Final Internship Report Murdoch University Internship at The BP Kwinana Refinery

MURDOCH UNIVERSITY
Final Internship Report

2013
Clint Armstrong
2/3/2014
A report submitted to the school of Engineering and

Information Technology, Murdoch University in partial fulfilment of the
Requirements for the degree of Bachelor of Engineering
ABSTRACT
WorleyParsons and Murdoch University have come to an agreement allowing one student the
opportunity in his/her final year of Instrumentation and Electrical Engineering to complete an
internship at the BP Kwinana Refinery, located in WA. This report demonstrates the work completed
and experience gained over the duration of the internship.
Background information is provided in this report to ensure that there is a substantial understanding
of the refinery’s processes and operation. This was required to complete the project work to a high
standard.
This report summarises all the major projects allocated during the time at the BP refinery. The
design, construction and commissioning stages of the project are discussed, detailing the
instrumentation roles of each. Projects will be covered in greater detail highlighting background
information, methods and procedures. The projects are listed below.
DCS Upgrade Phase 3 (HYDY2) project. This project is the upgrade of all obsolete control system
hardware on the hydrofiner unit. It is a multimillion dollar project that is estimated to be completed
May 2014.
TEL Load Cells project. Aviation fuel is a high quality manufactured product that requires accurate
dosing amounts of tetra ethyl lead. This project involves the installation of new load cells that will
accurately measure the TEL dosed in the AVGAS, as apposed to the current inaccurate setup.
WWTP Flow Weighting Autosampler project. The waster water treatment plant at the refinery is
required to sample and purify the water in order to meet environmental standards as explained in
section 3.4. It is required to program the autosampler to take averaged flow samples every hour on
the hour. In order to implement such project, optimisation techniques were used to ensure that
these samples would meet the minimum requirements.
The program affords the opportunity to be exposed to industry projects. This permits the student to
demonstrate and applies his/her skills learnt at university by putting what is produced in an office
environment and executing the practical part of the project on site.
II
DISCLAIMER
All of the work discussed in this report is the work of the author unless otherwise referenced.
I declare the following to be my own work, unless otherwise referenced, as defined by Murdoch
University’s policy on plagiarism.
Signed By Clint Armstrong: ……………………………………………….
December 2013
III
ACKNOWLEDGEMENTS
Foremost I would like to thank WorleyParsons and BP for providing the rare opportunity to complete
an internship with the Instrumentation and Electrical team at the Kwinana refinery. This internship
has provided first hand experience in instrumentation and electrical engineering projects.
Thank you to the Instrumentation and Electrical team at WorleyParsons for their patience,
enthusiasm and support. Special thanks to Mark Spiranovic who is the BP contract Manager and Paul
Copland who is the Instrumentation Manager for WA for making this internship possible. I would
also like to off my thanks to my industry supervisor Scott Russell for donating his time and effort to
ensure I received the best relevant experience and knowledge to contribute to my development as a
professional engineer.
I would also like to thank all the engineering staff at Murdoch University who has seen me develop
throughout the course of my degree. Very special thanks to Doctor Linh Vu for all her help and
support throughout the years of my degree and having faith in me and Dr Gareth Lee for mentoring
me through the internship. I also thank Associate Professor Graeme Cole and Professor Paris Bahri,
for providing the foundation to the School of Engineering and Information Technology at Murdoch.
IV
CONTENTS
List of Figures......................................................................................................................................................... 3
List of Tables .......................................................................................................................................................... 3
Acronyms and Abbreviations ................................................................................................................................. 4
1.0 Introduction ...................................................................................................................................................... 5
2.0 Background ....................................................................................................................................................... 6
2.1 Oil Refining Process ..................................................................................................................................... 6
2.1.1 Distillation ............................................................................................................................................. 6
2.1.2 Reforming .............................................................................................................................................. 7
2.1.3 Cracking................................................................................................................................................. 8
2.1.4 Alkylation ............................................................................................................................................ 10
2.1.5 Isomerisation ....................................................................................................................................... 12
2.1.6 Polymerisation ..................................................................................................................................... 13
3.0 Project Work ................................................................................................................................................... 14
3.1 DCS Upgrade .............................................................................................................................................. 16
3.1.1Background ........................................................................................................................................... 16
3.1.2 Scope ................................................................................................................................................... 18
3.1.3 Implementation .................................................................................................................................... 19
3.1.4 Project Constraints and Issues ............................................................................................................. 20
3.1.5 Project Status ....................................................................................................................................... 20
3.2 TEL Load Cells .......................................................................................................................................... 21
3.2.1 Background .......................................................................................................................................... 21
3.2.2 Scope ................................................................................................................................................... 21
3.2.3 Implementation .................................................................................................................................... 22
3.2.5 Project Status ....................................................................................................................................... 23
3.4 WWTP Flow Weighting Autosampler ........................................................................................................ 24
3.4.1 Background .......................................................................................................................................... 24
3.4.2 Scope ................................................................................................................................................... 25
3.4.3 Implementation .................................................................................................................................... 25
3.4.5 Project Status ....................................................................................................................................... 26
4.0 Remaining Project Summaries........................................................................................................................ 27
4.1 CDU2 Ex Register ...................................................................................................................................... 27
4.2 Procurement ................................................................................................................................................ 30
4.3 Instrument Protection System (IPS) Dossier .............................................................................................. 31
4.4 Hiway 7 Upgrade ........................................................................................................................................ 32
5.0 Additional Tasks Completed .......................................................................................................................... 33
5.1 Monthly Safety Meetings ........................................................................................................................... 33
5.2 Project Meetings ......................................................................................................................................... 33
6.0 Time Management .......................................................................................................................................... 34
7.0 Internship Review ........................................................................................................................................... 36
8.0 Conclusion ...................................................................................................................................................... 37
Bibliography ......................................................................................................................................................... 38
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LIST OF FIGURES
Figure 1 - Basic distilation process overview [23] ................................................................................................... 7
Figure 2 - Basic catalytic Cracking process overview [24] ....................................................................................... 9
Figure 3 - Basic hydro cracking process overview [25] ......................................................................................... 10
Figure 4: Carbon Bond structure .......................................................................................................................... 11
Figure 5 - Basic alkylation process overview [30] ................................................................................................. 12
Figure 6: Carbon bond structure .......................................................................................................................... 12
Figure 7 - DCS Overview [9] .................................................................................................................................. 16
Figure 8 -TEL isotainer tank................................................................................................................................. 22
Figure 9 - Isco4700 autosampler [17] ................................................................................................................... 24
Figure 10 - ORIFICE PLATE DIMENSION DIAGRAM ................................................................................... 31
Figure 11 - Cause and effect chart ........................................................................................................................ 32
LIST OF TABLES
Table 1 - Instrument tag reference table [20] ...................................................................................................... 15
Table 2 - Time delay and refresh rates for dcs [9] ................................................................................................ 17
Table 3 - Atmospheric zone classification [12] ..................................................................................................... 27
Table 4 - Ignition temperature classifications [12] ............................................................................................... 28
Table 5 - Instrument certificate numbers [12] ..................................................................................................... 28
Table 6 - Gas activation energies [12] .................................................................................................................. 29
Table 7 – Input parameters [21] ........................................................................................................................... 29
Table 8 - Weekly project time management ........................................................................................................ 34
Table 9 - Project task timeline .............................................................................................................................. 34
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ACRONYMS AND ABBREVIATIONS
BP British Petroleum
AIP Australian Institute of Petroleum
ALKY Alkylation
AVGAS Aviation Gasoline
CCB Central Control Building
CDU2 Crudes Distillation Unit 2
Cold Cut-over To completely replace control system
DCS Distributed Control System
DEC Department of Environment and Conservation
DIB Deisobutaniser
Ex Explosion Protected
FAR Field Auxiliary Room
FTA Field Termination Assembly
HCO Heavy Cycle Oils
