O&G

Process & Operations

Engineering
Day 3
9th of October 2021

Ahmed Mohamed Shafik Ali Attia

Process & Operations Engineering Expert
[email protected]
 Safety Moment

https://www.youtube.com/watch?v=QiILbGbk8Qk
Animation of Fire at Chevron's
Richmond Refinery, August 6, 2012
Failure in many business processes!!!!!!

Ahmed Mohamed Shafik Ali Attia

 Objective
Understand OPERATIONS as one of the most
attractive roles of
A Chemical Engineer
in
Oil & Gas Industry

Ahmed Mohamed Shafik Ali Attia

 Agenda

 Operations Interfaces.

 Operations Hierarchy.

 Roles & Responsibilities.

 Operations Documents.

Ahmed Mohamed Shafik Ali Attia

Operations Interfaces

Ahmed Mohamed Shafik Ali Attia

 Stakeholders

Engineering
Disciplines
Process
Commercial
Engineering

Maintenance HR

Operations
Projects Legal

Process
Supply
Safety
Contracts &
Agreements

Ahmed Mohamed Shafik Ali Attia

 Business Processes

RCFA

MOC PTW

Project
Management FRA
System

Operations
Incident
SAP / WO Investigation
System

Job Hazard
Interface
Analysis
Agreements
System
Performance
Appraisal

Ahmed Mohamed Shafik Ali Attia

Operations Hierarchy

Ahmed Mohamed Shafik Ali Attia

Field Operator

Panel Operator

Shift Supervisor
Shift
Superintendent
Head

Manager

Ahmed Mohamed Shafik Ali Attia

Roles & Responsibilities

Ahmed Mohamed Shafik Ali Attia

 Operations Directory

 Field Operator.

 Panel / DCS Operator.

 Shift Supervisor.

 Shift Superintendent.

 Operations Section Head.

 Operations Manager.
Ahmed Mohamed Shafik Ali Attia
Field Operator

Ahmed Mohamed Shafik Ali Attia

 Field Operator

• Works outside in the plant and is in continuous communication with the Panel
Operator and shift supervisor directly for manual adjustments to valves and
equipment etc.

• Observe local instruments, gauges, and meters to verify conformance to standard

operating practice.

• Collect samples of various streams and delivers them to the laboratory.

• Start and stop pumps, compressors and other equipment based on the operations
requirement and post proper communication and alignment with panel operator and
shift supervisor.

• Patrol the plant and ensures that the equipment is operating normally and that no
unusual conditions exist. Ahmed Mohamed Shafik Ali Attia
 Field Operator

• Responsible for preparing equipment for maintenance including isolation, draining,

steaming, and other procedures as required.

• Responsible for preparation such as plant isolation etc., for day-to-day maintenance
work.

• Perform daily check and minor maintenance based on the check list etc.

• Take appropriate actions in accordance with Panel Operator and Lead Operator in
case of emergency.

• Work directly with the foreign experts in the transfer of technical advice during the
initial period of operation.

Ahmed Mohamed Shafik Ali Attia

 Field Operator

• Monitor and operate equipment circuit breakers and switches as required for safe
and efficient operation of the plant. This includes opening, locking, and tagging for
isolation and maintenance.

• Report and respond to chemical spills and leaks in accordance with plant emergency
response plans.

• Receive fire fighting training based on fire fighting training program preparing for
emergency.

• Some of field operator, if appointed temporary firefighting crew, acts as a one of

firefighting crew In case of emergency.

• Comply with all company Health, Safety and Environment as well as Work Permit,
policies and procedures Ahmed Mohamed Shafik Ali Attia
Panel Operator

Ahmed Mohamed Shafik Ali Attia

 Panel Operator

• Responsible for all operational aspects of the plant during his shift, including
personnel and equipment safety.

• Ensures safe and efficient start-up, operation, and shutdown of the plant equipment
from the control room using the plant’s Distributive Control System (DCS) and
other available controls and indications.

• Fosters a team spirit.

• Performs any other tasks or assignments as determined by the needs of the company.

• Performs start-up, operation, and shutdown of equipment, systems, and the plant in
accordance with approved plant procedures.

