 or more years of experience. Similarly all the “mga krus” in the work place where that newsletter was published were pirated by a similar firm with compensation 6 times higher plus benefits that is the best in the land at that time.

28. Pre-com (General) Pre-commissioning – assurance of systematic conformity to design spec. 1. Pre-com encompass such requirement as: • Punch list and check out of system • Static/de-energized tests on equipment (calibration, loop checks and logic checks of inst, cold alignment and rotational checks of motors, testing of electrical equipments etc) • Flushing/cleaning of vessels/pipes • Leak testing • Test running all utility systems • Test running of all instrumentation including DCS, ESD and F/G systems • Test running of all electrical systems • Test running of all rotating equipment • Test running of all power generation systems • Performance testing of telecom systems • Testing of the accommodation module in its entirely

29. Pre-Com (General) Pre-com (con’t) • Pre-start up Technical Safety Audit – during the testing and pre-com phase, Owner shall perform a pre-start up TSA to confirm that the production facilities and associated facilities are ready for commissioning and initial operation. • After completion of pre-com and recommendation from audit, contractor shall apply to owner for the issue of a Certificate of Mechanical Completion, issue of w/c is required prior to the commencement of the commissioning of facilities. 2. Mechanical completion – shall means completion of pre-com activities with the punch lists of outstanding items agreed by the parties. All essential utilities, life support system, carnage, electric power (supply generation + distribution), drainage and firewater shall be commissioned as an integral part of pre-com prior to declaring mechanical completion The plant status reached at the end of pre-com is defined as Mechanical Completion or Ready for Commissioning

30. Pre-Com (General) 3. Commissioning – during this phase, the facilities, systems and equipment items are checked and prepared for the commencement of operations and oil in. • Mechanical completion • Electrical commissioning • Instrument commissioning • Telecommunication commissioning • Pipeline and Sub-sea Cable commissioning • HVAC commissioning

31. Pre-com (General) Activities undertaken at this time include: • Dynamic verification that each equipment items performs properly (motor run-in uncoupled, integrity checks of inst loops, electrical breakers operations etc) • Mechanical preparation, actual running and on line tests of plant utilities, and whenever practical, main process equipment being run in a closed loop condition. • Preparation of al systems so as to be ready for the introduction of hydrocarbons such as piping dry out, inerting, charging of various chemicals and refractory dry out. • Lubrication of equipment as required.

32. Pre-com (General) Completion of commissioning is defined as READY for START UP at w/c point the systems are ready for the introduction of hydrocarbon. Contractor shall apply and owner shall issue Certificate of Commissioning Completion only if the contractor performed to the satisfaction of owner the testing and commissioning of all parts of the FACILITIES in accordance with the approved Commissioning Manual. • The “punch list” items have been cleared • The completion of the maintenance activities, including maintenance activities that may have commenced during but not completed before commissioning • The submission of all required deliverables • The satisfactory completion of all formal training • Start up and Performance Testing – since the start up of utilities would have been carried out during commissioning, the actual start up begins with the introduction of hydrocarbons into the facilities as follows:

33. Pre-com (General) • Oil in • Bringing the plant into operation and its steady state • X hours test run (capacity performance testing) • XX days Production Performance Testing

34. General Pre-com Activities • System cleaning • Running test • Operational tightness test • Air freeing • Drying out • Catalyst, dessicant, chemical loading

35. Pre-com (general) System cleaning 1. Air blowing - A pipe cleaning method utilizing kinetic energy of air flow Method • Method A - air accumulation method • Method B - direct blowing method • Method C - scavenging run of compressor/blower Application • Chemical lines • Instrument/plant air lines • Nitrogen lines

36. Pre-com (General) Air blowing (con’t) • Hydrogen lines • LPG/ethylene/butane lines • Reactor and gas loop lines • Powder conveying lines • Pellet conveying lines • Flare and vent lines • Solvent, R20, and R21 lines • Catalyst lines • Catalyst activator lines

37. Pre-com (General) 2. Steam blowing - Steam blowing utilizes the kinetic energy of steam flow. Since blowing and cool down of the pipe concerned are repeated during steam blowing, rust, weld slag or spatter become liable to peel off from the pipe surface due to the repetition of expansion and contraction of the pipe. Application • Medium pressure steam lines • Low pressure steam lines

38. Pre-com (General) 3. Power flushing/water circulation - A pipe cleaning method utilizing kinetic energy of water Method • Pipes are flushed using the permanently installed pumps connected to the pipe but running on water instead of the normal process fluid • Flushing velocity must exceed the maximum process velocity during normal operation Application • It is basically applied to the following carbon steel pipes

39. Pre-com (General) Power flushing (con’t) • Raw water/filtered water service lines • Potable water lines • Demineralised water/boiler • Cooling water supply/return line • Condensate lines • Fire water lines • Process water lines

40. Pre-com (General) • Mechanical cleaning - manual cleaning. Wire brushes, hand grinders, broom for sweeping or industrial vacuum cleaners are used. Application The following are manually cleaned before using or closing them for process use: • Vessels • Column • Drum • Hopper • Tanks • Pits • Large pipes, etc.

