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AUGUST 2012
15
IN THIS ISSUE
From the CEO - Zero Harm, further expansion and communication HSE Training Business Unit Updates - Australia - Middle East - New Zealand - USA - South America Sales Corner Client Recognition Major Projects New Equipment General News - New Employees - Employee News - Colouring in Competition - New Arrivals - Weddings - Employee Interviews Contact Details 1 2 4 7 11 12 13 16 17 18 21 33 37 43 45 46 46 47 50
Cover Photo A Technician uncouples a Bundle Lifter from a Tube Bundle during a plant shutdown in Melbourne, Australia.
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OUR MISSION //
Zero Harm
Care for health, safety, community and environment.
Delivery
Changing the critical path by exceeding expectations.
People
Our most valuable asset.
Quality
100% right first time.
Customers
Working together for continuous improvement.
Presentation
Proud to stand out in a crowd.
Teamwork
Performance through teamwork.
Success
Commercially successful and sustainable.
Innovation
Leading in innovative technology and performance.
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HSE
12 Months LTI Free
by Susan Skee
On 30 May CR achieved 12 months without recording a lost time injury. This is something of an achievement in the oil and gas industry and particularly in the CR niche of specialised and high risk industrial services.
Internationally weve now achieved not only 12 months recorded lost time injury free but also 8 months recorded medical treatment injury free. This means we now have, across the CR group, a lost time injury frequency rate of 0 and a medical treatment frequency rate of 4.5. Thanks to everyone in CR for contributing to this record and particularly those who have been proactive in their on-the-job safety and injury management. While were proud of this achievement, we have a long way to go to reach our goal of zero harm. The graph below shows were still recording significant first aid treatments a sign that our people are still receiving small injuries that we need to do all we can to prevent. While the HSE team, managers, coordinators, and supervisors are all working hard on building safety into everything we do its still up to all of us to accept the responsibility to work safely at all times; do risk assessments using JSEAs or client Take 5 processes before we take on a task; wear PPE appropriate to the job at hand; and report hazards and suggestions using CR and client systems. In other words, doing all that you can to go home safely every day.
Chart Group wide injury stats for the last 14 months.
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HSE
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Training
Confined Space Training at Bankstown
by Glenn Lockhart
An internal Confined Space training course was conducted at the Bankstown site in May. The training facility, participants, and equipment were put through their paces by L&D and Training Coordinator, Rob Comerford. The three day training course encompassed all the requirements and elements of AS 2865-2009 Confined Spaces. The participants that took part included two new management trainees, two new chemical cleaning technicians, and two workshop personnel. The course was a good learning experience for those involved and showed the enormous potential of the Bankstown site as a superb training facility.
Photo Confined Space trainees about to be lowered into the confined space
Photo Team one discussing the task at hand and conducting a JSEA
Photo Dhiraj Singh who is now a first aider in our office area
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Training
Trainer On Board
by Susan Skee
Rob Comerford joined the HSEQT team in late March and CR Australia training has forged ahead since his arrival. In May Rob trained over 100 CR participants in Confined Space Entry, BA, First Aid, and Working at Heights nationally accredited programs both refresher and initial training. Just these 100 trainings have saved CR significant time and complications for people planning, simplifying our ability to place guys on jobs as well as around $30,000 in external training costs; quite an impact for someones second month in the job. The HSEQT Team have also been able to develop and release a national training calendar capturing Robs planned training across Australia as well as recording training scheduled for the Professional Development Program and other external training. The national training calendar is now on the Cyber Office under Company Document Repository Training. Anyone planning a job is encouraged to check the calendar for Robs training schedule for nationally accredited programs so we can make sure our guys are trained and ready for the job well in advance of job start dates. Rob joins CR after five years working as a trainer and thats after 25 years in the fire brigade where he first started pursuing his career in training. And all of that is after Rob spent 9 years as a plant mechanic. Robs background is a great match for CRs activities.