HF Hydrogen Fluoride
HI-WAY Control Communication Network
HMI Human Machine Interface
Hot Cut-over To simultaneously run old with new control system
HPM High Performance Manager
HYD2 Hydrofiner 2
IPS Instrument Protection System
IS Intrinsically Safe
LCO Light Cycle Oils
LPG Liquid Petroleum Gas
MIT Minimum Ignition Temperature
RCU Residual Cracking Unit
SDOOL Sepia Depression Ocean Outfall Line
TAR Turnaround
TEL Tetra Ethyl Lead
WP Worley Parsons
WWTP Waste Water Treatment Plant
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1.0 INTRODUCTION
The BP Kwinana refinery was first opened in 1955 and is located 30 kilometres south of Perth,
Western Australia. The Kwinana refinery is Australia’s largest oil refinery, producing 140,000 barrels
of oil a day with a workforce of almost 400 people [1]. It is Western Australia’s only refinery,
producing its petrol, diesel and jet fuel supplying the main operators in WA. The BP Kwinana refinery
is currently preparing for a multimillion dollar scheduled shutdown. This is a sign that the refinery is
here to stay in operation under BP indefinitely, since they will be spending money on maintenance
and upgrades. Australia’s high operating costs are often quoted as the reason refining margins or
profit margins are low. As a result the companies are currently considering a sale or conversion into
fuel import terminals [14].
Oil refining is a very complex process in the oil and gas industry with a small profit margin. This is
why there are very few small refineries around the world as it has proven to be more profitable with
higher barrel volumes. It is said “refineries need a production capacity of at least 200,000 barrels per
day (bpd) in order to reach the minimum efficient scale”[16]. With high volumes of fuel produced
sophisticated technology is needed to supply the industry with its needs. Therefore, instrumentation
and control teams continuously work on upgrades, monitoring and maintenance to ensure the
refinery runs safely and efficiently while being cost effective. This report will cover the projects that
have been completed or are undergoing construction by the Instrumentation and Electrical team,
detailing the background, scope and implementation of the work done.
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2.0 BACKGROUND
As a new employee to BP it is required that all staff have a substantial understanding of the
background information of the oil and gas refining processes, operations and control systems in
order to complete the work with full competency.
Therefore this section of the report will provide a brief description of each of the particular
processes throughout the refinery and the purpose that they serve. This enables a new employee to
the refinery to gain an understanding on a broad spectrum of the units and the projects to be
covered to ensure that engineering is completed to its utmost quality.
2.1 OIL REFINING PROCESS
The oil goes through three major stages: separation, conversion and purification. These processes
are divided into several other stages in the production of petrol, aviation fuel (AVGAS), liquid
petroleum gas (LPG), lubricant oils and diesel [7].
2.1.1 DISTILLATION
The objective for a distillation unit is to separate the feed stream into light-component and heavy-
component product streams.
The distillation process relies on the relative volatility between the components that make up the
feed stream. These consist of high volatility (lighter) components, which boil at a lower temperature
than will the low-volatility (heavier) components. Therefore, when heat is added to the column
through a bottom reboiler, the lighter materials are vaporized and will rise to the top of the column
where the overhead vapors are cooled until they condense and become liquid again.
The efficiency of the distillation depends on the amount of contact between the vaporising and the
liquid falling down through the column. As a result some of the overhead liquid product is sent back
which is also known as refluxed, to the top of the column. Increasing the reflux will improve the
purity of the overhead product. However, it also requires more heat from the re-boiler to re-
vaporize the lighter components in the reflux stream to ensure further purification. The basic
operation of a distillation column comes down to the balancing of two elements, for example the
product purity and energy use to complete the distillation process [7].
If the amount of vapor and liquid traveling through the column become too great, the column can
flood [6]. Other problems include reflux flow or too much re-boil heat. This results in too much vapor
and also can cause flooding. When flooding occurs, the efficiency of the distillation column is
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dramatically reduced, with corresponding drops in product purities. A diagram of the overall
distillation process can be found in Figure 1.
FIGURE 1 - BASIC DISTILATION PROCESS OVERVIEW [23]
2.1.2 REFORMING
Furnaces are used to heat the process feed material. Heat is created by burning fuel in burners on
the floor and /or walls of the furnace. The fuels, such as natural gas, liquefied petroleum gas (LPG),
refinery waste gas and fuel oil are used by the furnace for heating.
The process feed stream to a furnace is usually broken into multiple tube passes to improve heat
transfer. The most common configurations are two and four pass furnaces. The passes are
recombined into a single effluent stream after they exit the furnace. The outlet temperature of the
furnace is normally dictated by adjusting the amount of fuel burnt [8]. This downstream process is
used in a reactor or distillation column. In some cases, the furnace will provide enough heat to crack
the feed stream thermally from large hydrocarbon molecules to smaller molecules. In these cases,
the outlet temperature is used to control the amount of cracked components in the effluent stream
[8].
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2.1.3 CRACKING
The cracking process is an important process in oil refining where the breakdown of heavier
hydrocarbon molecules with high boiling points creates lighter products such as petrol and diesel.
These processes are split between catalytic cracking and hydrocracking, both processes will be
explained below in further detail [8].
Catalytic cracking is the process of cracking heavy feedstocks such as gas oils, vacuum gas oils, and
residual material into gasoline. The cracked components are produced by selective reactions in a
fluidized catalyst bed in the presence of heat, which in turn aids in the process of producing the
relative fuels.
Figure 2 shows how the incoming feed is heated in the furnace to the reaction temperature. The
feed enters a vertical reactor where it contacts hot catalyst powder. The feed vaporises and cracks
as it moves up the reactor, carrying catalyst with it. Coke precipitate formed from coking in the
catalytic cracking, is a bi-product used in the electrical power industries as fuel, is formed on the
catalyst as the reactions take place. The catalyst and the cracked material are separated. The spent
catalyst is sent to a regenerator where it is regenerated by burning off the coke. The regenerated
coke is recycled to the reactor. The cracked material continues on to a fractionating tower, where it
is separated into wet gas, distillate, LCO (light cycle oil), HCO (heavy cycle oil), and slurry. The wet
gas continues on to a gas plant. The distillate cut might be suitable for use as a gasoline blend
component [8].
Page | 8
FIGURE 2 - BASIC CATALYTIC CRACKING PROCESS OVERVIEW [24]
Hydrocracking is a process, which converts heavy feedstock into lighter components by selective
reactions with hydrogen in multiple heated catalyst beds. The process is most commonly used to
create gasoline or diesel product streams.
As shown in Figure 3 the incoming gas oil feed is heated in a furnace to the reaction temperature. It
is combined with a recycle hydrogen stream before flowing through the reactor with multiple
catalyst beds. Additional recycled hydrogen is added between each bed to control the cracking
conversion. The reactor effluent is sent to high-pressure, then low-pressure separators. The vapour
from the separators is recycled through a compressor back to the feed. Makeup hydrogen is added
to this stream as necessary. The liquid from the low-pressure separator is sent to a fractionator,
where the reactor effluent is separated into its component product streams.
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FIGURE 3 - BASIC HYDRO CRACKING PROCESS OVERVIEW [25]
2.1.4 ALKYLATION
The Alkylation unit is used to convert light olefins, usually propylene or butylene, produced by a
cracking unit or delayed coker unit into a gasoline blending component called alkylate. Alkylate is
one of more valuable blending components for gasoline because it has a high octane rating coupled
with a low Reid vapor pressure which is “a common measure of the volatility of gasoline”[18].
Olefins are a hydrocarbon that usually consists of propylene and butylene that are created by
catalytic and thermal cracking units. The carbon structure is shown in the Figure 4.
Page | 10
FIGURE 4: CARBON BOND STRUCTURE
As shown in Figure 5 the light olefin feed to an alkylation unit is mixed with recycled isobutene from
the deisobutaniser (DIB) tower overhead and is cooled before entering the reactor. The isobutene-
olefin mixture, along with sulfuric acid and refrigerant, is sent to the stirred reactor. In the presence
of the acid, the olefins and isobutene react, forming the alkylate compounds and generating heat.
Any propane that is produced in the reactor is concentrated in the refrigeration system and, after
caustic and water washes, is sent to a depropanizer. The depropanizer overhead is a propane
product, and the bottom stream is returned to the process [8].
The reactor effluent is sent to a settler where acid is removed from the hydrocarbons. The acid is
recycled to the reactor, which the hydrocarbon continues through caustic and water washes before
entering the DIB tower. Any makeup isobutene is generally added as feed to the DIB tower. The DIB
overhead stream is mostly isobutene and is returned to the reactor. The DIB bottom stream
becomes the feed to the debutanizer. The debutanizer bottom stream is the alkylate product for
gasoline blending [8].
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FIGURE 5 - BASIC ALKYLATION PROCESS OVERVIEW [30]
2.1.5 ISOMERISATION
The name isomerisation derives from the type of reactions that occur when hydrocarbon molecules
are rearranged to form other isomers without altering the number of carbon or hydrogen atoms in
the molecules. Isomerisation promotes chemical rearrangement of straight-chain hydrocarbons,
which are paraffins, so that they contain branches attached to the main chain [19]. Paraffins have a
single bond structure between each carbon atom usually known as propane shown in figure 6.
FIGURE 6: CARBON BOND STRUCTURE
Page | 12
This is done for two reasons; they create extra isobutane feed for alkylation and they improve the
octane of straight run pentanes and hexanes and hence make them into better petrol blending
components. Isomerisation is achieved by mixing normal butane with a little hydrogen and chloride
gas. This allows it to react in the presence of a catalyst to form isobutane and a small amount of
normal butane and some lighter gases. The products are separated in a fractionator and the lighter
gases are used as refinery fuel and the butane is recycled as feed [8].
2.1.6 POLYMERISATION
Under pressure and temperature, over an acidic catalyst, light unsaturated hydrocarbon molecules
react and combine with each other to form larger hydrocarbon molecules. Such process can be used
to react butenes with iso-butane to obtain a high octane olefinic petrol blending component called
polymer gasoline.
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3.0 PROJECT WORK
During the internship, contributions were made to a number of projects, which are outlined within
this section. Each project contains a significant portion of process control and instrumentation that
involved mainly upgrades to old control systems and field instruments. The projects discussed are:
DCS Upgrade
TEL Load Cells
WWTP AutoSampler
During the phases of a project, the engineers interpret electrical drawings and P&ID cross reference
hundreds of loops to ensure that they all relate to one another. The ability to read an electrical
single line diagram or a process and instrumentation diagram (P&ID) requires attention to detail.
One-way of becoming familiar one self with such drawings is referred to the standard [20]. This
standard establishes a uniform means of depicting and identifying instruments or devices and their
inherent functions. This includes instrumentation systems, application software functions used for
measurement, monitoring, and control by presenting a designation system. The designation system
includes identification schemes and graphic symbols [20]. The task of identifying names of
instruments in diagrams required particular attention. Table 1 provides a tabular form of the
alphabetic building blocks of the Instrument and Function Identification System in a concise, easily
referenced manner [20]. For example, to select the tag numbers for a temperature transmitter. The
first alphabetic column represents the assigned letter to the instrument, and in this example T is for
temperature chosen from column 1. For the second subscript letter, column 3, 4 and 5 are used to
select the transmitter part for the tag number, which also has the subscript letter T following the
table. Therefore a typical tag number for a temperature transmitter would be TT-001, 001 being the
number related to a particular area or pipeline and in this case it is just a default number chosen for
the example. Sections where labelled user’s choice can be customised to suite the project. These are
non-assigned subscript letters and therefore are available as spares for special instruments.
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TABLE 1 - INSTRUMENT TAG REFERENCE TABLE [20]
First letters Succeeding letters