Ahmed Mohamed Shafik Ali Attia

 Panel Operator

• Monitors and records plant operating parameters inside the control room; make
adjustments as required to maintain safe and efficient operation of the plant.

• Upon detecting faulty equipment operation, diagnose the cause then take proper
action to restore the equipment and plant to a safe condition. This includes stopping
equipment and switching to standby equipment if required and available, WITH
PROPER COMMUNICATION WITH SHIFT SUPERVISOR, LEAD OPERATOR
& FIELD OPERATOR.

• Monitor plant air and water emissions and take steps to maintain within acceptable
limits.

• Immediately notify Shift Supervisor of abnormal situations, including those that

may result in violation of regulatory requirements.

Ahmed Mohamed Shafik Ali Attia

 Panel Operator

• Coordinates with Field Operator as required to start-up, operate, shutdown, and

respond to abnormal situations from field.

• Provide periodic reports to the Shift Supervisor regarding plant status.

• Observe, report, troubleshoot, and correct situations that are likely to develop into
operational problems or safety hazards.

• Monitor, maintain, and verify proper chemistry control of steam generator water,
feed water, cooling water, condensate, condensate makeup, and wastewater.

• Obtain thorough turnover from Control Room Operator being relieved, including
special orders and unusual operating conditions.

Ahmed Mohamed Shafik Ali Attia

 Panel Operator

• Review operating logs and inspect plant controls and indications.

• Perform tests on critical safety systems, as directed, including lube oil pumps,
turbine valves, turbine system trips, boiler trips and permissive.

• Test and operate plant fire and chemical safety equipment as directed.

• Perform and direct equipment isolation in accordance with plant lockout/tagout

procedures.

• Maintain work area in a clean, orderly condition.

• Participate in scheduled safety meetings and training.

Ahmed Mohamed Shafik Ali Attia
Shift Supervisor

Ahmed Mohamed Shafik Ali Attia

 Shift Supervisor

• Management of staff, develop and motivate direct reporting staff.

• Administer your own shift team, including overtime, leave requests, shift swaps and
the vacation schedule as well as monitoring operator training and generating
development plans and performance appraisals

• To take full responsibility of the quality and product that is produced within the shift
in line with the companies quality systems, processes and procedures.

• Monitor, measure and report on production related issues.

• Establish proper communication (verbally or written) within shift team.

Ahmed Mohamed Shafik Ali Attia

 Shift Supervisor

• Ensure full compliance with the company Health and Safety Policies and
Procedures, such as PTW (permit to work), IIF (incident & injury free), IR (Incident
Reporting), etc.

• Perform problem solving and troubling shooting to identify root causes and take fast
effective action to resolve the problems arises during the shift.

• Efficient coordination with other Shift Supervisors to ensure production handovers

are effective communications tools.

• To ensure that the training skills are met for current and future demands of the shift.

• Actively promotes the company’s continuous improvement plan in light of company

mission and vision.
Ahmed Mohamed Shafik Ali Attia
 Shift Supervisor

• Maintain housekeeping standards to ensure a clean and safe workplace.

• Participate in the development of training programs for shift team and ensuring their
competence for the tasks in respective areas.

• Actively participating in HAZOP and model reviews – Key Participants.

• Develop pre-commissioning, commissioning and start-up procedures for your

assigned area and ensure validation based on applied procedures.

• Coordinate with discipline supervisors and ensure that all equipment meets required
safety specifications and standards.

• Take the lead in emergency response situations, in close cooperation with shift
superintendent Ahmed Mohamed Shafik Ali Attia
Shift Superintendent

Ahmed Mohamed Shafik Ali Attia

 Shift Superintendent

• Accountable for ensuring that shift meets organizational goals and objectives.
(safety, quality, cost, and customer satisfaction).

• Coordinates with Head of Operation in setting goals and objectives for the shift.

• Coordinates all production activities on a given shift to continuously improve

workflow, work product, and employee and customer satisfaction across all
departments.

• Communicates instructions and accurately report problem areas, and corrective

action during the shift.

