What is involved when you are asked to go to the field? If you are truly a knowledgeable and experienced designer or engineer you are supposed to know the answer to that question. If you are a novice, new to the business or if you have never been to a job site you will not know. However, you should be smart enough to ask. Yet, we see many cases where people show up at a job site, uninformed of what they are supposed to do, and unprepared to do it.
I remember a case that is a classic. A team of four were selected and sent to a job site. All the members had ten plus years of experience so the supervisor made the assumption that they all knew what was expected. The individuals involved happened to live in a widely scattered area and were to travel from different airports and at different times. This point eventually contributed in part to the problem because there was no face to face meeting in the office or at the airport before getting on the plane. Friday they were all given (or sent) plane tickets and directions for finding the plant and were to meet at the job site on arrival on Monday.
Three of the four seemed to know what was expected. The forth, a contract employee, new to the company, but with more than thirty years of total experience proved to be the exception. This person showed up in “dress casual” and with nothing in hand. The supervisor, thinking the person had left his work clothes in the car or some place close by, told him to change into his field gear and be ready to go to work. “Change, into what?” “What field gear?” To make a long story short, this person had only brought casual clothes and had brought nothing in the way of field gear or tools. He had no work shoes, no work clothes, no hard hat, no safety glasses, and no hearing protection. He also had no pencil, eraser, sketch paper, no clipboard, and no tape measure. Nothing! When asked why not, the answer was that he expected the company or the client to supply everything. As quietly as possible the person was told that he was fired and to leave the job site, go get on the plane and go home.
The situation proved to be an embarrassment to not only the supervisor but also the company. You see job sites such as the type we had in this case are tight little communities and you cannot keep secrets from people who are in charge. It was not long before the company construction manager and the client both knew about the fiasco. Although they agreed with sending the employee away, they were not happy with the cost and the effect on the schedule. They expected everyone to show up ready, willing and able to work.
Ready, willing, and able to work means everybody. It means all the members of the team. It includes the team leader and each individual engineer or designer. The balance of this article is intended to be a guide to any individual who is required to go to a job site to perform work. It is offered to held define the major procedural and technical issues related to making the field trip both cost effective and safe.
When it is recognized that a trip is required, the first thing that is normally done is to define the purpose of the trip and obtain all required approvals. This is normally done at the project senior supervisory and management levels. We will not dwell on why a field trip is required. What we need to do is insure that it is done right.
The next thing to do is activate the team. Engineers or designers assigned to a field team for routine fieldwork or specific problem solving need to be selected carefully. They should be selected on the basis of knowledge and prior experience. They may also need specific skills, or the familiarity with operations, maintenance, or construction.
In order to activate the team the following may be required:
Names & phone numbers of client site primary & secondary "Key" contacts
Names of the engineering company primary & secondary contacts
Name of the person responsible for decision making, time sheet and expense report approval
Team member names
Assign someone as the team leader, someone in charge
Team member release from present assignment (if applicable)
Travel arrangements (Airline, lodging, ground transportation, meals, etc.)
Maps to site location, site logistics, site safety criteria, badges, camera pass and site access
Charge number for this (Problem/Solution) assignment
Next, before leaving for the site, there should be a pre-trip meeting of all the team members. The direct supervisor who is responsible for the team and the results should conduct this pre-trip meeting. The agenda for this meeting should include a review of the purpose of the trip and the expected results. Have a plan for everyone and for all the work objectives. Other items that should be covered would include the chain of command, the schedule, the cost and expense issues, and an exchange of phone numbers for emergency contacts. Review what to do if someone misses the plane, etc.
On arrival, check in with the key Client contact person and the jobsite construction manager. Safety is the first and most important step of the actual site visit. Make sure that every member of the team has received the site-specific safety training. Know and understand the emergency warning system and the evacuation routes. Identify and agree on a place to meet, if there is a possibility of getting separated.
