CAREER EPISODE 1

SUPPORT ENGINEER AT Gorgon CO2 Injection Project

1.1 INTRODUCTION
In project entitled “Gorgon CO2 Injection Project” I, Eleuterio Anain, worked as a
support engineer. In this career episode I will detail about my roles and works
during the project. This project was carried out by Yokogawa Australia in Barrow
Island. This project was initiated in May 2019 and successfully ended in December
2019. This project was undertaken to capture and store carbon dioxide as defined
in project. Carbon dioxide will be captured directly from the gas field and would
be liquidated and transported to pre-defined location.

1.2 BACKGROUND
1.2.1
This Gorgon CO2 Injection Project is very first LNG project in Australia that
involves injection and storage of liquid CO2 into a deep reservoir unit. In it gas
was supplied from the field which was identified as a reservoir of carbon-dioxide.
This reserved gas was extracted from natural gas as a part of gas-processing
operations. Carbon dioxide was separated before natural gas was liquidated. It
was done by basic absorber and striper system and an amine based solvent. The
obtained carbon dioxide was compressed and injected in well where it will remain
trapped. Due to depth it was filled in, pressure rose and caused it to behave as
supercritical fluid which showed the property of bot liquid and gas. The carbon
dioxide remained trapped in the reservoir due to the combination of residual
saturation trapping and by dissolution into the waters in the formation. It was
done without hampering flora and fauna of environment.
Above described paragraph detail about the overall function and task of the
project. I was responsible for the technical operation of all machines, equipment
at the plant. There were multitude of tools like PCS, SIS and F&G which were
integral for smooth operation of project. I configured and monitored all those
devices. I performed entire predefined technical task that arouse in this project. I
represented Yokogawa vendor and did pre-commissioning of ICCS Loops. There
was also software to be implemented in all the machines utilized in the project.

1.2.2
The primary objectives of my work in this project are as follows:

 To work on ICCS Loops Pre-Commissioning.

 To validate the equipment, machines, systems and subsystems, other
system components that are installed.
 To test and operate all installed devices.
 To assist the client in software and hardware installation.

1.2.3
I successfully up took the responsibility shouldered upon me. With enthusiastic
colleagues I worked in this project. As per defined work I identified the
requirement of the project and developed methodology to accomplish the
project. The work was sub divided among members as per requirement.
1.2.4

Yokogawa Australia

Company Head

Department Head

Supervisor

Engineer

ME (Sub-Engineer)

Figure: Organizational Hierarchy

1.2.5 ROLES
I fulfilled following roles during the tenure of the project.

 To successfully pre-commissioned ICCS loops.

 To test all the instruments deployed in the project and verify their work.
 To provide technical support to the pre-commissioning team.
 To setup the field bus devices correctly and according to data sheets.
 To register devices in the Yokogawa Asset Management system.
 To provide technical support during software modification of DCS.
 To successfully replicate the code of DCS, SIS and F&G.

1.3 PERSONAL ENGINEERING ACTIVITIES

1.3.1
In the project, I was briefed about the task that I had to complete. I was
introduced to the devices and equipment of the plant. I did complete revision
regarding PCS, SIS AND F&G and enhanced my ability to operate them. I
researched about all the data sheets of the electric components used in this
project. I organized the entire task for smooth operation of task ahead.

1.3.2
I tested and verified the entire instruments and field devices that would be used
in future in the project. I was represented vendor of Yokogawa for ICSS Loop Pre-
Commissioning. Devices like namely Process Control Systems (PCS), Fire & Gas
(F&G) and Safety Instrumented Systems (SIS) were deployed in this project. I
inspected and checked the entire device to make sure that they were as
requested by client and no leak was present. I made sure those devices were
properly cleaned and flushed before operation. In presence of client those
devices were then verified.
1.3.3
After device were commissioned and verified they were then set up as per
requirement. I carefully stationed the entire device in pre-defined spot in plant. I
calibrated all devices according to their separate datasheet. It was vital as one slip
in calibration could lead to malfunction and break down of entire connected
devices. I provided every device with unique eight bit binary number address to
integrate them in main system. It also ensured the communication among all
connected device is established. I added Device Description (DD) file and Common
File Format (CFF) files with the software provide by parent company. It allowed
discerning the detail of all the visible information in a device. I imported the
DD/CFF files with the Interface Configuration Utility as it located the error in the
DD/CFF files if any. As there were no errors on the files, the Interface
Configuration Utility copied the DD/CFF files to the base directory. By completion
of above task I ensured all devices were recognized in system.