Column 1 Column 2 Column 3 Column 4 Column 5
Measured/ Variable Modifier Readout/Passive Output/Active Function Function Modifier
Initiating Variable Function
A Analysis N/A Alarm N/A N/A

B Burner, Combustion N/A User’s Choice User’s Choice User’s Choice
C User’s Choice N/A N/A Control Close
D User’s Choice Difference, N/A N/A Deviation
Differential
E Voltage N/A Sensor, Primary N/A N/A
Element
F Flow, Flow Rate Ratio N/A N/A N/A
G User’s Choice N/A Glass, Gauge, N/A N/A
Viewing Device
H Hand N/A N/A N/A N/A

I Current N/A Indicate N/A N/A
J Power N/A Scan N/A N/A
K Time, Schedule Time Rate of Change N/A Control Station N/A
L Level N/A Light N/A Low

M User’s Choice N/A N/A N/A Middle,
Intermediate
N User’s Choice N/A User’s Choice User’s Choice User’s Choice
O User’s Choice N/A Orifice, Restriction N/A Open
P Pressure N/A Point (Test N/A N/A
Connection)
Q Quantity Integrate, Totalize Integrate, Totalize N/A N/A
R Radiation N/A Record N/A Run
S Speed, Frequency Safety N/A Switch Stop
T Temperature N/A N/A Transmit N/A

U Multivariable N/A Multifunction Multifunction N/A
V Vibration, N/A N/A Valve, Damper, Louver N/A

Mechanical Analysis
W Weight, Force N/A Well, Probe N/A N/A
X Unclassified X-axis Accessory Devices, Unclassified Unclassified
Unclassified
Y Event, State, Y-axis N/A Auxiliary Devices N/A
Presence
Z Position, Dimension Z-axis, Safety N/A Driver, Actuator, N/A
Instrumented System Unclassified final control
element
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3.1 DCS UPGRADE
3.1.1BACKGROUND
The distributed control system was first introduced in the late 1970’s to allow a control room to be
centralised and control to be distributed around the plant. It is built around custom hardware and
interfaces, and contains four main components, Input / Output cards, the processor controller which
runs the control software, the computer screen to the operator which is Human Machine Interface
(HMI) and the historian. Some control systems may also include other computers to store and run
other software packages. A significant segment of the computer control hardware installed
throughout Kwinana is over 25 years old. The continued maintenance of the existing platform poses
a significant threat to operations at Kwinana. A system of this vintage presents some obvious
problems such as the ever increasing likelihood of failure and the rising costs of components and
hardware.
FIGURE 7 - DCS OVERVIEW [9]
Maintenance and support of this hardware is also becoming increasingly troublesome due to lack of
experienced technicians in the field. With the upgrade of the DCS there will always be discrepancies
in the process control. Some of these errors are a result of time delays in the control system, which
are extremely small compared to transport delays in processes. This upgrade will have a significant
increase in accuracy and reliability for process control and optimisation of the plant. Table 2 shows
some examples of time delays or refresh rates that could be expected in the control system.
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TABLE 2 - TIME DELAY AND REFRESH RATES FOR DCS [9]
Stage Scan Rates(secs)