Photo Rob Comerford, newest member of the HSEQT Team based in Bankstown.
by Susan Skee
Photo Four of our Management Trainees, left to right; Marcus Warren, Elliott Sandaver, Bruno Warren, and Samuel Whittaker Mills.
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Training
Photo Participants in the pilot of AIMs Applied Project Management Training course Left to Right: Rob Favretti, Dhiraj Singh, (trainer), Elliott Sandaver, Samuel Whittaker-Mills, Mohamed Ahmad, Blake Lupton.
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From a management point of view things are busy as always. Blake Lupton has joined our team for 3 months to gain an understanding of how the Lytton LTC site is ran. He will be shadowing myself and our 2IC, Andrew Patterson, while he is here, attending meetings, helping with quotes and the management of projects. Andrew and leading hand Andrew Owen have kept things running on the ground with the coordination of the work crews and the execution of various projects, their work load is set to increase in the upcoming month with the scheduled work. Sheryl Anderson has been a key member to the team, ensuring everything runs smoothly from an office admin point of view on a daily basis, as well as helping out on various projects.
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by Zoe Sin
RECOGNITION BBQ
On the 3rd of May 2012, a thank you BBQ breakfast was held for those involved in the recent FCCU shutdown. Although we performed a limited number of activities, our people demonstrated the commitment and need to care for each other. We thank D. Vassall, V. Pecanae, T. Dinh, C. Grayson, N. Arnolds, Louie Kiss, Terry Lennon, Evert Leroux, Mark Cook, and Daniel Vandewesthuize for your support. We especially thank Paul Wilson for his support throughout. Your experience and advice is always appreciated.
Photo From left to right: Carl Eve, Adam Mackie, Brendon Shearer, Jason Waddell, and Van Be Vo.
Photo From left to right: Mike Rooney, Samir Shah, and Ian Mckie enjoying their breakfast
KEY FOCUS
As you are aware our site is moving closer to becoming a terminal business. During these changing times we have made the commitment to build and maintain morale at Shell through our daily activities. - Pride in our services - Focus on present - Positive for future More activities are being planned in the coming months including decontamination, decommissioning, and tank cleaning. All employees are encouraged to share ideas or better ways that will help build pride, focus, or generate a positive mood at Shell.
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SAFETY DAY
Safety Day is an annual, one day event during which all Shell employees and contractors are encouraged to gather together to focus on safety. This year the theme is Time for Safety. We believe everyone should make time for safety no matter whether it is at home or at work. Paperwork and all those procedures might seem excessive but without them the risks can result in serious injury or cost you your life. Shane Bushell from Limb for Life was the guest speaker of the day and spoke from experience. We also demonstrated the Earth-Rite Static Grounding System recently fitted to our vacuum unit as part of the Safety Day. Thank you to Neil Morris, Ian Sayers, and others from the workshop for ensuring the truck was delivered on time. This technique is a great example of the continuous improvement within our company. The system ensures that the risk of fire or explosion caused by static electricity is removed from the material transfer process. Shell have been very supportive of the development and installation of this system and have been quick to realise the increased safety levels achieved.
Photo Back: Louie Kiss, Attila Veroes, Daniel Vassall. Middle: Warren Vassall, Carl Eve, Alan Alderton, Joel Alderton. Front: Be Vo, Mark Reynolds, Steve Fleming.
HAPPY BIRTHDAY
Guess Who! Its my grandpas 63rd birthday with a special homemade cake from his dearest granddaughter.
Photo Mike Rooney took the opportunity to learn the crane business.
And for those who couldnt guess Happy Birthday Alan Alderton (Coatings Supervisor). Wishing you health and happiness.
Photo The Safety Day message was delivered by Shell Management, then CR Management, followed by a group discussion for behavioural changes.
Photo Ian Sayers explaining how the static grounding system protects drivers, operators, equipment, and product from the ignition hazards associated with static electricity.
