Working at Pulau Ayer Chawan
Working at Pulau Ayer Chawan
Contributed by Moh Teck (14 June 2020)
What Goes on in an Oil Refinery
Contributed by Moh Teck (14 June 2020)
Introduction
When I
was quitting my job with PSA, I was looking for another job. This would be my
second job. Coming from a humble background, I realized that a better paying
job would enable me to save for a tertiary education at a later part of my
life. I chanced a job advertisement in The Straits Times for Refinery
Technician at Esso Singapore.
Although
I am willing to travel a long distance to a good job; not appreciating how far
my prospective employer was from my home, I naively applied for it. Had it been
Shell, perhaps my work history would work out differently but there was no
vacancy posted at that time.
However,
I knew that petrol driven cars and buses would slowly increase and that the
development of household appliances using electricity would spur the need for
oil powered power stations (such as St James Power Station and Pasir Panjang
Power Station). The industry seems bright and oil-related employers seems to
have deep wallets. I was too naïve then to know that the oil and gas industry
has boom-and-bust cycles.
A Bit
of History
Singapore
as an international oil refining center is a 20th century concept.
Singapore has a long history of involvement in the oil industry since the 19th
century. It played an important role in the growth of the 4 super major
companies Shell, ExxonMobil, Chevron and BP.
(source: Singapore, the Energy Economy: From the First
Refinery to the End of Cheap Oil ,1960 to 2010 written by Ng Weng Hoong,
published by Singapore Management University and International Trading
Institute ISBN 978-0-415-68675-4)
Singapore first involvement with the petroleum started in
1891 when M.Samuel & Co. of London decided to use Singapore as a base for
the import and distribution of kerosene from Russia. It appointed Syme &
Co, a merchant and agency house in Singapore, to establish and manage a
petroleum tank depot in town. The British government in Singapore rejected
their application and this lead them to establish the facilities on Pulau Bukom
(translated Shell Island) because of the deep and sheltered harbour, and
proximity to the mainland.
(Source: Pulau Bukom, Singapore Infopedia, National Library
of Singapore)
Esso
began its business in Singapore in 1893, selling kerosene to homes.
(Source:
ExxonMobil website)
Esso
entered into the oil refinery business in Southeast Asia after setting up its
first oil refinery in Port Dickson, Malaysia, in 1964. By 1965, plans were
underway to build an oil refinery in Singapore. Esso had originally intended to
build the oil refinery plant on Pulau Blakang Mati (present-day Sentosa) but
the plan fell through when the government redesignated the site for the
development of tourism and recreational facilities. Pulau Ayer Chawan, an
island one mile (about 1.6 kilometres) offshore from the Jurong industrial
complex, was offered to the company instead. In 1969, construction of the
refinery commenced. opened by then Finance Minister Hon Sui Sen on 19 February
1971.
(Source: Esso Refinery Opens at Pulau Ayer Chawan, History
SG, National Library Board)
Source of Map: Singapore Road Map: Ayer
Chawan, National Archives
Between the late 1960s and early ’70s, three oil
companies built oil refinery facilities on three of the southwestern islands
off mainland Singapore: Esso on Pulau Ayer Chawan, Singapore Refining Company
on Pulau Merlimau, and Mobil Oil on Pulau Pesek.
Jurong Island was conceptualised by Philip Yeo (then
Executive Chairman, EDB and Special Adviser for Economic Development in Prime
Minister’s Office) to operate as an integrated chemical hub with “a vertically
integrated structure where the output from one plant becomes the input for another,
allowing them to feed off each other symbiotically”. In 1991, Jurong Town
Corporation was appointed the agent for Jurong Island project.
Ten islands were amalgamated to form Jurong Island: Pulau
Pesek, Pulau Pesek Kechil, Pulau Ayer Chawan, Pulau Sakra, Pulau Ayer Merbau,
Pulau Meskol, Pulau Merliman, Pulau Seraya, Pulau Mesemut Laut and Pulau
Mesemut Darat.
