Career Episode 2: Field Survey Project for Modernization of Petro-Rabigh Old Refinery

Mohsin Bajwa conducted a detailed site survey for Old Refinery, Utility, Tank Farm, Terminal, and Marine Area to analyze the existing condition of Field Instruments, Junction Boxes, Local Panels, and DCS Panels. The project aimed to enable further plan in the Modernization of the Old refinery, Utility, Tank Farm, Terminal, and Marine Area. Mohsin Bajwa developed objectives and goals for the successful delivery of the research, analyzed the existing data and information related to the ongoing operational activities in the oil refinery, and proposed the best options those could be helpful in modernizing the old refineries. Read more about the project in this Career Episode 2.

COMPETENCY DEMONSTRATION REPORT
Career Episode 2
MOHSIN BAJWA

CE 2.1 Project Information
CE 2.1.1 Project Information
Name of the project: Field Survey Project for Modernization of Petro-Rabigh Old
Refinery
Location of the project: Rabigh, Saudi Arabia
Project Duration: Dec 14 to July 15
Organization: Yokogawa Services Saudi Arabia Company
Role and Designation during the time: Field Engineer
CE 2.1.2 Project Background
CE 2.2.1 Characteristics of the project
I was involved in a project to conduct a detailed site survey for Old Refinery, Utility,
Tank Farm, Terminal, and Marine Area to analyze the existing condition of Field Instruments,
Junction Boxes, Local Panels, and DCS Panels. I executed this project considering the
effectiveness those could be gained through the site survey and implement those findings that
can be helpful in enabling further plan in the Modernization of the Old refinery, Utility, Tank
Farm, Terminal, and Marine Area. I delivered the project considering the advancements those
could be gained through researching the existing refineries and analyzing the market for
proposing the best and effective options those could be gathered through effective and efficient
amendments and modifications.

CE 2.2.2 Objectives developed for the project
I developed the following set of objectives and goals for the successful delivery of the
research:
 To study the existing condition of field instruments and control systems
 To submit a detailed site survey report mentioning the obsoleteness,
recommendations to reuse, repair or replace due to degrade and design issues
 To obtain all the existing facilities related data and information for developing the
FEED & Detail Engineering in accordance with the project scope
CE 2.2.3 My area of work
I was assigned as the field engineer and I had to analyse the existing data and information
related to the ongoing operational activities in the oil refinery. I had to collect all the documents
those were on the desk or hidden for few time and thereafter, executed the survey. I had to
analyse the entire existing work environment of the oil refinery and propose the best options
those could be helpful in modernizing the old refineries. I had to thoroughly investigate the
existing operations and the ways through which the activities were being delivered for the
accomplishment of those activities. I had to collect all the information before executing the
analysis and then I had to prepare a report that can allow the heads to understand the research
being followed and approve the further amendments those I was going to recommend.

CE 2.2.4 Project Group
CE 2.2.5 My responsibilities throughout the project
I was responsible for effectively and efficiently survey the old refinery through personally
visiting and reviewing the machines and the ways in which the operations were being delivered. I
thoroughly surveyed the old refinery and collected the existing documentation about the entire
operational activities. I studied the existing documents for analyzing, preparing, and submitting
the field survey report.
CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
I delivered the project I manner to understand the existing environment of the old
refineries and implement the modifications those could bring revolution and enhance the services

and products being delivered to the consumers. I had to analyse all the existing information
relayed to the previously designed and working of the oil refinery and analysed them efficiently
in manner to discuss the modifications those could bring into the light for accomplishing the
better environment for the refinery. The executed survey will be helpful in positively analysing
the entire environment and prepare the strategies those could allow the innovation and change in
the existing system of the refineries.
CE 2.3.2 Engineering knowledge and skills applied in the project
I prepared a Check Sheet for Field Instruments to survey the existing condition of the
field Instruments and sent the check sheet for End-user approval. After getting the approval from
End-user I used the check sheet and following data was noted or checked,
• Manufacturer if readable
• Model number if readable
• Serial Number if readable
• To check the overall condition of the transmitter, control valves, switches,
gauges, indicators, detectors, temperature elements and vibration elements /
switches
• To check if the instrument is pneumatic or electronic
• To check if the electronic transmitter has display or not
• To check the condition of tubing and accessories
• To check the condition of the cable

• To check if the valve has P/P positioner or E/P positioner
• To check the condition of solenoid valves and limit switches
• To check if the control valves need overhauling
• To check the obsoleteness of the instrument along with the concerns from PRC
and giving the final recommendations
• To check EDMS and Library files to collect the details like model number and
make of the instruments.
CE 2.3.3 Accomplishment and task performed
I prepared a Check Sheet for Junction Boxes to survey the existing condition of the Junction
Boxes and sent the check sheet for End-user approval. After getting the approval from End-user I
used the check sheet and following data was noted or checked,
• Manufacturer if readable
• To check the overall visual condition of the Junction Box
• To check the cable entry and orientation of the entry
• To check the number of main cables and branch cables and available spare holes for
cable entry
• To check the certification and rating if available