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Al Salam O Alaikm from the Middle East, since the last Catalyst Magazine the operation in the Middle East has come a long way. Oman
CR now has a fully registered company in Oman. We are very fortunate to have been able to engage Anil Mani to manage the operation in Oman. Anil comes to CR from Plant Tech in India and is very experienced in managing projects. Anil has rapidly established a strong reputation with CR clients for safety and productivity. Anil has developed a very capable team of technicians to support him. 3 of them have been to both Australia and New Zealand to assist on shutdowns.
Qatar
The Qatar operation continues to develop steadily and our ability to be able to transfer people between countries is really starting to be a big bonus for us. CR has now undertaken 2 Pigging Projects in Qatar at the Qatar Petroleum Oil Refinery. The outlook for the Middle East is that after Ramadan things will get very busy again, so maybe there will be some more opportunities for visits to the Middle East.
Photo Kushal Shetty (Technician)
UAE
The Team in Abu Dhabi has grown in size along with the business. We have been very fortunate to have some excellent people join the team, including Hari Haran, Nithin Rao, Ravi Kaul, and Murtuza Khan. Since the beginning of 2012 we have now undertaken numerous projects in the Middle East Region. One of the largest was the shutdown at Takreer Oil Refinery in Abu Dhabi. CR undertook the change out of catalyst on 25 reactors and vessels, including the Dense Loading of 6 Hydrocracker Reactors. In the same shutdown we also undertook the decontamination of the Vacuum Column. While it was our biggest project to date and had many trials throughout the execution, we achieved many goals and came away with a very happy client. This was real credit to the team and many thanks go to Paul Dravitski, Paul Player, and John Bigmore, whose efforts greatly contributed to the success of the project. One of the more challenging projects was undertaken at Emirates Steel, where we were required to unload and reload over
Photo Equipment set up for Perlite unloading at Emirates Steel.
800 cubic metres of Perlite from the Cold Box. The project was managed by Babu Kattilancheri and after much discussion and ideas, the project was executed not only ahead of time but also in a very tidy and professional manner. The client was impressed that we were able to remove the Perlite efficiently, without making a big mess.
Photo Abdulla Salaiman: PRO/ Administrator/ Driver
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Asian Experiences
During May and June we completed two projects in Far East Asia. Gray Gardner assisted Nippon Ketjen with inspection services during catalyst loading of the No.1 RDS reactors at the Taoyuan Refinery in Taiwan. This is the fourth inspection project CR has completed for Nippon Ketjen in Taiwan in recent times and both the refinery operator CPC, and Nippon Ketjen appreciate the value we add to quality assurance during catalyst loading and performance after start up. Wayne Wilson led teams to complete the catalyst dense loading on two trains of ARDS reactors for Hyundai Oilbank in Korea. The first train was completed in May and the second in June. Four technicians using two machines loaded around the clock on each train to dense load more than 1,000 ton of catalyst using the UOP process. The client was delighted with both the quality of loading and speed of the project. Technicians came from the New Zealand and Middle East operations to complete the works.
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USA Update
by Trevor Penny
Photo Old regenerator screen being placed next to new regenerator head in the temporary structures
At the completion of the project around 200,000 pounds of new salt was melted, equating to approximately 12,600 gallons reintroduced into their process.
Photo Team members in hot suits to protect themselves when the hot liquid salt was being unloaded into the drums.
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by Trevor Penny
For around the past two and a half years, CHR has been working on and off with Petro Star in Valdez, Alaska.
Originally CHR went to Petro Star to perform the initial loading of 4 PSAs, 1 Shift Converter, 1 Desulfurizer, and 2 smaller reactors. This was executed very well and all parties involved were satisfied with CHRs performance. Since then, Petro Star has had some problems with their Reformer performance which we were also able to alleviate. The issues were caused by power outages during the winter months in Valdez. 12 months ago a backup generator was installed, thus leading to better performance and less unplanned outages. During the summer of 2010 a CHR crew was driving to their hotel after a shift at the site when they spotted a momma Grizzly Bear with 3 Cubs in tow on the local bicycle path. The CHR team members quietly remained in the vehicle to take photos and let them go on their way. CHR has developed a great relationship with Petro Star employees and the people of Valdez. They are not only our clients but have become our friends. The team at CHR would like to thank the people of Valdez and Petro Star for welcoming us into their community. CHR is looking forward to helping Petro Star with any of their future needs.