• Monitors employee progress in achieving assigned objectives and counsels or

corrects as required.
Ahmed Mohamed Shafik Ali Attia
 Shift Superintendent

• Prepare high level shift reports to Head of Operations and Operations Manager
identifying SWOT – Strengths / Weaknesses / Opportunities / Threats and ensure
full alignment with peers.

• Ensures long term production capability of the process equipment by maximizing

PM and machine reliability on assigned shift.

• Effectively communicate with and utilize all support activities such as Human
Resources, Tire Engineering, Industrial Engineering, Production and Material
Control, Process Engineering, Accounting/Finance, and Maintenance/Plant
Engineering.

Ahmed Mohamed Shafik Ali Attia

Operations Documents

Ahmed Mohamed Shafik Ali Attia

 Main Operations Documents

• Pre-commissioning & Commissioning procedures.

• Operation Manual.
• Standard Operating Procedures.
• Shutdown Procedures.
• Emergency Procedures.
• CSO/CSC – LO/LC.
• PTW Log.
• Shift Report.

Ahmed Mohamed Shafik Ali Attia

Pre-Com & Com

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

The Key Activities of Pre-Commissioning:

• Pipeline Pigging
• Chemical cleaning
• Water flushing
• Air blowing
• Steam blowing
• Motor Solo Run Test
• N2 purging
• Loop checking
• Rotating equipment alignment check
• Leak test
• Final box up of tanks, vessels and equipment

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

The Key Activities of Commissioning:

• Switchgear energization.
• HVAC Initial start up.
• Telecom Function Test.
• F&G Integrity test.
• SIS (Safety Instrumented Systems) function test.
• Rotating Equipment Dynamic Testing.
• Compressor Surge Test.
• FSNL (Full Speed No Load) Turbines Test.
• Boilers Boil out and preservation.
• NLDT (No Load Dynamic Test) for conveyors.
• Flare pilot lighting.

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

• The Key Stages of Commissioning Process

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

Pre-COM & COM

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

• Early inspection of individual items will allow any non-compliances to be identified

at an early stage, thus avoiding subsequent delays in construction progress.

• Furthermore, special attention to pre-commissioning inspection will contribute to

equipment reliability when the equipment is brought on stream.

• As it is not possible to complete all checks on any one item at the same time,
checklists should be used to ensure that essential points are not overlooked.

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

• The objective of inspection during construction or maintenance is to ensure that:

1. The equipment has been supplied in accordance with the purchase order.
2. The equipment has been installed correctly.
3. All required documentation has been completed.

• Punch list general principle

While the Pre-commissioning, Commissioning and Start-up activities have
being performed, all discrepancies shall be recorded in the Punch list

Ahmed Mohamed Shafik Ali Attia

 Pre-COM & COM

• One point is considered as a block point if it one of the following is put at risk :
1. The safety or operational aspect.
2. The system integrity.
3. Missing any requirement from particular local rules/regulations.

• From the construction to the routine operation three Punch List priority levels should
be considered:
1. PL A: Item considered as a block point for Commissioning activity of the sub-
system
2. PL B: Item considered as a block point for Start-up activity of the sub-system
3. PL C: Item not considered as a block point for Start-Up activity but linked to a
contractual performance from the equipment and milestone (for example Partial
Acceptance, Hand-Over, ….).

Ahmed Mohamed Shafik Ali Attia

Operation Manual

Ahmed Mohamed Shafik Ali Attia

 Operation Manual

• The operations manual is the documentation by which an organization provides

guidance for members and employees to perform their functions correctly and
reasonably efficiently and should be available for reference whenever needed.

• It captures the approved standard procedures for performing operations safely to

produce goods and provide services.

Note: Compliance with the operations manual will generally be considered as activity approved
by the persons legally responsible for the organization.

• It does not substitute for training but should be sufficient to allow a trained and
competent person to adapt to the organization's specific procedures.

Ahmed Mohamed Shafik Ali Attia

 Operation Manual

• The manual is either a book or folder of printed documents containing:

1. Standard operating procedures – SOPs.

2. Description of the organizational hierarchy.

3. Contact details for key personnel and emergency procedures.

Notes:

1. A good manual will reduce human error and inform everyone precisely what they need to
do, who they are responsible to and who they are responsible for.