Reclamation works for Jurong Island began in 1995 and were
completed in 2009 – 20 years ahead of schedule. Jurong Island was officially
opened on 14 October 2000 by then Prime Minister Goh Chok Tong (Source: Jurong
Island, Wikipedia)
Video: Philip Yeo: Be Prepared to Take on Opposition
(For further information on Philip Yeo, click on this
link https://en.wikipedia.org/wiki/Philip_Yeo You can also read on his views on Leadership here: "
How I Got the Job
I read somewhere that a favourite interviewer’s question
for young people who just the workforce would be “Tell us what do you know
about our company”. Then, internet was yet to be available. The only public
resource was the National Library. I chanced upon some past issues of Energy, an
in-house employee magazine.
I learnt that Esso Singapore had constructed 2 new Horton
spheres for propane or liquefied petroleum gas (LPG) so I tried to memorise
their capacities, along with other information about the company. My interview
quickly became an interrogation after I showed off my memorised tank
capacities. The interviewers were relieved after I revealed the source of my
sensitive information and I got the job.
Photo: Hortonspheres at Karlsruhe MiRo Petroleum Refinery. The
tank can used for LPG, Propane or Butane. Source: Wikipedia
What Goes on in an Oil Refinery
Crude oil is a fossil fuel. It has many
different hydrocarbons with different molecular lengths and boiling ranges that
can be used to make other substances and hydrocarbons contain energy.
Oil refining is about separating these
different hydrocarbons using fractional distillation and then crack (break
down), unify (combine) or alter (rearrange) the hydrocarbons. So sometimes you
will hear of refinery plant equipment such as hydrocracker and catalytic
reformer. The products are then treated for impurities and blended to make
commercially available products.
Diagram: The Refining Process Source:
Yokogawa website
Video: Crude Oil Distillation
I started work in year 1980 and was with Esso
Singapore for 2 years. Most of the trainees in my batch left for other careers.
Promotion prospects in the plant were limited and competitive. The job was a
dead-end job. Those that stayed on eventually took jobs as assistant plant
superintendents with new petrochemical plants that were built in Singapore.
The plant operates around the
clock, that is 24 hours daily and seven days a week, including Saturday, Sunday
and Public Holidays. We have to work 3 shifts. Other than working in the plant,
we also get to do day work, which is to do maintenance of plant equipment.
To travel, I had to take a number 10 double
decker bus, drop at Jurong East, then switch to a feeder bus, before getting on
a bump boat to go to the island. When I alight, I have to pass through a
security gate manned with guards. The whole journey took at least 2 hours.
At the point that I joined the Pulau Ayer
Chawan refinery, the 2 main plants were Fuel Oil and Lubricants. They had 2 or
3 hortonspheres for LPG. I was assigned to the Lube plant.
The operation staff at the plant works on 3
shifts. Two staff are deployed for each plant each shift at a cabin within the
plant complex. There are maybe two other staff and the shift superintendent
station in a control room always. The control room is an explosion (bomb blast)
proof room, complete with pantry and toilets. During the shift, we may come in
for a short break and talk to the staff inside. The room is blast proof because
refinery fires can be large and can lead to explosions.
Video:Blast Resistant Door (Fail and Pass Footage)
The job of the refinery staff in the control
room is to monitor the plant processes through instruments and lights on
control panels and make changes to variables either through the control panel
or by communicating with the refinery technicians in the plant. The refinery
control room operator must have the knowledge and experience of
pre-commissioning, commissioning (start-up) and shut down of plant processes.
Photo: Example of Control Room in 1980s Source:
Success Story Collection Yokogawa
Video: Distillation Control Systems
My Equipment and Work Uniform
Each refinery is issued overalls, helmet, Redwings
safety shoes, safety leather gloves, Decidamp foam ear-plugs, 3M safety glasses,
Rigid pipe wrenches and a handheld waterproof search light.