Photo Mother and young heading out down the bicycle path to get food (or bicyclists) we expect?
by Trevor Penny
Last issue we had a report on the Parex project that was completed in 2011 at ExxonMobil Baytown. In April of 2012 Catalyst Handling Resources were awarded a Nobody Gets Hurt award at this years Safety Banquet as a result of our safe operation during the project. Trevor Penny was present to receive the award and this was presented by Joe Blommaert (Site Manager, Baytown Chemical Plant) and Matt Lawrence (Maintenance Manager) and as you can see Joe seems pretty happy with our performance. Thanks to everybody for making this major project a safe one.
Photo Presentation of the safety award. Left to right: Joe Blommaert, Trevor Penny, and Matt Lawrence.
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Charles Wise
Charles Wise has joined the US East Coast office in Claymont as a Project Manager. Charles brings with him over 12 years experience in the catalyst handling industry and previously served in the USAF where he retired from after 23 years of service. Charles is a CPR/First Aid Instructor and has completed several projects overseas.
Deborah Stewart
Deborah Stewart has joined the US East Coast office in Claymont, Delaware as an Office Manager / Field Administrator. Deborah joined the team in January of 2012. Her experience with Document Control, Cost control, and Administration has been a blessing. Over recent years working at Sunoco, PBF, and Hess refineries it has meant we have been able to keep our administration running smoothly.
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South America
by Trevor Penny
Contract Resources and Nexxo were again quite busy during the first part of 2012, working at various locations and as normal all projects were completed safely and the clients are happy with what we achieved.
We completed the remaining reactors that had to be unloaded and reloaded at Enap Concepcion and also mobilized some additional people from New Zealand to assist with the unloading of the Chile 2 plant at Methanex in Punta Arenas, as both projects were being completed at the same time. The Methanex plant at Punta Arenas is likely to be relocated in the USA within the next 18 months. This will allow Methanex to make the best use of an existing asset and also gain access to the gas that is readily available now in the USA in a reasonably quick time frame. This has been the first project that we have completed on the site since 2006, as limited gas supplies have seen parts of the plant mothballed. It was good to return and see some old friendly faces. We are fortunate to still have a few projects left to complete in Latin America during the last half of 2012 and we will update you all on this in the next edition.
Photo The initial team that went to Punta Arenas to complete the unloading of the Methanol plant. Front Row: Cesar Prez, Ral Veas, Brayan Castro, and John Zamora Back Row: Fabin Rojas, Jason Howie, Jorge Martnez, Mauricio Carrasco, Hugo Maturana, Rody Escobar, and Pedro Valdebenito.
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Sales Corner
Maintenance & Tank Services Group Meeting
By Monique Bretones
A workshop was held in Brisbane on the 23rd of May to provide an oversight on the new structure and reorganised sales and product division within East Coast Tank and Maintenance Services.
Photo Group meeting in progress. From left to right: Phill Jones, Mike Connelly, Clint Connelly, Larry Tattersall, Clyde Dorman, Mike Fitzpatrick, and Stewart McCance.
All relevant Sales and East Coast Area Coordinators attended the group meeting to strategize initiatives that will deliver incremental growth and improve service delivery to the Maintenance and Tank business service and clients. It was a successful meeting with everyone voicing their opinions with a positive direction and understanding the importance of communication between one another. Mike Rooney gave an overview of the proposed 2012/2013 budgets and the company expectations. A power point presentation including personal handout booklet created by Frank Magaletta was provided regarding Commercial Risk and the importance of following the right steps with all of our submissions.
