RELATED LEARNING EXPERIENCE AT

JG SUMMIT PETROCHEMICALS GROUP

Simlong, Batangas City

A Narrative Technical Report Presented to

Industry – Academe Cooperative Education Program Office (IACEPO)
Batangas State University
Batangas City

In Partial Fulfillment of the Requirements for

The Degree of
Bachelor of Science in Chemical Engineering

By:

Bersabe, Julius M.
ChE-5102

December 2018
 INTRODUCTION

Our economy is changing daily, and with it, the talents, skills, and experience
needed to be a part of that growth cycle are too. The job market is a competitive one, and
often that is a tough learning curve for recent graduates. This is a big reason behind the
growth of applied learning and internship opportunities becoming a key part of the college
experience for all students. The training helps us to be more equipped in our field of
specialization, fabricate our confidence in associating with other individuals particularly
proficient ones which can give us open doors for future business. Additionally, we can get
the opportunity to see in real what our course is really all about and decide how we can
apply all the knowledge we have learned. In particular, through this training, we will have
the capacity to know ourselves more and be edified on what sort of industry we might
want to work later on.

The discipline ‘chemical engineering’ is often used to describe a really broad area
of engineering. It’s hardly surprising then that chemical engineers are known as ‘universal
engineers’. A chemical engineer is an ‘enabler’; someone who makes things happen
efficiently on a massive, industrial manufacturing scale. They aim to get the best results
at the least cost and with the lowest impact on the environment possible. And skills in
chemistry, physics and mathematics, and even economics are what makes a chemical
engineer so valuable.

The role of a chemical engineer in oil n gas industry is in the downstream sector
where the crude oil gets refined into petroleum products of lesser molecular weight and
the complex nature of the compounds are decreased.

Today, chemical engineering is one of the most stable and lucrative employment
sectors. As an extremely technical field, and one that is in high demand by companies in
many different industries, both public and private, there is a constant demand for qualified
professionals. So chemical engineers in most industries enjoy a plenitude of inter-industry
advancement opportunities and upward mobility.
 COMPANY PROFILE

JG SUMMIT PETROCHEMICALS GROUP

JG Summit Petrochemicals Group is a business of design, development,

manufacture, sales, and distribution of petrochemical products. The JG Summit
Petrochemicals Group complex is located 120 km south of Metro Manila, in Barangay
Simlong, Batangas City, overlooking the scenic Batangas Bay. At present, JGSPG has a
250-hectare fully integrated, world-class manufacturing complex that houses the Naphtha
Cracker Plant (JGSOC) and the Polymers Plant (JGSPC).

JG SUMMIT OLEFINS CORPORATION

JGSOC operates the first and only naphtha cracker plant in the Philippines.
Downstream of the cracker is JGSPC’s PE and PP polymerization facility which benefits
from the consistent supply of ethylene and propylene. The cracker’s two other products,
pyrolysis gasoline and mixed C4, are sold to producers who use these as raw materials
in the manufacture of intermediate petrochemical products such as benzene, toluene,
xylene and butadiene, which are in turn used to make solvents, dyes, paints, foams and
rubber.
JGSOC ensures stability in the supply and price competitiveness of widely used
EVALENE® HDPE, LLDPE, PP-H and PP-R resins for the Philippine plastics industry.
The Country’s First Naphtha Cracker Plant
JGSOC’s $700 million naphtha cracker plant uses Lummus Technology, and is
designed to primarily produce 320 Kilo Tons per Annum (KTA) of polymer-grade ethylene
and 190 KTA of polymer-grade propylene, which are feedstocks for the JGSPC polymers
plant. JGSOC is an integral part of JG Summit Petrochemicals Group.
Features of JGSOC’s ethylene process as adopted from Lummus Technology are:
 Use of Short Residence Time (SRT) pyrolysis furnace for high olefins yield, high thermal
efficiency, long run-length, feed flexibility
 Quick Quencher Transfer Line Exchanger (TLE) for low pressure drop and short
residence time resulting in minimum yield degradation
 TLE decoking technology for reduced maintenance, longer tube life and less emissions
 Low pressure chilling train for energy efficiency and lower investment cost
 Hydrogenation process for acetylene/diene towards higher selectivity, minimization of
green oil production and reduction of energy consumption
 Tertiary refrigeration that results in lower investment cost, enhanced reliability and
simplified maintenance

Compliance and Certifications

JGSOC operates a quality and environmental management systems which has been
assessed as conforming to ISO 9001:2008 and ISO 14001:2004 respectively.