Our safety gloves were similar to foundry
gloves or welding gloves. The palms were reinforced with metal strips and the
gloves need to withstand high heat. One of our tasks was to check the firing of
the burners in the furnace. We do this by opening a small window at the side of
the furnace, stand back as far as possible to look at the burners’ flames. Maintaining
a stable combustion is critical to the safe operations of the furnace.
Video: Looking Through the Furnace Door
Video: How Furnace Works
When needed, we would use chemical gloves and safety googles. The shift cabin within the plant will have Motorola MT500
radio set with battery charger. We will use this to communicate with each other
and the control room.
Photo: Motorola MT500 Portable Radio Highband
and Lowband, with desk-top charger (left) and mobile charger (right)
The shift cabin will also have explosimeter.
These are use to detect gas leaks within the plant.
Photo: MSA Model 2A Explosimeter Source: Mohawk Ltd
Photo: Top view of MSA Explosimeter Combustible Gas Indicator
Model 2A
Source: Worthpoint
Photo:
Opening a valve using a pipe wrench
Source: Egamaster
website
My Company Training
The company hired refinery technician in
batches. For newcomers, it put them through both classroom and field training.
The refinery is a chemical processing plant.
The refinery technician’s job in the plant is to operate the plant equipment to
enable the processing to be carried out.
To do this the refinery technician needs to
be able to locate and identify plant equipment, understand the processing
stages, identify on the grounds as to what the process pipings are carrying
from point A to point B. To do this, trainees are required to be able to read
piping and instrumentation diagram (P&ID). During their on-day shift, they
will then practice tracing the pipes and locating the equipment.
Video: How to Read Piping and Instrumentation
Diagram (P&ID)
Interesting Plant Equipment
There were many interesting plant equipment.
I only can share some information here. The safety shower and eye-wash are
safety plant equipment, to help wash off toxic, corrosive chemicals and to
douche fires if your clothes are on fire.
Diagram: Safety Shower and Eyewash Source:
Saferlife Products
Video: Safer Showers and Eye Washes Training
Pumps are used in the plant to move process
fluids from one place to another. As part of the training, we were taught to
recognise dynamic pumps and how to swing (change) from one pump to another. We
also learn how to start up (prime, open the discharge valve, start) the pump as
well as to shut and isolate the pump.
Diagram: Types of pumps Source: Elprocus website
Video: Types
of Pumps
Hydraulic
shock, more commonly known as “water hammer” occurs when the flow within a pipe
is suddenly forced to change direction, which creates a pressure wave that can
be characterized by a loud knocking or banging sound. In piping and process
systems, water hammer often happens upon closing a valve to stop or redirect
flow. It’s important to take steps that will reduce water hammer or mitigate
its effects, as repeated waves of pressure can cause significant wear on pipes
and joints over time. Even without wear, a strong enough pressure wave may
still burst weak threads or seals. (Source: Why Do Aft-Check Valves Inherently
Reduce Water Hammer, dft-valves website).
Process fluids moving pipes need to be controlled, either
in quantity, timing or flow rate. This can be done remotely or hand operated
using control valves. The valves act like a tap. Because the refinery has a lot
of combustible materials, we mostly use pneumatic (air-driven) control valves.
Video: Control Valve Types, Operation and Troubleshooting
The photograph below show Barton chart recorders. They are renowned
for the accurate, reliable measurement and recording of pressure, differential
pressure (DP), and temperature.
Photo: Barton chart recorders Source: Senia
Safety Training
The island has its own fire department, complete with fire
truck, professional firemen. However, refinery technicians need to undergo
advance fire-fighting training to reinforce the fire department’s manpower
during the case of an fire outbreak.
During the training, I have to wear the basic fighter gear.
Photo: Basic Firefighter Gear Source: San Antonio
Professional Firefighters Association
Video: Firefighter Gear
When in use, the fire hose is under high pressure and will
have a tendency to kick backwards (Newton’s law), so a number of trainee’s need
to hold the fire hose so that it will not whip from the left to right.