Analogue-Digital Conversion 0.25
DCS Analogue Input 1.0
Regulatory Controls 1–5
Advance Controls 15 – 60
DCS Screen Update 2–4
Data Historian 30 – 60
The DCS has 3 common modes of operation for the control loops in the plant, they are manual
mode, auto mode and cascade control blocks. Although these might be the common control types,
they are not the only control schemes. There are other control blocks which consist of more
advanced controllers depending on the complexity of the process, such as generic model control,
model based control, feed-forward and decoupling control to name a few which are all control
techniques widely used in the industry.
The C300 is a supervisory control system provided by Honeywell as a process control solution. This
control system “provides powerful and robust process control” [15] and is used widely in the
industry.
Honeywell is the vendor supplying the C300 control system. Honeywell specifies that it “offers [the]
best-in-class process control and supports a wide variety of process control situations, including
continuous and batch processes and integration with smart field devices, including valves, pumps,
sensors, and analysers” [15].
Honeywell realises that there are a wide range of other control packages in the industry that is why
they have made it compatible with “many input/ output (I/O) families, including Series C I/O and
Process Manager I/O, and other protocols such as FOUNDATION Fieldbus, Profibus, DeviceNet,
Modbus, and HART” [15].
The system capacity for the DCS has become crowded and overloaded, which is making expansion
and development work more difficult for future upgrades. This is why redundant hardware is to be
removed within the FAR building allowing space for new Experion cabinets making these future
upgrades much easier, cost effective and efficient.
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3.1.2 SCOPE
The scope of this section covers Phase 3 of the HYDY2 DCS upgrade required to equip the area with a
modern future-proof DCS solution. Three units out of a total of five, have phases that are being
currently executed simultaneously.
The upgrade from the obsolete control hardware to the installation of a modern control system is
the essential task in this project. All the installations will be done as cold cutovers during the
turnaround scheduled for May 2014 unless specified. The hot cutovers on the other hand, may
require an individual unit shutdown, supposed to a plant shutdown, prior to the turnaround.
The project scope of work required the installation of fibre optic cabling, fibre optic cabinets for
communication of the control system to be completed, which was supervised during the time of the
placement. These tasks were done before the turnaround scheduled in May 2014 ensuring that the
infrastructure and cabling is installed and routed to reduce the down time that it will cause. In doing
so it had increased productivity, as there is a small timeframe during the shutdown. The tasks had
proven to be beneficial, as the refinery will achieve improved overall process control and decrease in
the communication transmission delays and alarm signalling back to the DCS once completed. The
second Hydrofiner unit (HYDY2) Hi-Way control system hardware that has become obsolete over the
years of service has proven to be reliable but not efficient. In its place it will be upgraded to the new
Honeywell Experion C300 control system implemented by Honeywell staff and not site engineers. It
was required that appropriate tag numbers for the instruments were allocated to the new processor
cards prior to installation so that Honeywell can seamlessly match communication addresses. The
HPM hardware, which is high performance manager [15], has also become outdated and has
become difficult to find replacement parts for servicing. The HPM has been included in the scope, as
this particular system will also be upgraded as a part of Honeywell’s control system package
upgrade. The serial communication involved the installation of multiplex (MUX) boxes and new field
junction boxes for new critical temperature transmitters. It was supervised by site engineers to
ensure the integrity of work completed by both, design and construction teams [2].
All the upgrades are taking place in the HYDY2 field auxiliary room (FAR). This building is the control
building for the Hydrofiner unit, with all communication on the unit using this as a gateway to the
CCB. In order to communicate to the construction team regarding what was needed, all
specifications are documented and sent through document control as work packs. The design
engineers specifying all work, which was to be done within the FAR, signed off these work packs.
Construction work packs have specific detail such as terminations of control loops, earth cable runs,
switchboard isolations and installations. And as well as bench testing of instruments prior to their
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installation, bench testing requires the instrument to undergo pressure testing and ensuring that the
fail to open and fail to close actuator is true as specified by the datasheet. Due to the integrity and
importance of the DCS migration, BP’s Process and Controls team will conduct the HI-Way cutover
on the DCS side of the migration, as they have the experience and knowledge to work inside the
panels which are classified as critical if something were to go wrong, which can be detrimental to the
control system and overall process. Staff from an outsourced construction company will conduct all
other construction work within the work pack, leaving BP and WorleyParsons engineers to approve
the finalisation of the project. Which BP controls team will then operate.
The advantage of having this particular control package supplied by Honeywell is that it will “allow
engineers to address their most demanding process control requirements from integration with
complicated batch systems to controlling devices on a variety of networks such as
foundationFieldbus, Profibus, or Modbus. It also supports advanced control with Profit Loop, which
puts model-based predictive control directly in the controller to minimize valve wear and
maintenance” [15].
3.1.3 IMPLEMENTATION
The infrastructure for the FAR was completed by December 2013 under the supervision of both the
junior and senior engineers. The Hydrofiner FAR bathroom was removed so that the new C300
cabinets could be installed. Once the bathroom wall was removed, construction and installation of
the new cable ladders were done so that the new power and FTA cables could run to the new
location. For the new cabinets to be able to fit in the required locations, relocation of the Bentley
fibre optic cabinet [26], which is a central gateway for all fibre communication, will need to be done.
This cabinet was relocated to a more serviceable area for the convenience of personnel required to
conduct work within the cabinet.
Once the cabinets are installed and secured in place, power from switchboard and earthling cabling
will need to be installed to power the cooling fans. The cabinets will need to be earthed, as they will
have live control system signals within the panelling and intrinsically safe barriers. It was required to
install the Experion system cabling supplied by Honeywell and installed and terminated in the
appropriate terminal blocks.
The Hi-Way Migration will involve the installation of all patch cabling between each cabinet of
relevance. Patch cabling is the cabling that allows the communication between the different field
terminal assembly (FTA) and marshalling cabinets for the control system. All these cables will be
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terminated before the May 2014 turnaround. The cables that will connect directly to the DCS will
require the unit to be shut down prior to installation.
The HPM Migration will also be executed during the turnaround, with the installation of three new
temperature transmitters that are categorised as critical and will be hard wired directly to the DCS.
Currently there are two wireless temperature transmitters. However the signals take too long to be
registered back to the DCS as the wireless devices require booster signals from other instruments
surrounding the area to ensure the signals are strong enough to be recognised. There are cables that
will become redundant from the existing cabinets, where it will require remarshaling into the new
Honeywell cabinets installed during the infrastructure work pack.
The Serial Communications Migration work pack includes the installation of new multiplex boxes for
for the temperature transmitters that are not classified as critical devices and installation of new
field junction boxes with is intrinsically safe for hazardous areas. This is the final work pack to be
issued and to be executed during the turnaround. Once this work is completed the unit will be ready
to go online.
3.1.4 PROJECT CONSTRAINTS AND ISSUES
The DCS upgrade is a relatively large project, in one of WorleyParsons biggest jobs at the Kwinana
refinery since the contract was established 10 years ago. With the large scale and tight timeline
every single document needed to be issued on the proposed dates. The reason for this is because of
long lead-time items, which are items that can significantly affect the time schedule for the project,
that need to be purchased. These are usually custom products supplied from the vendor to suit the
design requirements of the project. During the course of the year all the preparation has focussed on
the May 2014 shutdown, where the refinery will shut down a number of units so maintenance and
upgrades can be done. Everything that has been designed and purchased over the year will need to
be constructed and installed in that short period of time during the shutdown, which usually lasts
around two to four weeks. This has proven to be a very stressful period on previous DCS upgrades
but have shown to be successful.
3.1.5 PROJECT STATUS
The project is currently four months away from construction as of the beginning of February 2014.
Most of the work prior to the turnaround should be completed as the remaining construction and
cutovers will be done during the turnaround. The project is slightly behind schedule as there were
changes in the scope that caused delays in the work pack release dates. Once this phase is complete
it is straight onto the next phase, which will involve a different process unit.
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3.2 TEL LOAD CELLS
3.2.1 BACKGROUND
Avgas is a high-octane fuel, which is dosed with tetra-ethyl lead (TEL) to improve the antiknock and
overall wear and tear properties of a motor engine. Oil companies have been dosing TEL in their fuel
products since 1922 [13]. As shown in this section, the production of the Aviation gasoline, TEL
dosage amount is crucial when determining the sale of the high quality fuel to customers, and
therefore this project will increase the quality of the fuel.
As TEL is dosed, the level in the TEL isotainer tank decreases and subsequently decreases the
pressure in the TEL dosing line. This results in two-phase flow, which causes the coriolis meter to
indicate false high flow rates. Two phase being the separation of different fluid properties in one
medium. Currently a crane is used to suspend the TEL isotainer while the Avgas is being dosed and
the crane scales are used to measure the amount of TEL dosed by means of weight difference.
The process of aligning product-scheduling requirements with crane availability and task supervision
is difficult. The crane scales do not provide an accurate enough weight difference and the dosing
operation has to be redone regularly to correct the TEL content of the Avgas product. This increases
the risk for refinery to incur unnecessary shipment costs due to the docking extension time, as the
dosing, circulating and testing sequence can take up to 24 hours. The second dosing operation
usually results in a higher TEL content than that is required to meet the specifications.
Due to the faulty nature of the crane measuring the appropriate amount of TEL, it is difficult to
determine the liquid level in the TEL isotainers and the right amount of TEL to does the AVGAS. As a
result of this, it is difficult to decide when to change isotainers over and some isotainers are sent
back to the supplier with TEL still in the container.
3.2.2 SCOPE
The project aims to retrofit the Avgas TEL dosing system with equipment that will enable accurate
on-line measurement of the TEL dosing rate, thus eliminating the regular over dose and under dose
incidents that occur with the current TEL isotainer tanks and their system as shown in Figure 8.
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FIGURE 8 -TEL ISOTAINER TANK
It is required to install eight load cells under each corner of the two tanks and install a local control
box. In order to implement and construct the project, procured items from the vendor such as the
weight terminal transmitter, which is the communication link between the scales and the DCS and
the 8 load cells, need to be installed under the two isotainer tanks on each corner with the
interconnecting cables having a series connection between all the cells will need to be supplied and
installed. The reason for 8 load cells, 4 on each, is to use a process of elimination as some cells can
read a huge discrepancy factor affecting the dosing amount. In this case if three load cells have the
same reading the DCS will ignore the fourth, however if two of the four record different weights, this
will alarm an unusual situation and will need to be looked immediately. The terminal acts as a local
control panel and requires a stand and sunshade in the location specified by the engineer. This
terminal allows anyone to be able to read the individual weight reading of the scale at any point of
time that will be monitored by the DCS. A hazardous area inspection will have to be completed for
the items being installed as they must comply to hazardous area [27] standards and ensure that the
instruments are suitable for that area, from this an explosion protection (Ex) [28] register, will be
created and kept on record.
A DCS control logic narrative was created to describe how the new setup of the load cells would aid
in the process control of the unit. This is required to ensure the process is correctly operated and
that the operating conditions are met so that the TEL dosing can be accurately measured so it can
produce a higher quality AVGAS fuel. It is important for AVGAS to be produced at a high standard
with no exceptions, because it is used in the aviation industry to increase performance and efficiency
in aircraft engines. It is also responsible for reducing the wear and tear of the engines, as would
standard fuel would not do. The control narrative outlines conditions such as trip settings, interlocks
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in case of failures, permissive logic control with the controlling of pumps and control valves. Vacuum
pressure limits are programmed as safety features, when the pressure is greater than the minimum
requirement, sending an alarm to operator to take action if necessary.
Avgas is a high quality product fuel used in the aviation industry so it is important that the correct
dosing is measured accurately at all times. When designing the control logic, interlocks had to be put
in place to ensure that contaminated product will not feed into the TEL isotainer tanks as this would
ruin the process and cost the plant a lot of money and downtime. In order for this to work there are
instruments in place to closely monitor the set constraints and at the slightest discrepancy the trips
would trigger and the necessary valves would close. The risk factor, which is measured on safety and
monetary value, was high for this project as it is regarded as one of the most important units at the
refinery.
The project is currently completed and commissioned in the 16 week time which was the allocated
time frame for the this project. It is hoped that in future this new control system will save BP more
money than it is planned. In the past there was a lot of wasted TEL due to the incorrect dosing
amounts.
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3.4 WWTP FLOW WEIGHTING AUTOSAMPLER
3.4.1 BACKGROUND
Water discharge permits specify the maximum allowable amounts of pollutants that can be legally
discharged into receiving waters. The permit limits ensure that there are minimal impacts on oxygen
depletion and toxicity to aquatic life, in the receiving waters. These permits relate to conventional
and priority pollutants [9].
Conventional pollutants are pollutants such as heat, small PH levels, and total suspended solids, oil
in water, biological oxygen demand (BOD), chemical oxygen demand (COD), total organic
compounds (TOD), ammonia and sulphide [9]. There are 129 priority pollutants but the main ones to
be mindful of are, BTEX (benzene, toluene, ethyl benzene, xylene), polynuclear aromatic
hydrocarbons (PAH) which are molecules containing two or more benzene rings joined together,
polychlorinated biphenyls (PCB’s), phenolic compounds, heavy metals and cyanide ions [3]. All the
pollutants listed above should be checked in the WWTP at BP when discharging the water into the
Sepia Depression Ocean Outfall Line (SDOOL), which is Water Corporation’s standard for safe
practices [29]. Failure to comply with these regulations and permits can result in financial fines, loss
of license and/or imprisonment.
The waste water generated by the refinery comes from many sources throughout the plant. An
arbitrary segregation of refinery wastewater could be from crude oil desalting and storage tanks,
process waters and other sources.
The Refinery’s final effluent discharge to the Water Corporation’s SDOOL is sampled using the ISCO
4700 composite automatic sampler as shown in Figure 9. The sampler collects a constant, set
volume of the effluent every hour, on the hour, over a 24-hour period, without consideration of the
flow discharged.
FIGURE 9 - ISCO4700 AUTOSAMPLER [17]
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The Refinery’s Department of Environment and Conservation (DEC) License stipulates that it is
necessary to have a representative sample of the final effluent. In order for the sample to be
representative the flow rate cannot vary by more than 10% over a day. Since the flow rate of the
effluent through the plant, to SDOOL, varies by more than 10% over a 24-hour period, the auto
sampler does not collect a representative sample. This greatly restricts WWTP operations
(limitations on throughput changes) and is a high compliance risk for the refinery. This project will
ensure compliance with the requirement to collect a representative sample and give more flexibility
around the plant throughput and final effluent discharge.
3.4.2 SCOPE
The overall objective of the current project is to mitigate the compliance risks around maintaining a
flow representative sample of the final effluent. It is extremely important to achieve these
objectives. The most important task is to connect up the existing discharge flow transmitter to the
ISCO SDOOL Final Effluent autosampler so that the amount of volume collected is proportional to
the flow. To set up a control loop so that the autosampler automatically switches off when discharge
to SDOOL is stopped, the error state of the autosampler must be connected to the DCS. This last
objective will be included in the scope subject to cost. Initial investigations to determine whether
there is capacity in existing cabling back to the DCS should be firstly carried out. A supervisor role
will be played on this project ensuring that the tasks are completed to the engineer’s satisfaction.
This project involved research for an optimal solution for the testing of the wastewater. The device
the lab was using is an auto sampler, which samples the water every hour, as programmed by the BP
lab. The water was sampled regardless of the flow being measured by the flow transmitter and in
turn the sample was always the same.
The project was designed to directly receive the input signal from the DCS, which will send a 4-20mA
signal to the auto sampler. This avoided the installation of terminal blocks and the running of
additional wires. The next part of the project was to find the optimal bottle size for the autosampler.
It was concluded that the automsampler would have four 5-litre glass beakers to collect the samples.
This allows for the adequate sample size. The design considerations for this was if the flow meter
was reading maximum flow for 24 hours, the volume collected in the bottles would be sufficient
enough and will be safe enough for manual handling by the lab technicians.
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The only issues and constraints related to this project was the recalibration of the flow meter that
will determine the sample size. Originally the flow meter was calibrated at 0-500kLph(kilo litres per
hour), where the calculations to obtain the correct operating conditions required the recalibration of
the flow meter range to be 0-300kLph. BP was not satisfied, as this would affect other processes that
are directly affected by the WWTP. The calculations were then reviewed, revised and resolved. The
sampling size was not greatly affected by the original calibration. This had a slight delay on the
project as it takes time to formally reissue the documents that were signed off initially but had
complications that were significant enough to be addressed.
The project is currently commissioned and successfully on-line and operating as the designed
objectives. With the succession of this project the refinery can now ramp up production in units that
were previously affected by the WWTP.
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4.0 REMAINING PROJECT SUMMARIES
Additional tasks were assigned as a contribution to other on-going projects for WorleyParsons.
These tasks were of significant importance for the project, as they had to be completed on time and
to a professional standard. The reason why these tasks were just as important than the project itself
is to do with safety. If the incorrect instruments were purchased, or wrong calculations were made,
it can be detrimental to the unit and personal working on the site. This section will cover those
additional tasks completed and experience gained from them. These tasks include:
CDU2 Ex Register
Procurement
Instrument Protection System Dossier
Hiway 7 Upgrade
4.1 CDU2 EX REGISTER