41. Pre-com (General) Running Test • Mechanical run in of compressors - To check mechanical performance such as vibration, noise, heat generation on bearing of compressor systems including drivers and compressor auxiliary functions during start up or initial operation. Application • Mechanical run in shall be conducted for all compressors. The recommended test period of mechanical run is about 4 hours. • Fluid used – nitrogen or actual gas.

42. Pre-com (General) Running Test • Mechanical run in of pumps - To check mechanical performance of pump system including drivers and pumps auxiliaries using either water, lube oil or gas oil as pumping medium. Vibration, heat generation on bearing are checked. This testing enables early detection of machine problems and is intended to minimize problems during operation. Application • In principle, process pumps except auxiliary pumps for lubrication shall be mechanically run in with water or actual fluids.

43. Pre-com (General) Running Test (con’t) • Some pumps can be operated with water, while other pumps can only be operated with actual fluid due to reasons listed below: 1. Overload of motor Overload will occur during run in with water for pumps which handle fluid of lower specific gravity than that of water. Throttling the pump discharge flow rate to avoid overload may cause another problem that the minimum allowable discharge flow rate can not be maintained. 2. Water contamination not allowed Remaining water may enhance corrosion, abnormal reaction with actual fluid, contamination, potentiality of icing/hydrate formation and the likes at or after start up.

44. Pre-com (General) Running Test (con’t) 3. Circulation route not practical Appropriate water circulation loop can not be realized. Once through run in route is planned only for pumps with normal flow of less than 1 m3/hr. 4. Difficult post work drain out or dry out operation of piping/pumps as a post work of water run in is considered to be a very big job giving an impact on pre-com schedule.

45. Pre-com (General) Running Test (con’t) 3. Blower/fan mechanical run in - To check machine for vibration, noise, heat generation on bearing of blower/fan system including their drivers to confirm motor performance. Application - All blowers/fans

46. Pre-com (General) • Operational Tightness Test - Checking entire plant or part of the plant for leakage. In general, plant handles combustible, poisonous or other dangerous materials. Where tightness is lacking, material handled will leak resulting to disasters. In some cases, operation can not be continued. Further the leakage of handled material will result to large economic loss. To prevent leakage during operation tightness test is carried out to confirm that the plant complies with the required tightness before start up.

47. Pre-com (General) • Operational Tightness Test (con’t) Method - The system is pressurized with compressed air or nitrogen (or steam in some system). If pressure holds for 2 hours, system is considered leak free. - Detection of leak is done using soapsuds. All flanges should be taped to give better results. Application - The test shall be performed for all piping and equipment processing/handling hydrocarbon/hydrocarbon container within process units, utility/offsite facilities, marine facilities.

48. Pre-com (General) 4. Air freeing - To remove potential hazard of forming an explosive mixture when combustible hydrocarbons are mixed with air (substantially oxygen). Method - Nitrogen or steam is introduced from one end of the system or equipment and vented from the other end until specified oxygen level is attained. Application - All hydrocarbon process pipeline/equipment and flammable chemical lines within the process unit. - Pipe/equipment for handling or transferring fluids in utility /offsite /marine area facilities.

49. Pre-com (General) 5. Dry out Refractory drying – carried out by heating the furnace (or equipment with refractory) to remove moisture and to stabilize the crystalline structure of the refractory under a previously specified temperature-time program. Circuit drying 1. Normal drying – carried out by blowing air or nitrogen to remove moisture remaining to agreed specification. 2. Vacuum drying – Carried out by vacuum pump etc to remove moisture remaining to agreed specification. Method Drying will be carried out as follows: 1. Drain out – carried out after hydraulic test or water flushing until no water drains out from low points. Application - All hydrocarbon process pipeline/equipment and flammable chemical lines within the process unit. - Pipe/equipment for handling or transferring fluids in utility /offsite /marine area facilities.

50. Pre-com (General) 5. Dry out (con’t) Method Drying will be carried out as follows: 1. Drain out – carried out after hydraulic test or water flushing until no water drains out from low points. 2. Drying out with air – preliminary drying out shall be carried out with air during air blowing. 3. Drying out with nitrogen – final drying out shall be carried out with nitrogen during air freeing Application - All system where moisture would interfere with operation, cause icing and corrosion.