JG SUMMIT PETROCHEMICAL CORPORATION

JGSPC’s polyolefins manufacturing processes are based on UNIPOL™ PE

Process and UNIPOL™ PP Process Technology, known for its safety, environment-
friendliness, simplicity, operational stability, cost-effectiveness and versatility.
UNIPOL™’s relatively low pressures and low temperatures eliminate over-pressurization
and runaway reactions, making it one of the safest PE and PP polymerization
technologies available today. This gas phase process is also the cleanest in its class due
to the absence of liquid and solid effluents emitted to the environment.
Today, The Dow Chemical Company’s fully owned Univation Technologies is the
licensor for UNIPOL™ PE Process, while W.R. Grace & Co. is the licensor for UNIPOL™
PP Process Technology. The licensing agreements with these companies are
characterized by continuous liaison, extensive documentation, complete training and
technical assistance, which ensure the continuous improvement of the Plant and our
personnel.

Facilities

The JGSPC subsidiary plant includes the following facilities:

 Two reactors for Polyethylene with 320 KTA combined capacity
 One reactor for Polypropylene with 190 KTA capacity
 Central Control Room with Distributed Control System (DCS) Technology by Honeywell-
Yamatake
 Tank Farm with cryogenic and ambient storage tanks and Flare Facilities
 Laboratory with state-of-the-art instruments for Quality Control, Quality Assurance,
Product Applications and Technical Services
 Closed-loop Cooling Water System, with heat exchange to sea water
 Jetty that can accommodate 54,000 DWT vessels
 Three-hectare covered warehouse for storing up to 37,000 tons of packaged products. It
includes a packaging facility for loading products into 25kg, 750kg, and 1,000kg bags, as
well as in-house heavy duty bag-making equipment.
 Modern safety equipment and fire prevention facilities situated in accessible locations all
over the plant to ensure the safety of employees and surrounding communities.

Compliance and Certifications

All EVALENE® grades comply with FDA Philippines food-contact requirements for PE and
PP resins, and are likewise Halal certified.
With our ISO 9001:2008 and ISO 14001:2004 certifications, our customers are assured
that we adhere to the highest standards for quality management and environmental
performance.

PURPOSE AND VALUES

JG Summit Petrochemicals Group is a pioneer in the petrochemical industry as it

continuously strives for excellence in serving the Filipino nation. It creates a culture of
innovation by providing sustainable solutions for the changing world. Innovation plays a
major role in the organization. With the right technology, JG Summit Petrochemicals
Group is able to build long-term business partnerships, responsible manufacturing of
petrochemical products and various opportunities to improve the lives of each and every
Filipino.
 VISION

We are the market leading, preferred supplier of innovative world-class

petrochemical products and solutions in the Philippines.

MISSION

Our mission is to deliver sustainable value to our stakeholders, our customers and
the community. We will achieve this through our people who are our most valued asset.
We carry out our operations in a safe and efficient manner because we are
environmentally responsible in all aspects of our enterprise. We conduct our business
with an overarching goal to contribute to nation building and to industrialization in the
Philippines.

CORE VALUES

 Customer Focus
 Safety, Health and Environment
 Teamwork
 Integrity

OFFICE STRUCTURE/WORKFORCE

We at JG Summit Petrochemicals Group employ highly competent, motivated and

dedicated employees who will be contributors to the attainment of our vision to become
the market leading, preferred supplier of innovative world-class petrochemical products
and solutions in the Philippines. Our expansion has created many career advancement
opportunities for professionals and trainees alike.
We make sure our top-of-the-line technology is partnered with equally world-class
human resources. Our employees undergo continuous skills and competence
improvement by participating in various leadership, technical and non-technical programs
here and abroad.
Here in JGSPG, passion is considered an intangible key to success. Our people,
driven individuals who constantly strive with unparalleled dedication, and guided by our
commitment to make life better through innovation, greatly contribute to our success.
We encourage our people to maintain a healthy balance between their work and personal
lives through programs, activities, and social initiatives designed with their total well-being
in mind.

The Process Automation Department ensures the continuous, efficient, stable,

safe and profitable performance of the JGSPC process control and auxiliary systems
through proper maintenance of the systems and management of associated projects.