At the Kwinana refinery a strict compliance to hazardous area classification is extremely important
when installing new instruments. All instruments that are installed in a hazardous area zone must be
intrinsically safe and must comply with the hazardous area standards [27] set for this industry. There
are various ways to classify an instrument for a particular area to ensure that the instrument will not
have a detrimental effect on the operation or the refinery if something wrong were to happen. This
is shown in Tables 3, 4, 5 and 6. This is why the vendor, when deciding what areas they can be
installed in, classifies each instrument individually. Failure to do so can cause significant financial
loss, injury or even loss of lives.
Each area of a process unit will have a zone classification based on the potential risks if a spark were
to occur in that particular section. How they are classified is based on flammable exposure for
certain periods of time, therefore the longer the atmospheric exposure higher the risk as shown in
Table 3.
TABLE 3 - ATMOSPHERIC ZONE CLASSIFICATION [12]
Zone Description
Zone 0 Flammable Atmosphere continuously present, or present for
long periods. (MORE THAN 1000 HOURS PER YEAR)
Zone 1 Flammable Atmosphere is likely to occur in normal operation.
(BETWEEN 10 AND 1000 HOURS PER YEAR)
Zone 2 Flammable Atmosphere is not likely to occur and if it occurs
will only exist for a short time.(LESS THAN 10 HOURS PER YEAR)
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The minimum ignition temperature (MIT) of a gas and or air mixture is experimentally determined by
gradually increasing the temperature of a significant quantity of the mixture in a closed container
until an ignition occurs. The temperature at which combustion takes place and becomes self-
sustaining is called the MIT or Auto-ignition temperature (Moxi. 2005).
There are six hazardous area auto-ignition temperature classifications defined as T1 through T6. The
designated ranges for these classifications are shown in Table 4.
TABLE 4 - IGNITION TEMPERATURE CLASSIFICATIONS [12]
T Class MAXIMUM SURFACE TEMPERATURE