Engineers and Designers who visit a Client facility or site are expected to know the type of work they will be doing when they arrive and should be prepared to take prompt action to address that work. They are also expected to have with them the tools and supplies required for their jobs.
Standard safety clothing and personal protective equipment (PPE) Requirements:
- Hard hat
- Goggles or safety glasses w/ permanent side shields (no contact lenses and no removable side shields)
- Work shoes (check, some job sites require steel toed work boots)
- Gloves
- Ear protection
- Respirator with Cartridges (When required)
- NOMEX or Equivalent flame retarding outer wear (This is sometimes optional depending on the client or type of plant)
Basic tools:
- Pencils and markers, a clip board, straightedge
- Sketch paper and Isometric forms
- 25 ft. Tape measure
Alternate tools that may be helpful
- String line, Plumb Bob, and String Level (Used for measurements)
- Stopwatch (Used for checking frequency of events)
- Medical type Stethoscope (Used for listening for unusual noises inside of pipes)
- Camera (Requires Client approval and pass)
The team should not expect to borrow any tools or supplies from the Client. If a new requirement for tools or supplies is identified, after arrival at the site, the team should arrange to rent or purchase the item and turn in the cost on an expense report. An exception may be made if the required item is unusual and or very costly and the client has the item available.
Once in the field and trained in the site safety criteria, the team is ready to go to work. Everyone should go about the work in a prompt and professional manner. Where possible, fieldwork should be done by two person teams. The people on each team should check each other’s work as the work progresses. They should review their list of activities and tasks as they proceed. Review the trip plan. It’s better to get too much information thus insuring you do not miss something. Remember that this job site may be thousands of miles from your home office. A return trip for one missed item could be very costly.
Check in with the home office daily or per previous instructions. Let the home office supervisor know the progress of the planned work and ask if there are any new requirements. Proceed through the list of all planned trip requirements. Perform all activities and tasks. Do no return from the job site until all planned items are complete (unless directed otherwise). It is also recommended that you check in with the site construction manager on a daily basis. There may be additional project needs that have come up. There may also be a change in some critical site condition that could effect the team safety. When leaving the job site you should check out with the construction manager and your client host.
Upon return to the office, there should be a debriefing meeting. The responsible supervisor, the project engineer (or manager) and all team members should attend. Review the purpose of the trip, the results. Review the trip plan. Did you accomplish everything that was required? If not, why not? Were there any problems? Were they solved and what were the solutions? Are there any lessons to be learned from this trip? Is another trip required? If so why? And when will the next trip be required?
Every field trip should be planned and executed in a proper and cost effective manner. If so, then the project will benefit. The individuals on the team also benefit. They gain value and a reputation for being an experienced and effective candidate for future fieldwork.
1, Definitions
Offsite -- In a process plant (Refinery, Chemical, Petrochemical, Power, etc.), any supporting facility that is not a direct part of the primary or secondary process reaction train or utility block. Offsites are also called OSBL.
Onsite - Any single or collection of inter-related and inter-connected process equipment that performs an integrated process function. Typically any Onsite Unit could be made to function independently of another Onsite Unit. Onsite Units are also called ISBL.
Utility Block - A single or multiple grouping of facilities that generate the support services required by the Onsite Process units to function. This normally includes: Steam Generation, Plant Air, Instrument Air, Decimalized Water, Plant Water, etc.
Balance of Plant - This is another term for Offsites and/or anything else other than the Onsite Units or the Utility Block.
Battery Limit -- Line used on a plot plan to determine the outside limit of a unit. The Battery Limit line is usually established early in the project and documented on all discipline documents such as Plot Plans, Site Plans, Drawing Indexes, etc... (1)
Property Line -- A Property Line is the recorded boundary of a plot of land. (2) Defines the separation between what is recognized legally as Owner's land and non-Owner's or other land.
On Property -- All land and or water inside the Property line shown on the property map or deed.