2. The operations manual is a document that should be periodically reviewed and updated
whenever appropriate to ensure that it remains current.
Ahmed Mohamed Shafik Ali Attia
Operation Manual Content

Ahmed Mohamed Shafik Ali Attia

Operation Manual

Ahmed Mohamed Shafik Ali Attia

Operation Manual

Ahmed Mohamed Shafik Ali Attia

Standard Operating Procedure
SOP
Ahmed Mohamed Shafik Ali Attia
 3- Standard Operating Procedure

• Let’s know about the Standard Operating Procedure (SOP) Of Pumps.

• Starting a centrifugal pump for the first time can be a troublesome experience unless
the plant crew has made a thorough check of the unit during and after installation,
there are probably more unusual accidents and troubles during initial starting of a
pump than at almost any other time.

Steps Of SOP:-

1. Inspection Works Before Start-Up.

2. Pre Start- Up Check Points.
3. Start-Up Procedures.
4. Post-Start-Up Check Points.

Ahmed Mohamed Shafik Ali Attia

 Standard Operating Procedure

1. Inspection Works Before Start-Up:

• Pipe Cleanliness. Field Operator

• Alignment Of Pump. Maintenance

• Rotation Of Rotor.
• Pump Bearings.
• Sight Glass.
• Lube oil System.
• Lubricants.
• Pump Exterior.
• Pump Auxiliary Piping.
• Pump Driver.
• Priming And Barring.
Ahmed Mohamed Shafik Ali Attia
 Standard Operating Procedure

2. Pre-Start- Up Check Points:

• The lubrication system of all bearing points must be check. Field Operator
• Cooling water must be circulating through all water-cooling systems. Maintenance

• Prime mover power (electricity or Steam, etc. as a driving force)

should be checked.
• Rotate the Pump rotor by hand.
• level of liquid at the suction side should be check.
• Delivery valve closed for Centrifugal Pump otherwise delivery valve
should be open.
• The pump should be warmed gradually by slowly circulating hot
liquid through the pump.

Ahmed Mohamed Shafik Ali Attia

 Standard Operating Procedure

3. Start-Up Procedures:

• The suction valve should be open. Field Operator

• Priming should be performed properly. Panel Operator

• The re-circulation valve or spill-back line should be opened.

• When the pump reached normal operating speed open the discharge
valve slowly.
• The liquid is brought into the pump by venting the casing.
• The suction line should full of liquid to be pumped.
• The direction of rotation should be check by the ON-OFF switch.
• The pump should started-up with the aid of prime mover.

Ahmed Mohamed Shafik Ali Attia

 Standard Operating Procedure

4. Post-Start-Up Check Points:

• Process parameters such as pressure, temperature, flow, etc. Field Operator

Panel Operator
• Temperature and vibration of all bearing points. Maintenance
• Abnormal Sound. CONMON

• Motor amps / Turbine load.

• Check the leakage from the stuffing box.
• Adjust sealing water.
• Check the bearing lube oil flow and pressure.
• Check the suction, discharge, lube-oil, cooling water, pressure, and
temperature.

Ahmed Mohamed Shafik Ali Attia

Operational Safety Docs

Ahmed Mohamed Shafik Ali Attia

1- Job Hazard Analysis - JHA

Ahmed Mohamed Shafik Ali Attia

 2- Incident Investigation Report
Incident Reporting Instructions
Incident Investigation must be completed w ithin 7 days of the incident
Basic Form
Complete all items on the f orm.

1. General Information -
Date of Incident Complete the Date and Time the incident occurred.
Date Reported Enter the Date and Time, w hen w as the incident w as f irst reported to anyone.

Location Enter location of incident

Functional Location Identif y the designated f unction location e.g. f loor no. or unit no. Admin,
w orkshop, HSE Of f ices, Secondary areas, etc.
Category Indicate the site category f or the incident. Choose the appropriate Category
f rom the list.
Department Identif y the company Responsible department f or the incident
Contractor Indicate the designated Contractors Name f or the incident. (Note: Secondee
staf f to company is classif ied as an employee NOT a Contractor)

Classif ication Choose one of the f ollow ing classif ications.