AND MINIMUM AUTO IGNITION TEMPERATURE
T1 450 C
T2 300 C
T3 200 C
T4 135 C
T5 100 C
T6 85 C
Based on the classifications shown in Table 4, the task at hand was to locate 200 existing
instruments in the field on the Crudes Distillation Unit. Once this was achieved, records were made
as to what zone and temperature class the instrument fell under. Once these details had been
identified, it must comply with the Australian and European standard for ignition classification. The
certificate numbers are stamped on the instruments and must be recorded in the register as shown
in Table 5. This is because the standard could change in the future and the instrument may no longer
complie with the new standards, and therefore must be replaced. This certificate number proves if
the instrument is an I.S. instrument. Ignition certificate numbers are as follows:
TABLE 5 - INSTRUMENT CERTIFICATE NUMBERS [12]
Certificate Number Classification

Ex e Increased Safety
Ex n Non-Sparking
Ex ia Intrinsic Safety 2 fault tolerant
Ex ib Intrinsic Safety 1 fault tolerant
Ex iaD Intrinsic Safety 2 fault tolerant
Ex ibD Intrinsic Safety 1 fault tolerant
Ex v Ventilation (Heat Dissipation)
The spark ignition energy is the required energy it takes to cause a spark, which will in turn cause a
fire or explosion. It is an important classification because it details the minimum energy required for
an ignition source to cause an explosion. Table 6 shows the group classification identified on an
instrument nameplate describing the energy requirements for the spark potential.
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TABLE 6 - GAS ACTIVATION ENERGIES [12]
Group Class Gas Type Spark Ignition Energy (micro joules)

IIA Propane 180 J
IIB Ethylene 60 J
IIC Hydrogen 20 J
Once the required fields were filled, the next step was to do the cable calculations to determine if
the limiting current from the I.S barrier will be sufficient to supply the instrument with a strong
enough signal. This is done by determining the length of the cable from the barrier within the FAR to
the instrument in the field. The capacitance, voltage and inductance of that particular instrument
are then used to calculate the minimum requirements for each instrument to meet. Once the
calculations are done, it is then clear to the engineer to see if the instrument will fail or pass the
standard of I.S equipment in a hazardous area.
Once the gas group class, zone class and temperature class have been established, it is then required
to produce the cable calculations for each individual instrument. The calculations determine if the
instrument will pass the minimum requirement for voltage through the cable. These calculations
confirm that it will be safe to use the instrument in that area by maintaining a sufficient voltage
signal and supply to the device for operation. Some specific information about the electrical inputs
and outputs is required from the vendor to complete such calculation as shown in Table 7. These
values are for a Rosemount 3144P temperature transmitter. The subscript ‘i’ represents the initial
parameters of that particular unit of measure.
TABLE 7 – INPUT PARAMETERS [21]
Power/Loop Sensor
Ui = 30V Uo = 13.6V
Ii = 300mA Io = 56mA
Pi = 1.0W Po = 190mW
Ci = 5nF Ci = 78nF
Li = 0 Li = 0
As this document is important to the installation of new intrinsically safe instruments, it is also to
keep a record of existing instruments up to date as standards can change and the refinery is aware
of the certified instruments out in the field. In the event of a fire or explosion, the first thing the
investigating authorities will look at is the Ex registers to see if there were any non-IS instruments in
the hazardous area that were not certified. Companies become exposed to new litigation claims.
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4.2 PROCUREMENT
Procurement is the purchasing of items for a project. It is an important part of a project as it is a
huge cost and has potential to throw a project over budget if not managed properly. Some
instruments can cost up to several hundred thousand dollars, whereas the instruments explained in
this section were all a manageable amount for an intern.
When purchasing an instrument, communication between all disciplines is necessary. A datasheet is

created with a list of basic information of the instruments that are mostly capable of achieving the
desired objectives. The datasheet requires an engineering mark-up defining the process conditions
to realise if the selected instrument is suitable within those conditions. These conditions consist of,
temperature, pressure, flow rate, fluid state and fluid type. The next step is to liaise with the
mechanical and piping engineers to see if the instrument will line up and fit perfectly within the
process line. This is usually to do with flange connections, direct tapings or sometimes complete new
piping all together. In some of the smaller jobs assigned, it was required to purchase and install
three orifice plates with flange connections, six pressure gauges, which were direct mount indicators
and four temperature indicators with brand new thermo wells which are temperature probes within
the device.
Each instrument that needs to be purchased must have gone through a series of checks and drafting.
Engineering mark-up is often the first step, which it is then sent to the originator to formally
originate the datasheet. Once they feel as if it is ready, a senior engineer or a lead engineer will then
check it. Once the mark-up is completed it is then sent back to the originator to back draft any
mistakes or changes. After the checks are complete the datasheet then requires three signatures
from the originator, checker and approver.
Figure 10 shows a datasheet for an orifice plate detailing all the specific dimensions to be specified
to the vendor.
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FIGURE 10 - ORIFICE PLATE DIMENSION DIAGRAM
4.3 INSTRUMENT PROTECTION SYSTEM (IPS) DOSSIER

An IPS dossier is produced for use by the Maintenance and Engineering team at Kwinana who carry
out tests to facilitate periodic on-line testing and testing during plant shutdown, normally following
overhaul of the equipment. The IPS must be fully tested during every unit overhaul along with all
field devices, which should require calibration before inspecting logic systems and final control
elements [22].
It is not considered necessary to carry out a full overhaul and calibration if the unit is taken off-line
before a six-month time period has elapsed from start-up after overhaul unless, during that outage,
the IPS has been modified or disturbed. The exception to this would be if the unit were left
shutdown for production reasons for more than one month [22]
This report will specifically cover Manual Initiators, Automatic Initiators, DCS and Hardwired Alarms,
Solenoid valves and their trip initiators and final control devices in cases of a trip. The initiators are
anything that can change the state of the device from either being open or closed. For example a
manual initiator is a manual valve that can only be manually operated. This will be the same for
automatic valves and specifically for solenoid actuated valves. These devices will be activated to
achieve a particular outcome, which must accurately represent a cause and effect chart as shown in
Figure 11. Trip limits of control valves and pumps have to be specified to ensure that the protection
system is correctly calibrated during every shutdown and start-up of the unit. When producing this
document, the intern’s job was to ensure all of the above mentioned items are covered in the
instructions in the cases of an alarm being triggered and the procedures to get the problem sorted
and the unit back online. Many of these tests are done off-line as they are more of a maintenance
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procedure, however some tests require more frequent maintenance than others and need to be
tested while the unit is operating.
FIGURE 11 - CAUSE AND EFFECT CHART
4.4 HIWAY 7 UPGRADE