Off Property - Off property is any land (or water) outside of the Property line shown on the property map or deed.
Right of Way (ROW) -- Any land (On Property or Off Property) set aside and designated for a specific use or purpose. A Right-of-Way within a piece of property may also be designated for use by someone other than the property owner.
Setback or Setback Line -- A line established by law, deed restriction, or custom, fixing the minimum distance from the property line of the exterior face of buildings, walls and any other construction form; s street, road, or highway right-of-way line (3). Setback is a clear area normally at the boundary of a piece of property with conditions and restrictions for building or use.
Easements -- A vested or acquired right to use land other than as a tenant, for a specific purpose; such right being held by someone other than the owner who holds the title to the land (2). An easement is typically a strip of land within which overhead power lines or underground pipes are run.
(1) -- Lamit, Louis Gary, 1981 Prentice-Hall
(2) -- Construction Dictionary
2, Codes, Standards, & Practices
ANSI (American National Standards Institute)
API (American Petroleum Institute)
ASME (American Society of Mechanical Engineers)
ASTM - American Society of Testing Materials
AWS (American Welding Society)--
AWWA (American Water Works Association)
CFR (Code of Federal Regulations)
Division of Weights & Measures --
DOT (Department of Transportation)
FAR (Federal Accounting Regulations)
IRI (Insurance Regulators Institute)
Local Permits (Country, State, City, etc.)
MSS (Manufacturing Standards Society) --
NACE (National Association of Corrosion Engineers)--
NFPA (National Fire Protection Association)
OIA (Oil Insurers Association)
PFI (Pipe Fabrication Institute)
USCG (United States Coast Guard) Regulations
3, Site Issues
Brownfield (Revamp Existing)
Climate (Wind Rose)
Demolition
Feed stock type, source and method of delivery
Future growth
Grass Roots or Greenfield (New construction)
Impact across the fence
Power requirements and source
Products, Primary, Secondary and by-products
Seismic zone
SHE (Safety, Health and Environmental)
Utilities requirements
4, Terrain, Grading, Roads, Ditches & Drainage
Terrain
- Level vs. Sloping
Geotechnical influences
- Type of soil
- Angle of repose
- Grading
- Contours
- Grubbing (Tree and shrub removal)
- Rough Grading
- Finished Grading
Roads
- Primary
- Secondary
- Type and purpose of traffic
- Right hand or left hand drive
- Traffic pattern, potential for congestion
- Pipeway or Sleeper Crossings (Overhead Vs Ramp & Culvert)
Rail Spurs (see Loading and Unloading for additional criteria)
- Number
- Location
- Capacity (number of rail cars)
- Elevation
- Roadbed & Ballast Details
- Vertical and Horizontal Clearance requirements
- Standards and jurisdiction of Rail company (Right of Way)
Drainage systems
- Storm
- Oily Water
- Chemical
- Sanitary Sewage
- Contaminated
- Other
Ditches
- Depth
- Width
- Slope
Culverts
- Location, Size, Type
- Invert Elevation
Basins & Ponds
- In ground or On ground
- Lined vs. Unlined (or Rip Rap)
- Skimmers & Aerators
- Overflows & Runoff
- Fenced or Unfenced
- Access
Stiles, Stairs, Catwalks, and Platforms
- Existing or new
- Material if existing
- Material if new
- Location & Elevation
- Access
- Valve extension stem requirements
5, Tankage
Types & Purpose