I prepared a Check Sheet for Control Systems to survey the existing condition of the related
Panels and sent the check sheet for End-user approval. After getting the approval from End-user
I used the check sheet and following data was noted or checked,
• PIB location where the cabinet is installed
• Cabinet number
• Overall condition
• In case of DCS system cabinet, to check the controller, node, power supply, I/O cards,
spare slots and the cable and connecter condition
• In case of DCS marshalling cabinet, to check the relay board, terminal board, power
supply model, terminal spares.
• To check the condition of the accessories
• To check the grounding bus bars and shield bars
• For other cabinets visual inspection and condition were checked
I checked the condition of all Control valves including actuators, accessories, and
evaluate requirement for overhauling or complete replacement of valve. I identified all old P/P
positioners and I/P converters related to Control valves and recommended to replace with new
E/P positioners.

CE 2.3.4 Identified issues and their solutions
One of the challenging task was to give my recommendations on the old instruments and
best possible solution to modernize the refinery. The general recommendation which I gave to
End-user for different Instruments are as follows,
i. Pneumatic Displacer type level transmitter
Recommendation: For Displacer Type level instruments I propose to replace Install new
HART type level transmitter.
ii. Level switches
Recommendation: If the existing chamber is small and not covering the range, we
propose to replace the switch or install new transmitter. For switches that are being used for
shutdown and interlock, the recommendation to replace with new transmitter.
iii. Pneumatic Transmitter
Recommendation: For Pneumatic transmitter, I propose to replace / Install new
transmitter (HART/SMART)
CE 2.3.5 Plan to produce creative and innovative work
Pneumatic Positioner
Recommendation: For control valves with pneumatic positioners, I propose to
replace / Install new E/P positioner
v. Emergency Shutdown Valve (ZV / EIV)

Recommendation: For different type / make of existing shutdown valves, I
propose to replace / Install new ESD positioners having partial stroke with HART
Protocol communication. Existing local shutdown JB shall be demolished. As per 34-
SAMSS-634, partial stroke feature is mandatory for all Emergency Isolation valves.
Feasibility study shall be conducted with EIV actuator/valve vendor during FEED phase
to check the possibility of installing ESD positioner for existing valves
vi. Sight Glass Type Level Gauge
Recommendation: For existing sight glass level gauge, I propose to replace with
magnetic float type level gauge.
vii. Dial Type Pressure, Flow and Temperature Gauge
Recommendation: For existing dial type pressure gauge, I propose to replace all
gauges. For pressure gauge installed at Pump Discharge and Suction, Recommendation
to replace with new transmitter (HART/SMART) based on the criticality of the Pump
Operation shall be done during FEED / Basic Engineering
viii. Pneumatic Local Controllers
Recommendation: For pneumatic local controllers, I propose to demolish such local
controllers and to be upgraded with DCS controller
Thermocouple
Recommendations: It is recommended to replace all existing thermocouple with new
duplex type thermocouple with transmitter. For the cases where temperature ranges are higher or
requires more accuracy RTD with transmitter shall be recommended.

DVC-6000 positioners
All existing DVC-6000 positioners and older DVC models to be replaced with DVC-
6200 PD (Performance Diagnostics) type positioners. I summarized the all the field survey data
and established a Master Database for Field instruments with obsoleteness report and final
recommendation. Field Junction Boxes and Panels. Cabinets and panels in the various PIB’s and
substations
CE 2.3.6 Collaborative work
The project would have never been completed without the effort of every individual
involved in the team for the execution of the survey necessary for the implementation of the
newly introduced features and operations for the old refineries. The project had more than one
phase and hence, it was not a single man job and hence, the entire project group contributed in
the efficient and effective manner in manner to accomplish the effective survey that can result in
positive response for the old oil refineries.
CE 2.4 Project Review
CE 2.4.1 Project Overview
The detailed site survey was completed before schedule by distributing the survey tasks
within 8 teams and getting the report from each team on daily basis. I used the system backup to
retrieve the hard IO’s which were coming from Field Instruments and I revalidated the
Instrument Index. My detailed report helped customer to convince their board members and to
allocate a specific Budget based on the inputs and recommendation provided in the report for
modernization of the refinery.

CE 2.4.2 My contribution to work
I contributed in leading the survey and developing the management plan that can allow
specific roles and responsibilities for every individual involved in the project. I managed the
entire team on how to execute the survey within specified timeline. I made sure that every
objective and activity of the project lead us towards certain results and output of the survey that
can alternatively contribute in implementing the modernization within the old oil refineries.