BP have had some recent concerns about a particular Hi-way on their DCS that was displaying faults
which resulted in the tripping of several instruments and pumps on the Steam Generation Area unit
(SGA). There was an urgent push to upgrade the existing process management system, field cabling
and field junction boxes to ensure this could not occur again. The problem proved to be weathered
junction and multiplexed boxes in the field where the cabling was shorting out within the
marshalling of these cabinets. The project required a design of the most feasible option that would
reduce cost and downtime but preserve safety, maintenance and minimise the frequency for future
upgrades. Several options were designed to meet the objectives. The result was to dismantle old
Hi-way 7 cards that had the field instruments controlling them and allocate all existing points to a
new Input/Output Processor (IOP) on the HPM system. This project was in the preliminary stages
and had not started construction during the time of the internship. But from what was designed and
discussed and suggested it had the go-ahead and was due to be completed in the upcoming weeks.
This project will have to undergo a live cutover as the cost to shut the unit down for this project will
be too much down time and loss in production. In a prefeasibility discussion with BP, such issues as
this was carefully thought of, as it is important to establish the risks that will be involved in a live
cutover. Employment of the right people is important because it is a high-risk job and it is imperative
during the construction phase. It requires experienced and compliant personnel to complete the job
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5.0 ADDITIONAL TASKS COMPLETED
The additional tasks in this section are not outlined in project scope of works or strictly related. This
work includes the tasks, which an engineer would do on a daily or periodic basis that are related to
the operation, maintenance and safety of the refinery. These tasks are highlighted below.
5.1 MONTHLY SAFETY MEETINGS

The last Friday of every month, the Kwinana Projects Team hold a safety meeting lead by Mark
Spiranovic, who is the contract manager for WorleyParsons. This meeting included all safety updates
not only limited to projects, but also anything that has the best interests of everyone’s safety on site
from the maintenance and operations to the engineers who are mainly in the office. The items
specifically discussed in the meetings are to do with assessing any incident that occurred for the
month, realising what could have been done to prevent it and as individuals can assure this will
never happen again. Everyone in of the projects team will attend this meeting and sign an
attendance sheet to show that they were aware of this month’s updates and have no excuses to
follow through the discussion objectives for the following month. This helped develop a safer
perspective in the designing phase of projects and increased employees awareness to hazards during
day-to-day work.
5.2 PROJECT MEETINGS

During the course of a project it is required that all personnel on the project schedule a meeting to
ensure everyone is up to date and ahead or on schedule and that any issues that have occurred to
be addressed immediately. The most important meetings are usually the ones that involve time
planning and scheduling. In one project it was imperative that all of the engineers met the required
dates for issuing the work, as the construction work would take place during the turnaround, which
is a scheduled shutdown. This meeting was for everyone to discuss and inform other disciplines as to
why there might be delays in the issuing of work packs. This detail must be communicated to the
project managers and client to ensure that everyone is kept calm and understand of what is going
on. Other meetings related to the preliminary stages of projects, where the discussion is what is the
scope of work, what is the timeframe and urgency and when is the project expected to go online.
Other topics of discussion at these meetings include the typical costs and what resources are going
to be used on the project to ensure a high quality of work, efficiency and being cost affective at the
same time.
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6.0 TIME MANAGEMENT
An important part to working as an engineer is being able to manage the time across projects, and
assuring that the tasks will be met at the required deadlines. Each project will have a breakdown of
the individual tasks for budget and scheduling. Table 8 shows a brief overview of the average hours
on a working week. It was created as a journal to document the projects to be worked on, on a day-
to-day basis. Table 9 displays how long the individual tasks take over the scheduled time frame of
the project.
TABLE 8 - WEEKLY PROJECT TIME MANAGEMENT
Date 7-Oct-13 8-Oct-13 9-Oct-13 10-Oct-13 11-Oct-13

Project Project number Monday Tuesday Wednesday Thursday Friday Total hours
DCS phase 3 HYDY2 401012-01421 - - 2 - 5 7
DCS Phase 2 CDU2 401012-01780 5 - 2 4 3 14
Packinox Online 401012-01911 3 - 1 4 - 8
CDU2 off Gas to RCU 401012-01825 - 8 3 - - 11
AutoSampler 401012-01793 - - - - - 0
TABLE 9 - PROJECT TASK TIMELINE
DCS HYDY2 Project Timeline

Tasks Start(week) Duration(weeks)
1 Task 1-Infrastructure SOW Work Instruction 0 5
2 1a-Originate Infrastructure SOW 2 1
3 1b-Create Associated Document list 3 1
4 1c-Hazard Identification 3 0.25
5 1d-Inspection and Test Plan 3 1.5
6 1e-Issue Work pack for Check Print 4 1
7 1f-Infrastructure Work Pack Client Issue 5 0.5
8 1g-Pre TAR Construction 14 4
9 Task 2-HI-WAY SOW Work Instruction 5.5 6
14 2e-Issue Work pack for Check Print 11 1
16 2g-Pre TAR Construction 20 6
17 Task 3-HPM SOW Work Instruction 8 4
22 3e-Issue Work pack for Check Print 10.5 1
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With this project task timeline a gannt chart has been created to outline the amount of time and
estimated start and finish dates for all-important project that were assigned. This chart was used to
manage the progression to monitor the project and has been constantly modified throughout the
internship as project time management plans differ due to external factors.
There will always be external factors that will affect the project time line and deadlines. That is why
it was important to remain flexible in scheduling. The compromising of quality was not an option
when it comes to safely designing something or the money spent shouldn’t be a factor that will
cause a detrimental risk to the life span of the project and people’s safety.
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7.0 INTERNSHIP REVIEW
The internship program has been an invaluable experience with extensive exposure to the field of
Instrumentation. The projects assigned had been structured to ensure that the engineering and
design was of valuable experience to the intern. This allowed the opportunity to apply the skills and
knowledge gained from both fields of Instrumentation and Process Control Engineering.
WorleyParsons has shown great structure in their student and graduate training programs to ensure
the professional development for a young engineer.
Having completed the internship, the BP refinery is only a small portion to what the oil and gas
industry has to offer. The process units that had current projects, allowed the study of processes in
further detail, such as, control logic and production extracts. All projects were conducted in a safe
and professional manner with no compromising of designs or work ethic. Having a good
understanding for the procuring of instruments is something that will be of great use in professional
development. The experience in tracing control loops was extensive and demanded great attention
to detail. Overall this was a great opportunity and will recommend this program to future students
looking for a placement at the refinery.
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8.0 CONCLUSION
From a design, maintenance and operations perspective, the refinery requires a high level of quality
engineers from all disciplines, specifically the Instrumentation Control and Electrical team. The
knowledge gained from the projects worked on at the Kwinana refinery offered to the intern has
been an invaluable learning experience for the 16-week period. Such as procurement processes,
installation of new instruments, commissioning new PLC’s and understanding and interpreting
relevant documents related to instrumentation. The internship has enabled the realisation of rare
opportunities, learning and experiences in the specific time at the refinery. The project work
completed for the duration of the internship has been arduous, fulfilling and immensely relevant to
the discipline.
This report has presented the project work completed during the intern’s placement agreement with
BP, underlining specific engineering practices executed to achieve desired outcomes for the project.
Through the project work completed it will prove to have a beneficial effect on the refinery in terms
of its operations, increased efficiency and decreased equipment failure. Having worked towards the
project objectives, invaluable knowledge has been gained from the tasks assigned to an
Instrumentation and Control Engineer. In addition to the project work completed, the intern has
been exposed to realistic workplace situations involving communication between disciplines as well
as client and vendors in relation to administrative duties and unplanned engineering issues.
This internship has been successful, providing a leading edge to the engineering industry enabling
the ability to obtain the experience in the Instrumentation discipline. The time spent at the Kwinana
Oil refinery has facilitated the professional development from an engineering student to an engineer
working in the industry.
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BIBLIOGRAPHY
[1] BP Kwinana refinery. Kwinana home website
http://www.bp.com/sectiongenericarticle.do?categoryId=9026995&contentId=7049443
Retrieved: September 2013. (Information on the overall site production and general information
was obtained from the home page).
[2] BP Supplied Documents. DCS Upgrade Project Phase 3 Hydy 2 Inlec Construction Scope of Work.
Retrieved: October 2013. (This document is originated from the statement of requirements
specified from BP outlying the scope of the project. Once the document has had the appropriate
approval the construction scope of work and procurement can begin).
[3] BP Supplied Documents. WWTP Autosampler Project Inlec Construction Scope of Work
Retrieved: October 2013. (BP produced the information specified in the statement of
requirements document where they state that this project must meet the requirements for
Water Corp Australia standards for the Sepia Depression Ocean Outfall Line. From there we can
specify and design the project around those requirements).
[4] BP Supplied Documents. TEL Load Cells Project Inlec Construction Scope of Work. Retrieved:
October 2013. (BP has produced all information in this document unless specified otherwise.
Figure 2 was taken from this document).
[5] Vendor Supplied Documents. Honeywell FTE Specification, 29th May 2008. Retrieved: October
2013. (This document is supplied to BP by the vendor as a information pack on the software
package purchase. Figure 1 was taken from this document.)
[6] Oil refining process. http://oilrefiningprocess.com/. Retrieved September 2013

(Basic oil refining processes were found on this website; no real content was obtained and put in
the report but more of a gain in understanding of the oil and gas industry.)
[7] Australian Institute of Petroleum (AIP). http://www.aip.com.au/industry/fact_refine.htm.