- Atmospheric vs. Pressurized
- Cone Roof
- Floating Roof
- Bullets
- Spheres
- Spheroids
- Other (Used tank cars as storage)
Tank Construction
- Single Wall vs. Double Wall
- Metallic vs. nonmetallic
- Unlined vs. Lined
- Insulated, Jacketed, Heated, Cooled,
Commodity Grouping & Spacing Criteria
- Commodity (Compatible vs. non compatible)
- Single Tank
- Multiple Tank Group -- Same Size
- Multiple Tank Group -- Different Sizes
Spill Containment
- Containment Criteria
- Earthen Berm (Dike)
- Wall (Concrete)
- Topography
- Combination
Tank Supports and Foundations
- Foundation Types
- Foundation Details
- Sloping Bottoms
- Settlement
Tank Auxiliary Equipment
- Heaters & Coolers
- Internal Coil Type
- Internal Bayonet Type
- External Type
- Mixers
- Motor Driven Mechanical Types
- Jet Types
- Support requirements
- Removal methods and clearance
Fire or ignition suppression
- Snuffing steam to V/PRV (Vacuum & Pressure Relief Valve) Tail Pipes
- Water Spray Systems (Deluge Systems)
Tank Nozzles & Appurtenance
- Primary Inlet & Outlet Connections (Single vs. Multiple)
- Vent Connections (Closed, Open, Flame Arresters)
- Drain Connections (Closed, Winterized, Non-winterized)
- Instrument Connections (Flow, Level, Pressure, and Temperature)
- -- Level Controller & Gage
- -- Float & Target Board
- -- Automatic (Tape Type) Tank Gage
- -- Gage Hatch
- -- Pressure Taps
- -- Thermowells
- -- Radar type Level Instruments
- -- Sonar
- Heating Coil Connections (Inlet/Outlet)
- Mixer Mounting Nozzles
- Manholes
- Internal Nozzles
- -- Internal Piping
- -- Swing Lines (Winch, Clearance, Accessibility)
- -- Internal Pipe Supports
- -- Internal Floating Roof Supports
- Orientation & Elevation
- Size & Rating
- Projection
- Recommendations
- -- Avoid weld seams
Ladders, Stairs, and Platforms
- Orientation
- Primary access - entrance and exit
- Roof traffic Vs Formal Platform
- Safety - Tank Edge Handrail
Pumps
- Types
- Location
- Sumps
- Piping Elements
Product Piping
- Differential Settlement
- Location of First Support
- Natural Anchors (Dike Sleeves)
- Slops Collection System
Hot Oil Systems
- Asphalt Tankage & Distribution
Utilities Piping
- Condensate
- Instrument Air
- Nitrogen
- Plant Water
- Plant Air
- Potable Water
- Steam
- Glycol
- Ammonia
- Cooling Water
- Chilled Water
- Tracing Fluids (Low Temp. or High Temp.)
Dike Penetrations (Piping)
- Sleeves (U/G Protection & Grounding)
- Double Containment
- Casings
Operations Issues
- "Roll Over"
- "Boil Over"
Maintenance Issues
- Access (Mobile Equipment)
- Cleaning and Repair
- Housekeeping Pads (Spillage control)
- Utility Station Location & Access
- CIP (Clean in place)
- Wash Stations & Spray Wands
6, Flare, Incinerator, and Thermal Oxidizer
Flare
- Location Criteria
- Prevailing Wind (Wind Rose)
- Flare Header
- System Study
Flare KO Drums
- Horizontal
- Vertical/Stack base integrated
- Support
- Pump out
Flare Number and Types
- Number of Flare Stacks
- Ground Flare
- Elevated -- Free Standing
- Elevated -- Derrick Supported
- Elevated -- Cable Guided
Flare Accessories
- Flame Arrester
Flare Stack Utilities
- Fuel Gas
- Pilot Gas
- Igniter Line
- Atomizing Steam
- Flame Arrester Drain
Incinerators
- Location Criteria
- Prevailing Wind (Wind Rose)
- Collection System
Incinerator Utilities
- Fuel Gas
- Pilot Gas
- Igniter Line
- Atomizing Steam
Thermal Oxidizers
- Location Criteria
- Prevailing Wind (Wind Rose)