SAFETY, HEALTH AND WORK ENVIRONMENT

Our commitment to health, environment and safety begins with ensuring that our
employees are provided with a safe and healthy working environment.
Through our stringent safety measures, mandatory safety trainings, and the overall
culture of safety we encourage in our people, we are able to provide hazard-free work
locations for our employees. We cultivate a culture of safety within JGSPG by instilling in
every member the importance of safety, and how each person is responsible not only for
himself, but for others as well.
We have an ongoing greening program within the complex to continuously provide a
stress-free and conducive working environment for our employees

ON-THE-JOB TRAINING ACTIVITIES

This chapter presents the internship training activities that the Process Automation
Department (PAD) would assign to the trainees.
 The table below presents the training subject list to be done by the trainees during
the 500-hour on-the-job training program.

PROCESS AUTOMATION DEPARTMENT- NAPHTHA CRACKER PLANT

NO. TITLE

1 PAD Function and Organization

2 NCP Yokogawa DCS/ESD Architecture Overview
DCS Overview (DCS vs ESD vs PLC)
Yokogawa Centum VP DCS Components/Elements
Network Architecture
3 Area Familiarization
Control Room
Hot/Cold/Utility Sections
HIS & Auxiliary Panels
Rack Room
DCS & ESD Panels (PDP, IRP, MP, System, Network)
Hardware Familiarization
Loop Tracing
4 Human Interface Station
DCS Graphics
HIS Navigation (Hierarchy)
Trends
Tuning Window
Historical Reports
5 Basic Process Control System Overview
Control Loops
Simple & Complex Loops
DCS Interlocks
6 Basic SIS/ESD Overview
Logic Gates (OR, AND, NOT, SET-RESET)
ESD Logic
7 Advance Topics
Control Loop Performance Monitoring
System Application and Products (SAP) Overview
 PROCESS AUTOMATION DEPARTMENT- INFORMATION SYSTEM

NO. TITLE EDUCATION HOURS

1 Overall PIMS System 2.5H
-Server Architecture 0.5H
-PHD Server and Software Familiarization 1H
-LIMS Server and Software Familiarization 1H
2 Operator Training Simulator 1H
-System Architecture 0.5H
-Dynsim and Intouch Overview 0.5H
3 Process Historian Database 6H
-Role of PHD Server (JGSPIMS01) 0.5H
-PHD Server & Collector Architecture 0.5H
-Introduction to Uniformance/ End User Application 2H
-PHD Configuration Tool/ PHD Tag Configuration/ PHD Tag 1H
Routing
-Graphics Builder and Graphics Creation 2H
4 Laboratory Information Management System 3H
-Role of LIMS Server (JGSPIMS02) 0.5H
-LIMS Server components and Architecture 0.5H
-LabMate and Instrumate Software 0.5H
-LIMS to PHD Interface 0.5H
-Laboratory Sample parameters configuration 0.5H
-Sample parameters Tag assignment & configuration 0.5H
5 Workcenter Server 2.5H
-Role of Workcenter Server (JGSPIMS03) 0.5H
-Workcenter Builder and Graphics Creation 2H
 6 Uniformance Insight Server 3.5H
-Role of UI Server (JGSPIMS12) 0.5H
-UI HMI Web Builder Graphics Creation 3H
7 Automated Workflow System Server & Access Control 1.5H
System Server
-Role of Production & Development Server (JGSPIMS07/ 0.5H
JGSPIMS10)
-Access Manager Software Familiarization 1H
8 Software Installation and Backup 1.5H
-PHD Collector Backup 0.5H
-Veritas Backup Exec Software Familiarization 1H

INTERNSHIP TRAINING ACTIVITIES

The responsibilities designated to the trainees during the internship improved our
abilities and knowledge by learning and experiencing the work done by the process
automation engineers. To perform this everyday task we must have the motivation,
enthusiasm and hard work, for our self to comply the work needed in the company. Also,
there are many challenges that we can learn to it and can be applied to the personal
growth.

Observation

During the first day of training, the trainees were oriented about the company
profile and safety regulations of the plant. They were oriented on using personal
protective equipment (PPEs) all the time to ensure safety while working. Safety is one of
the top priorities of the plant.
 They were introduced to their supervisors and to the other workers and
professionals in the plant who will guide them throughout their internship. They were
oriented about what is Process Automation Department, the objectives and the training
checklists to be done within their stay in the company. Then, the trainees were oriented
on the daily routine that will be assigned to them.