Figure: Fieldbus Communication System

1.3.4

I managed and controlled PCS. I connected it to workstation and field instrument

devices that constituted valve, switch and sensors. I checked the valve and
positioner to be sure it performed reasonably well. I checked valve dead band to
determine its performance. I conducted valve maintenance task. I performed test
for determination of process time constant, process gain, and process dead time. I
used these values to calculate new gain and reset settings for the controller
connected to that valve or final control device. Prior to conducting the test, I
assessed signal filtering values and sample rate settings to ensure accurate test
results.

Next I checked and verified the fire and gas field instrument. I checked the tag
number, range and description of fire and gas system. I verified its color of display
(Normal: Green, Abnormal: Red blinking; Acknowledged Alarm: Static Red; Fault
value: Yellow. I also verified if sound was audible to all people and work place. It
checked if there was any gas or fire leakage. Such leakage would be risky and
cause catastrophe in the plant. I set detectors and panels which monitored sense
if there was any variation.

Now I tested the most important one .i.e. safety instrument system (SIS) as it
concerned the safety of staff and also the device used. Beyond any production
and economic growth human life is paramount. I checked the stages of shutdown
for any unit. I checked whether individual process train shut down or not in case
of any applicable trip. All equipment was shut off in itI set the system to monitor
dangerous conditions in plant and take required action when needed. I set
sensors to find the deviation in the plant. I did it to find the deviation regarding
process values, temperature, pressure and action of actuators and valves. If they
go above acceptable level alarm is issued. I also programmed logic solver which
process and analyzed the data from sensor to give out certain data. If obtained
data is critical then it would close the certain half of plant or close down whole
plant.

Figure: Complete DCS System

1.3.5

After the full inspection of critical devices I then commenced and connected all
devices to main frame by software. I used DCS software issued by Yokogawa. I
installed HMI software in the DCS workstation and Control software in controllers
that performed basic control functions. I implemented changes according to client
need with approved Work Permit and Job Hazard and Safety Analysis. I simulated
the overall system on software to verify the need of the consumer and
implemented complex changes. After simulation I corrected functions which
failed during testing and also improved according to necessity. All change I made
was tested and witnessed by client in close coordination with other disciplines to
ensure it was done safely and did not impact other sections of the plant. On
completion of testing I closed the Change Request after client accepted. The
codes were sensitive for the client. Hence I replicated software code for the DCS,
SIS & F&G. I carried out it according to the approved Change Request which
typically refers to the completed trains as basis for the changes. I acquired
stringent compliance for the SIS & F&G changes being Safety to Functional Safety
Standards of Chevron. I also followed strict peer-review process and quality and
safety checks before a change was implemented.

1.3.6
After successful integration of software with all devices, I registered all devices of
plant in the Yokogawa Asset Management system Plant Resource Management
(PRM) so it can be maintained outside the ICSS systems. I did to so as to do
continuous monitor of all devices and their operation. Devices were bounded to
system as I provided them company registered IP address. For those devices
where this process was not possible, I connected them to computer and operated
from there. Those computers were obviously connected to main system.

By its completion, I successfully accomplished the task bestowed upon me.

1.3.7 TECHNICAL DIFFICULTY AND SOULTIONS

1.I found out that Rotork Fieldbus Valves could not be operated during function
testing. It was implemented for distributed control as control was done by specific
device and not by monitoring computer. But here we found out that it was not
functioning. Due to it, certain devices were not functioning properly. Our whole
operation was ceased. To solve this issue I performed careful investigation and
did top to bottom checking of valve. I found out that the fieldbus device settings
were incorrect. I found out that the valve was not properly closed and
percentage up to which it should be opened was not also as desired. So, I worked
on this issue. I properly closed the value and also set the desired percentage of
openness of valve as per client requirement. After performing this action, I found
out that Rotork Fieldbus valves operated properly. Hence I corrected the device
setting of field bus device. This has always been an issue with Engineers working
on fieldbus systems. Lack of understanding of the concept of fieldbus has always
been a stumbling block during commissioning. I checked the manual for further
certainty and successfully eliminated this issue.