- Collection System
Thermal Oxidizer Utilities
- Fuel Gas
- Pilot Gas
- Igniter Line
- Atomizing Steam
7, Piperacks and Sleepers
Support Types
- Elevated (Overhead) Racks
- Sleeper Racks
- Bridges
Materials of construction
- Steel
- Concrete
- Combination
Overhead Racks
- Height
- Number of levels
- Current Space Requirements
- Future Space Requirements
- Operating Temperature induced expansion
- Solar induced expansion
- Maximum Spans
- Minimum Line Sizes
- Piping Loops
- Shoes, Anchors, & Guides
Pipe Sleepers
- Height
- Changes in Direction (Flat Turn vs. Elevated)
- Current Space Requirements
- Future Space Requirements
- Operating Temperature induced expansion
- Solar induced expansion
- Maximum Spans
- Minimum Line Sizes
- Piping Loops
- Shoes, Anchors, & Guides
Pipe Bridges
- Number
- Location
- Height
- Span
Auxiliary Piping Services & Systems
- Utility Systems
- Steam Tracing
- Jacketed Piping
- Internal Cleaning requirements for piping systems
- Future (space allowance)
Miscellaneous Piping Details
- Process Vents & Drains
- Hydrotest Vents & Drains
- Size, location, and access
- Cleaning connections (Maintenance)
- Slip Lining
8, Pipelines
Types and Purpose
- Cross Country
- Inter Plant
- Intra Plant
Accounting Meters
- Meter Provers
- "Bonded Zone"
- Fencing and Security
Pig Launchers & Pig Catchers (Receivers)
- Package System
- Vendor or Third Party Sub contracted
- Stick build
Pipe Line Pigging Criteria
- Minimum bend radius
Slug Catchers
- Types
Special Valving Considerations
- Types
- Support
Special Instrumentation
- SCADA
- Pig Signals (Pig Sig)
9, Loading / Unloading Racks (Truck, Rail, Barge, and Ship)
Product Data
- Liquid Products
- Gas Products
- Dry Products
- Non-flammable Liquid Chemical Products
- Flammable Liquid Hydrocarbon Products
- Liquefied Petroleum Gas (LPG) Products
Shipping method
- Truck
- Rail
- Barge
- Ship
Loading & Unloading Method
- Loading Arms or Loading Hoses
- Top Loading
- Bottom Loading (Truck & Rail only)
- Vapor recovery criteria
Shipping Plan
- Number of shipments
- Frequency of shipments
- Loading time
- Unloading time
Loading Rack Size & Location Criteria
- NFPA Criteria
- Size of Carrier (Truck, Rail Car, Barge/Ship)
- Minimum distance between loading "Spots"
- Outline of structure
- Loading Arm Type
- Loading Arm reach
- Loading Arm rest position
- Height and reach of swing-down platforms
- Access & clearance for Operators
- Stair and Ladder access and egress
Barge & Ship only
- Fixed or Floating Dock
- Tide & Current Data
- Maximum "Swing" envelope (Vessel empty at high tide vs. vessel full at low tide)
Auxiliaries
- Meters
- Grounding Lugs
- Spill containment
- Shelters
- Piping
Utility Requirements
- Utility Steam
- Plant Water
- Plant Air
- Breathing Air
- Nitrogen (for blanketing)
Safety & Fire Protection
- Monitors
- Hydrants
- Deluge Systems
- Fire Blankets
- Fire Extinguishers
- ESD (Emergency Shut Down) System
- Foam Systems
10, Cooling Water Supply Systems
Types
- Once through system
- Closed loop Cooling Tower system
- Atmospheric (Flooded) System
Water Source
- Municipal Water Supply (City, County, etc.)
- River Intake
- Ocean Intake
- Lake
- Wells
- Surge Pond
Water Intake & Outfall Structures
- River
- Oceans & Bays
Tower Types
- Forced Draft
- Induced Draft
- Natural Draft
Prevailing Wind
- Direction (primary and secondary)
- Timing (Spring, Summer, Fall, and Winter?)