Participation

The trainees were assigned to the Process Automation Department: Naphtha

Cracker Plant, Petrochemical Plant, and Information System. They were tasked to
conduct the daily, weekly, and monthly routines which are done by the Process
Automation Engineers. The trainees also finished their checklists; assisted the other
engineers in doing preventive maintenance, and in modifying graphics; and shadow in
Process Automation Engineers when doing works.

RESULTS AND ASSESSMENT

Accomplishments, Projects and Outputs

The internship training at JG Summit Petrochemicals Group helped the trainees

established their abilities through the activities that was given to them. Through this, they
have been presented to the genuine workplace and realize what it look like to work with
various types of individuals and activities. The preparation likewise indicated how they
can apply what they have learned at their course in the field.
In our first and second week stay in Process Automation Department- Petrochem
(PAD-PET) we learned about the PAD organization and what PAD is all about, I learned
that PAD is a technical support for the engineering maintenance, system administration,
and improvement of control system, safety instrumented system. PAD also manage
software licenses. We had this orientation also about PAD rackroom house rules. Also
in this week we are introduced in our task for the daily monitoring of DCS and ESD,
SCADA Connections, APC Status, Alarms and Errors. Then the backup of files are done
every Thursday. To complete our first and second week we had an overview about the
basic process of the petrochemical plant. For the basic process overview we tackle the
products marketed of the JG Summit Petrochemical plant these are HDPE and LLDPE
for the PE1 and PE2 plant and Homo-PP and Random-PP for the PP plant. Also the basic
process from raw materials to product, the raw materials Ethylene, Propylene, Butene,
Hexene, Isopentane, Hydrogen and Nitrogen will undergo purification system in which it
will remove the impurities of the raw materials and protect the reaction system from
different poison. After purification system it will go to the reaction system to perform the
polymerization reaction. Then it will proceed to resin degassing to remove the
unnecessary gas in the resin to improve its quality, gas that is remove from resin
degassing will go to vent recovery system to increase the efficiency of the monomer. The
resin will then go to the additive handling and pelleting to improve the physical and
chemical properties. Lastly it proceed to the packaging system. We also check procure
spare parts in the warehouse and conduct preventive maintenance of DCS workstation.

The third week starts with an overview about Process control, I learn that process
control is Important because it makes the operation run smoothly, increase efficiency and
ensure safety. We discussed the element of control loop, Process variable(PV) condition
of the process fluid that can change the manufacturing process in some way, Set
Point(SP) is the process variable that is desired to be maintained, Manipulated
Variable(MV) condition of the process fluid that must be kept with the selected SP. Mode
of controller action overview which is Proportional, Integral, Derivative controllers,
proportional action corresponds to how much change controller output relative to how
much change in the controller input, integral action corresponds on how frequent the error
existed, and the derivative action is the change of the rate of change of the error. We also
had the instrument loop drawing overview, in which it indicates the end to end
implementation of IO and it is used for troubleshooting. It indicates also the physical
connection starting from the field up to the rackroom. Marshalling Cabinets, PLC
Cabinets, and ESD Cabinets are the ones which the PAD engineer troubleshoot. Locating
IO Card, Channels, Input Number, and Model of the Card are also taught using the ILD’s.
 For the fourth week, we had the alarm management philosophy overview. In this
overview I learned that alarms are properly chosen and implemented, properly controlled,
monitored and maintained, and should be configured on the best indicator of the root
cause of the situation. When there is an abnormal condition requiring a response,
equipment malfunction and process deviation there should be an alarm. We also had the
Honeywell Experion overview for the BPCS, Honeywell Safety Manager Overview for the
ESD and Honeywell Master Logic overview for the PLC. In this week also system
architecture, and rackroom familiarization layout are tackled.

In our last week we had PID Control Loop Familiarization which includes Simple
Feedback, Cascade, Feedforward, Ratio, Split, and Override Control. Simple
Feedback control take the system output into consideration, which enables the system to
adjust its performance to meet a desired output response. Cascade control has a
secondary control that is set up to control a variable that is a major source load
disturbance to the primary control. Feedforward control anticipates load disturbances and
control them before they can impact the process variable. Ratio is has a dependent
stream and a wild stream. It has two controller but one final control element. Split has one
controller but two final control elements. We also tackle ISO Documents, PHD and APC
Overview. Advance Process Control (APC) is the supervisory control and use for
optimization of the reactor. Interlock Logic Diagram (ILD) is also discussed, here we learn
how to identify logic symbols and what the use of it are. Lastly we had an overview about
Piping and Instrumentation Diagram (P&ID), the purpose of this diagram is to indicate the
instrument or control devices attached to the process and control system architecture
associated to the process. I also learn the parts of the how to read the P&ID.