Retrieved October 2013.
[8] Emerson Process Management (EPM). 2004. Control Valve Sourcebook. 1sted. Fisher Controls.
USA (This handbook was provided by the vendor who came to site, the information on refining
was obtained from this book along with the basic process diagrams.)
[9] BP Learning Management Systems (LMS). 2013. Refining Engineer Training. BP (BP’s learning
management system is used for training new staff or even as a refresher course for the
individual process units and all details and background on what is needed to know about
refining.)
[10] American National Standard. 2009. Instrumentation Symbols and Identification. ISA. North
Carolina USA
Page | 38
[11] Australian Standard. Electrical equipment for explosive atmosphere AS/NZS 2381.1. Australia
Retrieved November 2013
[12] MOXI. 2005. Competencies for Working with Electrical Equipment for Hazardous Areas (EEHA)
Training Module NUEH001 Explosion-Protection Principle. Moxi. Perth Australia
Retrieved November 2013
[13] “Today I found Out”-Why Lead used to be Added to Gasoline (feature article). November
14th.2011.http://www.todayifoundout.com/index.php/2011/11/why-lead-used-to-be-added-to-
gasoline/
Retrieved January 2014
[14] The West Australian.“Kwinana Shutdown a sign BP’s here to stay”. Peter Klinger. Wednesday
January 8 2014.
[15] HoneyWell C300 Controller Product Information.

https://www.honeywellprocess.com/en-US/explore/products/control-monitoring-and-safety-
systems/integrated-control-and-safety-systems/experion-pks/controllers/Pages/c300.aspx
Retrieved January 2014.
[16] The conversation. Security In Doubt as Australia’s aging oil refineries shut down. February 2012.
https://theconversation.com/security-in-doubt-as-australias-aging-oil-refineries-shut-down-
5553
[17] Isco 4700 Autosampler product information.

http://www.isco.com/products/products1.asp?PL=201
[18] Low Reid Vapour Pressure. http://en.wikipedia.org/wiki/Reid_vapor_pressure

[19] Reforming and Isomerisation Processes. http://www.repsol.com/es_en/corporacion/conocer-

repsol/canal-tecnologia/aplicamos-nuevas-tecnologias/refino-productos/procesos-reformado-
isomerizacion.aspx .
Retrieved February 2014
[20] Instrument Symbols and Identification. ANSI/ISA 5.1 2009. Retrieved December 2013.
[21] Rosemount 3144P datasheet. Rosemount Instruments. Retrieved November 2013.
[22] Instrument Protection System Dossier 2013. BP Document.
[23]Figure 1: http://en.wikipedia.org/wiki/Fractionating_column
[24]Figure 2: http://en.wikipedia.org/wiki/Cracking_%28chemistry%29
Page | 39
[25] Figure 3: http://en.citizendium.org/wiki/Hydrocracking
[26] Bentley Nevada 3500 product information. http://www.ge-mcs.com/en/bently-nevada-

monitoring/continuous-online-monitoring/3500-series.html
[27] Australian Oil and Gas standard. Moxi.EEHA.2005
[28] Hazardous Protection(Ex) http://atex.webeden.co.uk/#/ex-inspections/4532941079
[29] Sepia Depression Ocean Outfall Line.https://www.watercorporation.com.au/-

/media/files/about%20us/environment%20and%20sustainability/ocean%20outfall%20of%20wa
stewater/point%20peron/monitoring-management-plan-sdool-june-2011.pdf
[30] 2013, BP Supplied Document. Kwinana Refinery.
Page | 40

Final Internship Report Murdoch University Internship at The BP Kwinana Refinery

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Final Internship Report Murdoch University Internship at The BP Kwinana Refinery

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MURDOCH UNIVERSITY

Final Internship Report

A report submitted to the school of Engineering and

Signed By Clint Armstrong: ……………………………………………….

2.1 OIL REFINING PROCESS

FIGURE 1 - BASIC DISTILATION PROCESS OVERVIEW [23]

FIGURE 6: CARBON BOND STRUCTURE

First letters Succeeding letters

A Analysis N/A Alarm N/A N/A

H Hand N/A N/A N/A N/A

L Level N/A Light N/A Low

R Radiation N/A Record N/A Run

S Speed, Frequency Safety N/A Switch Stop

T Temperature N/A N/A Transmit N/A

V Vibration, N/A N/A Valve, Damper, Louver N/A

FIGURE 7 - DCS OVERVIEW [9]

Stage Scan Rates(secs)

3.1.4 PROJECT CONSTRAINTS AND ISSUES

3.1.5 PROJECT STATUS

3.2.4 PROJECT CONSTRAINTS AND ISSUES

3.2.5 PROJECT STATUS

FIGURE 9 - ISCO4700 AUTOSAMPLER [17]

3.4.5 PROJECT STATUS

4.1 CDU2 EX REGISTER

TABLE 3 - ATMOSPHERIC ZONE CLASSIFICATION [12]

TABLE 4 - IGNITION TEMPERATURE CLASSIFICATIONS [12]

T Class MAXIMUM SURFACE TEMPERATURE

TABLE 5 - INSTRUMENT CERTIFICATE NUMBERS [12]

Certificate Number Classification

Group Class Gas Type Spark Ignition Energy (micro joules)

TABLE 7 – INPUT PARAMETERS [21]

When purchasing an instrument, communication between all disciplines is necessary. A datasheet is

4.3 INSTRUMENT PROTECTION SYSTEM (IPS) DOSSIER

FIGURE 11 - CAUSE AND EFFECT CHART

4.4 HIWAY 7 UPGRADE

5.1 MONTHLY SAFETY MEETINGS

5.2 PROJECT MEETINGS

TABLE 8 - WEEKLY PROJECT TIME MANAGEMENT

Date 7-Oct-13 8-Oct-13 9-Oct-13 10-Oct-13 11-Oct-13

TABLE 9 - PROJECT TASK TIMELINE

DCS HYDY2 Project Timeline

[6] Oil refining process. http://oilrefiningprocess.com/. Retrieved September 2013

[7] Australian Institute of Petroleum (AIP). http://www.aip.com.au/industry/fact_refine.htm.

[15] HoneyWell C300 Controller Product Information.

[17] Isco 4700 Autosampler product information.

[18] Low Reid Vapour Pressure. http://en.wikipedia.org/wiki/Reid_vapor_pressure

[19] Reforming and Isomerisation Processes. http://www.repsol.com/es_en/corporacion/conocer-

[21] Rosemount 3144P datasheet. Rosemount Instruments. Retrieved November 2013.

[22] Instrument Protection System Dossier 2013. BP Document.

[26] Bentley Nevada 3500 product information. http://www.ge-mcs.com/en/bently-nevada-

[27] Australian Oil and Gas standard. Moxi.EEHA.2005

[28] Hazardous Protection(Ex) http://atex.webeden.co.uk/#/ex-inspections/4532941079

[29] Sepia Depression Ocean Outfall Line.https://www.watercorporation.com.au/-

[30] 2013, BP Supplied Document. Kwinana Refinery.

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