Video: Fire Hose Handling
One of the advance fire-fighting exercise that left a deep
impression on me was I have to turn off a gas valve (tap). The fire fighting
facility had erected a pipe with an opening. When the gas valve was opened, the
gas would travel along the pipe and leak out of the hole. To simulate a gas
fire, the instructor used a torch to burn the gas that was coming out of the
leak-hole.
Video: Fire Hose Nozzle
The team has to manage fire hoses that was using a fog
nozzle. My job is to go forward under the protection of the fog of water and
turn off the valve that was supplying the gas to the fire. If the team did not
handle the hose well, I could possibly get burnt. Well, I managed to turn off
the valve but the team also blew off my fireman helmet with the water and it
was badly damaged by the fire.
Video: Advanced Fire Fighting
Refineries Are Potentially High Risks
Workplaces
As part of my safety training, I had to watched some safety
videos that recorded refinery accidents, fire and explosions. Although I do not
have those videos, the following news footage of actual incidents will show you
the potential dangers of working in a place where there are a lot of
combustible materials and heat.
Plant fire and
accidents can happen during operations and maintenance. In a serious incident,
you can fireballs into the sky; explosions; toxic gases; ground shaking or
windows shattering many kilometres away; heavy objects being hurled many
kilometres away.
Video: Philadelphia Energy Solutions Refinery Fire and
Explosions 21 June 2019
Video: Analysis of Philadelphia Energy Solutions
Refinery Fire and Explosions.
Article: We Finally Know What Caused the Refinery Blast
That Rocked Philadelphia
Video: Mega Explosion in Oil Refinery
My Life Lessons
This job taught me to have a great respect for fire,
safety and the need for crisis planning. If you do not think that this
statement applies to you, watch the following video on kitchen fire
Video: Kitchen Fire
My Job in Hindsight
The fortune of the Rockefeller family was made
in the American petroleum industry during the late 19th and 20th
centuries by John D. Rockefeller and his brother William Rockefeller, primarily
through Standard Oil (source: Rockefeller family, Wikipedia)
In 1911, U.S. Supreme Court rules that Standard
Oil was ruled an illegal monopoly. It was broken down into 84 companies, which
some later became ExxonMobil, Marathon Petroleum, Amoco, Chevron. Currently
ExxonMobil’s primary brands are Exxon, Esso, Mobil and Exxon Chemical. (Source:
Standard Oil, Wikipedia; ExxonMobil, Wikipedia). The wealth of the extremely
wealthy is unimaginable.
Despite of their philanthropy, the wealthy are
profiteers. It is really “stealing from Peter to pay Paul”. They will do
everything to convince the public that whatever it is doing is good for the
community. They do that through propaganda and through deceptions.
In the US, many refineries are located near to
community. The dangers to communities are not only potential fires, explosions
but also the health hazards from invisible toxic fumes released into the air over
long periods from normal refinery operations.
I am glad that Singapore refineries are located
on islands and that Kallang gasworks was relocated to Senoko gasworks. However,
there are still some small tank farms inland.
But if you are an investor, then ExxonMobil and
Shell are the ones that you would be eyeing.
Video: The Mayor Gayle of Richmond California spoke out
against Chevron Oil Refinery Fire in Richmond California. She outlined why the
people of Richmond do not trust Chevron and see them as putting profit ahead of
worker and community safety. She spoke about Chevron’s propaganda campaign
including setting up their own newspaper and their involvement in politics. She
estimated that Chevron would spend $2 million to get Chevron friendly
candidates elected at the upcoming Richmond council elections.
Likewise, Shell and Exxon in 1980s knew that
carbon dioxide emissions from the use of their products would lead to global
warmings.
https://www.theguardian.com/environment/climate-consensus-97-per-cent/2018/sep/19/shell-and-exxons-secret-1980s-climate-change-warnings
Why I Left Esso Singapore
One day while on shift, we had American investigators
from the U.S. head office. A former Singapore plant had contracted cancer. He sued
the head office in U.S. for letting him work in a plant environment for a long
period exposing him to invisible toxic gases, leading to his cancer. This was
sign that I should look for another job.
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