In the 5 weeks stay in the PAD-PET we attend also different meetings, these are
the Improvement of Process Automation Engineering and Modification Request
Procedure, Alarm Handling for PM/CM Activities, Automation Control Solution for the Coal
Fired Power Plant by Yokogawa and Honeywell and Major Process Hazards. We also
attend in the weekly department meeting with our manager and other members for the
updates regarding of what our activities that have done in the last week. In the weekly
meeting also we are updated regarding what are the latest safety issues that happen in
the company.

Our outputs within our stay in PAD-PET were the Barrier Cabinet Inventory
delegated by Sir Ifor, Documentation and Rationalization (D&R) of Alarms designated by
Ma’am Renren and the changing of the priority of Bad PV Alarms designated by Sir Jude.
Other outputs are the daily monitoring activities, this is to check the current state of the
plant if there is any abnormal things happen. Back up of files and database, done weekly
and to guarantee that the files generated on the past week has a backup. PM of
workstations (cleaning of CPU, monitor replacement etc.), cabinets and printers, this is to
ensure that the workstations, cabinet and printers is operating at a good condition.

We are also doing the daily monitoring of SCADA Connections, APC Status,
Alarms and Errors. The backup of files are done every Thursday.

For our first week in PAD-NCP, different cabinets like ESD and Marshalling
cabinets were discussed and know their purpose and difference. We also tell apart the
differences of the cabinets from NCP and Polymer Plant. Area familiarization and
diagnostic exam are done in this week. We also discussed how to do loop tracing. This
activity is done for we are able to see the path of signals coming from the cabinets. The
basic processes of Naphtha Cracker Plant is also discussed which start from Thermal
Cracking and Quenching, Compression and Acid Removal, Separation and Recovery
Section, C4 Hydrogenation, and Gasoline Hydrogenation. NCP DCS Centum VP R4.03
and the Human Interface Station were taught to us. Also, there is a one week training
held about Centum VP which enriches my knowledge on the control system about the
NCP.
In our second week, we had an overview about Control Loop Performance
Monitoring. Control Wizard, Tune Wizard was also discussed. We are able to know the
difference between Hysteresis, Stiction, and Non linearity. Overview about ProSafe-RS
was also done. Safety, Risk, Safety System were defined clearly. The security levels,
Safety Control Unit, Processor Unit, and the meanings of LED Display were also defined.
We also had a five days training in ProSafe-RS which I really learned a lot about the
safety system. Like in the Petrochem we had an overview about Control loops which are
the feedback, cascade, override, split, and ratio.

In our third week, Human Interface Stations (HIS) Filters were cleaned for the
preventive maintenance. We also had our Plant tour in Petrochemical Plant and in
Naphtha Cracker Plant which helps us to see the different equipment and process in both
plant. The Case Study about E-0603 control loops was also presented in this week.

In our last week, we did the preventive maintenance of DCS Marshalling Panel,
DS, and ESD Marshalling Panel. We also had a brief overview on System Application
and Products (SAP). The use of SAP Application is to display PM Orders, raise orders,
to close orders, and etc.

For the outputs within in PAD-NCP were the daily routines which are the Visual
Checking of CPU Idle Time and the status of each node, Temperature and Air Conditioner
Monitoring in the Rackroom, and ACS Terminal cleaning. The weekly and monthly
routines which are the Onsite and Offsite Backup of DCS, ESD, CCTV and AMS
Database and CCTV Checking were also one of the outputs. The DCS Tags Master
Database, Image Backup of NCP DCS Graphics, screenshots of OSBL and ISBL
modified graphics, and the case study of control loops involved in E-0603 were the others
outputs that we have done in PAD-NCP.

Lastly, in PAD-IS we discussed about the system architecture of the plant on how
NCP and Petrochem system are linked in PAD-IS. For the interns’ outputs are the editing
of graphics in Uniformace, editing and checking of email address of the employees and
backup of database from NCP and Petrochem.