Enough intro. So, I've been busy over last month. As you have read in my previous posts, the refinery I'm working at is having its turnaround (TA in short, basically a routine major shutdown). A lot has happened within this time span. I am currently relaxing within the comforts of my own home, after gruelling hours spent working. I'll try my best to share what went on and all that, just so that you guys have a feel.
The TA begins with the handover of the plant from the Operations team to the TA team, which is on December 3rd, according to my Twitter. The plant comprises of equipments such as distillations columns, heat exchangers, pressure vessels, relief valves, furnaces, and many more, the size is just massive! I was given the responsibility to supervise the works for pressure vessels. Basically the works will be done by the contractor, and it is my responsibility to ensure everything goes well, within the require time frame, and ensure work execution was done safely. Pressure vessel works started with the equipment isolation (to make sure no hydrocarbon enters the vessel before entry), opening of the manhole, pre-cleaning inspection, cleaning, full inspection, inspection by Department of Occupational Safety and Health (DOSH; more about them later), manhole closing and de-isolation, and I think it applies pretty much the same for other equipments. Some of the equipments operate in high pressure (to give you an idea, there's a picture of the size of the bolts and nuts used to seal the manhole and contain the vessel), and there are some which is located in high elevation, so heavy lifting is required to remove some parts (as you can see later, the cranes used are just like the Transformers)
The stud bolts used at of the pressure vessels. Huge!
The 400T crane used for the heavy lifting. There are 2 of these, and a smaller oneThe TA is also the time you can see inspection works carried out in a bigger scale. Basically for an equipment to operate, it must have a CF (Certificate of Fitness). You need to know how good/or bad your equipment is after operating for a certain period of time. Parameters checked include corrosion rates, signs of deterioration, hairline cracks, weldin intergrity, and many more. The inspectors always have the coolest gadgets! They have infra red, ultrasonic, CCTV, boroscope. You name it, they have it! They are like the CSI of engineering. I happened to witness some of the inspection works carried out, such as CCTV, Ultrasonic Thickness Scanning (UTS), and it was a great experience.
TA challenges are totally a different ball game. You'll never know what to expect till you actually see it. We've encountered this coke substance (solidified, hardened carbon deposits) stucked at a few of our heat exchangers, then I've experienced pyrophoric material first hand (stuff that auto ignites when exposed to air). We've had issues with heat exchanger leaks during hydrostatic tests, seized bolts till it requires flame cutting, unprecedented thinning in one of our heat exchangers; problems are encountered one after another. Not to mention the weather has not always been on our side (what do you expect, it's the time of the year, the monsoon season). It kinda slowed down our progress a little bit. We're a bit off-schedule, but heck; work must be completed at all costs!
Throughout this TA, I was on a journey to explore my true mental and emotional limits. The contractors just like pushing our buttons, and sometimes they just get into your cracking nerves. By the final week, I think my mind works differently than my body (basically dah weng la). My bosses almost got into a fist fight, mind you because of these emotional stresses! That is how tensed all of us are. I even followed one of my colleagues for a full body massage (haha, not to be shared in this post, next one perhaps?:p)
I lost track of what to write next. Ahaa, let's talk a bit about the DOSH fellas. They basically are the ones who determined whether these equipments are fit to run. They're from the G, so yeah, they got the power. What I found out is that all of them are relatively young (the one I escorted is just a year older than me!), lack of experience, mostly a diploma holder. But from what I heard (biasala, office gossip), they demand! They had new bags, uniform, shoes each day they come for the visit, escorted by their entourages, dining VIP style, came and go whenever they feel like it, banyak lagi la. Hahaha, hopefully this stays here.
I lost ideas of what to write. Will update soon of any. Have a good weekend!
TA challenges are totally a different ball game. You'll never know what to expect till you actually see it. We've encountered this coke substance (solidified, hardened carbon deposits) stucked at a few of our heat exchangers, then I've experienced pyrophoric material first hand (stuff that auto ignites when exposed to air). We've had issues with heat exchanger leaks during hydrostatic tests, seized bolts till it requires flame cutting, unprecedented thinning in one of our heat exchangers; problems are encountered one after another. Not to mention the weather has not always been on our side (what do you expect, it's the time of the year, the monsoon season). It kinda slowed down our progress a little bit. We're a bit off-schedule, but heck; work must be completed at all costs!
Throughout this TA, I was on a journey to explore my true mental and emotional limits. The contractors just like pushing our buttons, and sometimes they just get into your cracking nerves. By the final week, I think my mind works differently than my body (basically dah weng la). My bosses almost got into a fist fight, mind you because of these emotional stresses! That is how tensed all of us are. I even followed one of my colleagues for a full body massage (haha, not to be shared in this post, next one perhaps?:p)
I lost track of what to write next. Ahaa, let's talk a bit about the DOSH fellas. They basically are the ones who determined whether these equipments are fit to run. They're from the G, so yeah, they got the power. What I found out is that all of them are relatively young (the one I escorted is just a year older than me!), lack of experience, mostly a diploma holder. But from what I heard (biasala, office gossip), they demand! They had new bags, uniform, shoes each day they come for the visit, escorted by their entourages, dining VIP style, came and go whenever they feel like it, banyak lagi la. Hahaha, hopefully this stays here.
I lost ideas of what to write. Will update soon of any. Have a good weekend!
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