Type If applicable (f or security reporting only)
Choose the appropriate Security Type f rom the list.
Dollar Amount Enter the dollar amount of damage. It is acceptable to provide an estimated
value/w orth.
Description of Incident Describe the incident using a f ew w ords. You should be as f actual as
possible and use w ords to brief ly describe w hat happened.
For example: Individual f ell, broke leg.
Detailed Description Enter a detailed description of the incident.
Individual's Activity Choose the general activity perf ormed by the individual at the time of the
incident.
Example: Erecting or dismantling scaf f old. Choose "scaf f olding".
Choose an activity f rom the list.
Site This f ield relates to the site f or the incident e.g. Equipment no. of f ice no.
street, etc. (exact location of the incident)
Weather/Temp/Wind/Seas If available, provide atmosphere details at the time incident occurred.
Est. equip/property damage Only applicable w hen classif ied as a Property Damage/Loss. Note: If $
exceeds 50K, then supplemental report may be required by the f inance
department.
Was Incident Witnessed If "Yes" then include w itness details in detailed description.

Ahmed Mohamed Shafik Ali Attia

 Incident Investigation Report
2. If Injury or Illness - (Guidance from Company Medical)
Job Position Choose a general Job Position f or the individual f rom the list.
Name/Company If available, Provide Name and Company of the individual.
Injury or Illness Type Choose a specif ic Type f rom the list.
IMPORTANT: Look f or the injury/illness in the "drop-dow n". Select the
appropriate injury/illness listed.

Body Part Choose the appropriate Injured Body Part f rom the list. If more than one Body
Part is involved choose the body part w ith the most injury.
Position Choose the appropriate "body placement" of the individual at the time of the
incident. Select the appropriate Position listed.
Medical Response Enter the type of treatment provided and type of response; ongoing
Taken/Treatment Provided examinations or pending results
Est. Days To Be If available, Provide Number of Days the individual w ill be ef f ected.
Lost/Restricted
Years of Service & Experience If available, Provide number of Years of Service and Experience.

3. Incident Severity Scale ( Refer to Company Incident Notification & Severity

Actual Severity See Incident Notif ication and Severity Matrix
Potential Severity This is the w hat if thinking-- w hat severity could the incident have been

4. Incident / Near Miss Investigation Summary

Primary Contributing Causal Use one of the investigation methods or RCA to analyze the incident f indings
Factors
Other Signif icant Contributing Identif y other f actors that contributed to the incident or sub-f actors f or RCA
Causal Factors methods
Corrective Actions Action must name a person w ho is responsible f or the corrective action and
estimated date of closure
5A thru 5C Free text

6. & 7. Endorsement (Investigation Team Leader & Section Head)

Distribution: Upload to the Incident Management Website and attach to the e-incident
notif ication
8. Corrective Actions Completed
Note:
Ahmed Mohamed Shafik Ali Attia
 3- Permit To Work - PTW

• Permit-to-work (PTW) refers to management systems used to ensure

that work is done safely and efficiently.

• These are used in hazardous industries and involve procedures to

request, review, authorize, document and most importantly, de-conflict
tasks to be carried out by front line workers.

• A permit to work is not a replacement for robust risk assessment, but can
help provide context for the risk of work to be done.

Ahmed Mohamed Shafik Ali Attia

 Permit To Work - PTW

A permit to work form typically includes:

• The work to be done.

• The equipment to be used and personnel involved.

• Precautions to be taken when performing the task.

• Other workgroups to be informed of work being performed in their area.

• Authorization for work to commence.

• Duration that the permit is valid.

• Method to extend the permit for an additional period.

• Witness mechanism that all work has been completed, and the worksite restored to
a clean, safe condition.

• Actions to be taken in an emergency. Ahmed Mohamed Shafik Ali Attia

 Permit To Work - PTW

PTW TYPES

Ahmed Mohamed Shafik Ali Attia

THANK YOU

Ahmed Mohamed Shafik Ali Attia