- Force
- Duration
Basin Design
- In-ground
- Under-ground
- Strainers and Filters
- Fixed Screens
- Rotating Screens
Pump Types & Location
- Vertical
- Horizontal (same level next to basin)
- Horizontal (elevated above basin)
Operations
- Stand alone
- Manned
Maintenance
- Portable crane
- Built-in lifting facilities
Cooling Water Supply and Return Piping
- Material
- Location (Above ground or below ground)
Water Treatment Chemical piping
- PVC
- FRP
- Stainless Steel
- Alloys
Cathotic Protection
- Type
- Pipe Riser Location
- Insulating Flange Sets
11, Hazardous Chemicals Handling and Storage
Commodities List
MSDS (Material Safety Data Sheet)
Unloading Facilities
Storage
Loading
Handling
Safety
- Safety Shower/Eye Wash
Winterized (Tempered water system)
12, Waste Treatment Facilities
Types
- Storm Water
- Oily Water
- Chemical
- Sanitary
- Contaminated
Collection Locations
Collection and transfer methods
- Gravity (only) to Treatment
- Gravity to Sump & Pump to Treatment
Types of Treatment
13, Electrical & Instrumentation
Equipment Types
- Instrument Rack/Cabinets
- Junction Boxes
- Load Centers
- Substations
- Switch and Starter Racks
- Transformers
Aboveground Distribution
- Cable Trays
- Conduit Racks
- Light Standards
- Power Poles
- Push Button Stations
- Telephone Poles
- Transmission Towers
Underground Distribution
- Direct Bury Cable
- Duct Banks (Concrete encasement)
- Electrical Manholes
- Electrical Pull Boxes
Clearance criteria Electrical to:
- Process Equipment
- Piping
- Structures
- Pipe Racks
- Roads
- Rail Facilities
14, Buildings & Auxiliaries
Buildings and purpose
- Administration -
- Cafeteria --
- Change House (Locker Room) --
- Chemical Storage --
- Control (House) Center --
- Fire House --
- First Aid --
- Gate or Guard Houses --
- House of Worship (Mosque) --
- Laboratory (Product QC) --
- Machine Shop --
- Maintenance --
- Safety Center & Training --
- Warehouse --
Auxiliaries
- Parking Lots
- Truck Loading/Unloading Docks
Utility Services
- Chemical Waste --
- Chilled Water --
- Comfort Steam & Condensate --
- Contaminated Waste
- Hot & Cold Water
- Lab Gas --
- Potable Water --
- Sanitary Waste --
- Storm Water --
Piping Materials
15, Fire Protection & Safety
Fire Protection & Safety Plan
- Basic Safety Plan
- Contingency Plan
Fire Water System
- Fire Water Source
- Fire Water Storage
- Fire Water Pumps
- Fire Water Loop (Mains and Laterals)
- Fire Hydrants and Monitors
- Foam Chambers (Number and Orientation)
- Foam Stations (Number and Orientation)
- Fire Protection Manifolds (Pumper Connections)
- Fire Hose Carts
Materials of Construction
- Carbon Steel w/ external coating
- Carbon Steel w/ Internal Lining & external coating
- Ductile Iron
- FRP Piping
- Cement Lining
- Nonmetallic Linings
- Thrust Blocks & Anchors
Fire Training Area
- Location
- Facilities
Fire Equipment
16, Product packaging
LPG Bottling Facility
- Type,
- Open, sheltered, enclosed
- Empty bottle receiving
- Filling
- Full bottle storage
- Bottle shipping
- Truck scales (weighbridge)
Lube Oil packaging facility
- Type
- Sheltered
- Enclosed
- Size
Shipping method
- Truck
- Rail
17, Solids Storage & Disposal
Type
- Sulphur
- Coke
- Treated waste
Consistency
- Dry
- Semi-dry
Storage
- Open
- Sheltered
Disposal
- On property
- Off property
Shipping method
- Truck
- Rail
- Barge
- Other