Chris Lawrence provided a detailed introduction about the new sales process, Old Methods Vs New Methods and how we are going about moving forward and developing with the growth of CR. A CRM (Customer Relationship Management) programme was also introduced. This is a system to manage CRs interactions with customers, clients, and sales prospects. It involves using technology to organise, automate, and synchronize business sales processes and activities. A new look in the way we present our Expressions of Interest and Tender Submissions was shown, with view of professionalism, consistency, quality, and relevance. Overall the day was a great success including perfect weather and surroundings.
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Client Recognition
Quick Response Prevents Loss of Production at Kinleith Mill
Quotes from some of our clients
Impressed with the crew. Strong safety focus but without compromising the timeline. No idle time. Any idle time was spent on housekeeping. The site was left in better condition than when they arrived. Flexible work approach and a watch on the weather saw the guys make the most of good conditions. Evert [LeRoux]s crew completed this and other work in a most timely and safe manner. Everts co-ordination and supervisor skills are effective and much appreciated. It is always a pleasure to work with Contract Resources and Reno [Panozzo] especially. Im sure he receives positive feedback from others as well.
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Client Recognition
The personnel nominated to complete the work alongside our staff were helpful, polite, and hard working. Very pleased with the prompt action we experienced, fitting in with our clients urgent requirements. The first project that CR has completed for me and I look forward to working together in the future. A very professional team with solutions for every problem. A lot of other contractors could learn a lot off you. Well done.
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Client Recognition
Client feedback:
Please pass on our compliments and appreciation to CRs management on a very onerous task safely and professionally completed. Once again CRs have demonstrated why we hold them in high regard as one of our key support services. - Peter Simpson (Bayu Undan Operations Manager) CR worked extremely hard and it was pleasing to see how effective and efficient they were as individuals and as a team. My congratulations to Graeme and his team for a job well done over the Christmas period, and look forward to them coming back out for other work in the field. - Paul May (Bayu Undan OIM)
Photo Jason Roach and Kelvin Sath enjoying Christmas day
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Major Projects
Christchurch Earthquake Recovery Works Feb 2011 to April 2012
By Michelle Manley
Contract Resources began its sojourn into Christchurch, New Zealand on February 25th 2011, following the magnitude 6.3 earthquake.
A Supervisor and a Technician travelled over from Reefton with NT022 to empty a damaged tank at Meadow Fresh. 40,000L of unspoilt chocolate milk was disposed of as there was no possibility of it being processed. From that day the operation grew; more staff members were brought in and we contracted directly to City Care. Initially 7 crew, 2 Vacuum units (NT022 / NV063), and 2 HPW units (NT040 / NT013) continued the operation. These were later swapped out when Vacuum Unit NT022 went to Taranaki for a rebuild and was replaced by NV031. HPW unit NT040 went to Kawerau, to be replaced by NT059 as it could get into narrow driveways. NT059 also allowed the crew to investigate manholes and unblock drains that were located in the middle of roads, without disrupting the flow of traffic as much as the larger units did. This required crew members to undergo additional traffic control training. Most of the work Contract Resources completed during the time in Christchurch was in the hardest hit Eastern suburbs, parts of which will never be built on again. Removing liquefaction from sewage lines became the ongoing, everyday task. Due to aftershocks the crew were often returning to sites they had been to clean up previously, which was a cause of frustration at times. The support our technicians received from the locals in the early days following the initial quake was amazing; they had people bringing out coffees and cooking them lunches on the BBQ. There was no power or water supply and no-one had a flushing toilet, but the locals were happy to see anyone who was helping them. Sadly, after months of aftershocks people moved away and the crew were often working in deserted streets, most of which has now been classified as the Red Zone. 14 months later on the 13th of April, 2012, our time in Christchurch came to an end with the winding up of the earthquake recovery phase. The long process of rebuilding Christchurch is now underway. Our success in Christchurch is attributable to our crew and thanks must go to those past and present who worked in Christchurch. Much of the credit goes to those that handled the aftershocks and remained in Christchurch for the long haul. Special thanks go to John Nesbit, Jason K Smith, Greg Crawford, Brian Gutsell, Michelle Manley, Murray Fearn, Murray Sinclair, Paul Brunt, Jason Smith, Murray Smith, Dion Ayres, Ken Frederickson, Neville Hurley, Alan Harding, Chris Tihi, Rob Nepia, Ron Flavell, Rob Gowans, Rei Kipa, Matt Kapea, Steve Parkinson, and Paul Mansfield.