2. Another technical issue I stumbled upon was HMI graphic replication was slow
and there was no tracking mechanism to know what HMI graphics have been
updated and download to stations in the plant. Due to it, it was difficult to
operate, monitor and control plant various parameters and devices. It was also
difficult to take action according to function of devices. To solve this issue I wrote
an Excel tool to speed up the HMI graphic replication process and another one
that tracks what HMI graphics have updated and which stations they were
downloaded. I first created script in HMI RT application and then created an
EXCEL table to run parallel with script. I created row for writing data into table
after script execution. After every execution of the script I wrote “integer”, “real”
and “bool” strings into the new line of excel file. And after execution of script,
data were inserted into excel table and script was tested. Values of internal HMI
tags of strings were saved in excel. After this information and data of the state
and process of the devices was obtained instantly. I was able to take action
efficiently according to the function of other devices. This also helped to speed up
the process. HMI became fast and I was also able to see its updated status. Then, I
was able to operate, monitor and control plant various parameters and devices.
1.3.8 CREATIVE WORKS
It was important for every designated staff to know and understand HMI. Else
one small deviation could create large complication. So to mitigate this future
issue, I created a page where one could see the status of HMI and all the device
operation under it. From it one could see which device is performing at which
level and if there is any issue present in them. By doing so, individual could alert
and call the designated personal for its maintenance.

1.3.9
I was support engineer and every task that came under verification, test,
installation and operation of all devices in plant were done by me and team under
my management. I assigned all of my team members their daily task according to
their technical capacity. I made sure that all members understood and could
operate as required. I also adhered the request of client and performed operation
as per their request. I held meeting and discussion between client and my team
so as no desired operation was left incomplete I consulted with my senior chief if
any issue aroused in the project and kept them up to date about the operation.
After the completion I submitted report to my senior and also to client.

1.3.10 ETHICS AND STANDARD

It was absolutely necessary to follow the ethics of the work and to operate under
standard set. With full honesty I followed the guideline provided to me by my
company. I also studied the work guideline of Client Company and operated
under it. I also followed IEC 61508 which is the international standard for
electrical, electronic and programmable electronic safety related systems. It sets
out the requirements for ensuring that systems are designed, implemented,
operated and maintained to provide the required safety integrity level (SIL). Task
is done as per approved Work Permit and Job Hazard and Safety Analysis and
Toolbox meeting conducted prior to commencing work for the day. For any non-
conformance or discrepancies observed I am involved in the investigation on the
Yokogawa ICSS side and rectification where necessary.

1.4. SUMMARY
1.4.1
All the devices that were installed in plant were sensitive in nature. It was to be
handled and operated carefully. This is where my expertise came in. I verified
Process Control Systems (PCS), Fire & Gas (F&G) and Safety Instrumented Systems
(SIS). I also tested those devices to check if they were functioning as per
requirement of clients. They were vital to provide automation in the operation of
plant. It also provided safety to all the worker and equipment in plant. It avoided
damage in the plant. I also made sure that all the devices are connected according
to datasheet. Without it, the devices may malfunction or may not function at all.
For the smooth operation of system and to avoid complication software was also
installed in the plant. It was calibrated according to client need.

1.4.2
This project was a vibrant experience for me. It helped to transcend my
knowledge about instruments and their successful operations. I was able to
develop the understanding about all the devices used in plants. My knowledge
regarding about connecting all the bus and devices become more sharp, crisp and
fast. My sea of knowledge regarding instruments also increased tenfold as I
consulted to books and papers written about them. I got more experience about
instrument operations and how to operate them with fluidity. Most importantly, I
got more experience of how to communicate with clients. I got better on not only
listening to their issue but also understanding them. By it, I was able to solve any
technical and non-technical issue that aroused during the project. It will certainly
be helpful in long run. Hence this project enlightened me regarding many
important aspects of work.