Photo Parts of the rebuilt CBD; dubbed Container City for their use variously as building premises, ATMs, shop front displays, and other functions throughout the area.
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Major Projects
by Mike Highwood
After receiving a call to respond quickly, Peter Tuenon and Josh Wilson set off to carry out the Cold Cutting of an underground Fuel Storage tank at the Old Ford building at Woolloomooloo. This allowed for a final clean before it was lifted out of the ground.
The project was completed safely and successfully, despite fumes generated by the sludge remaining in the tank, by using magnetic systems for attaching the cutting rails and chain drives, developed by Robert Old. A 20K HPW unit was used for the project. The system allowed for speedy setting up and manoeuvring of the cutting rail. It was very effective as the tank was at an awkward angle being still half buried, plus it eliminated the need for any additional guides/lugs to be attached to complete the job.
Photo Set up of site nearly completed. Photo Radial cuts being carried out with the magnetic drive chain anchors. Photo View of longitudinal cut in progress showing the magnetic clamping unit.
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Major Projects
Photo Some of the cleaning crew after the job was completed.
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Major Projects
Photo Spread Technicians Decanting Catalyst using a Twin Drum Decanter at the Woodside KGP May Shutdown. Full article page 32.
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Major Projects
by Paul Wilson
Photo Mini cyclone set-up ready for the removal of material and Ben checking the vessel entry
A small crew was sent to LIHIR O2 plant in Papua New Guinea to carry out a LOX Guard Bed Catalyst change on their Linde plant.
The LOX Guard Bed is a small but critical vessel in the process of making pure oxygen as it captures any CO2, and any other impurities which can adversely affect the operation of the Cryogenic process. Led by Jay Symons, the crew of Jaye Jeynes and Ben Gugliandolo vacuumed the Silica Gel from the vessels 150mm top nozzle, using CCTV to see how they were going and to look for any damage. Due to the small volume involved, the Gel was hand screened to remove dust or undersized material before re-installation in the vessel with new top up material. As to be expected in LIHIR, rain and weather hindered the project and frustrated the crew but in the end a very successful result was obtained.
Photo Loading crew in discussion with ground support during the loading
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Major Projects
Photo View of the work fronts on the top section of the column.
Photo The view of the work fronts from the shuttle bus.
Photo View of work site from level 5 showing structured packing being cleaned and stored for re-installation, as well as the new tray lay-down area.
Photo Trays without the need for scaffolding were another time saving measure.
Photo Nathan Arnold arriving in the shuttle bus to take another load of packing to grade.
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Major Projects
Photo The bundle puller being lifted from the structure with 50mm of clearance each end.
Photo top The bundle taken from its shell and before being lifted from the structure.
Photo Ian waiting for Bundle Puller to arrive in the loading dock.
Photo Joshua talking the crane down into the loading dock
Photo The Bundle Puller set waiting for the new Bundle.
Photo Bundle Puller loaded and ready to go back into the structure.
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Major Projects
Photo Equipment designed and built by Bryce Nicholson for the project, including an electrically powered vacuum pump and 2 Concrete Scarifiers
Photo The Vector tunnel team ready for work bright and early in the morning. From left to right Fergus Gardner, Glenn Porteous, Stephen Devcich, Charles Aramoana, Bryce Nicholson, and Hugh Gardner.
Photo The boys catching the train to the Hobson Street end of the tunnel.
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Major Projects
Wesfarmers Turnaround
by Dave OConnell
Earlier this year WCCHMS were invited to tender for the 2012 Stage one Turnaround which included full turnkey activities on four Columns, nine Heat Exchangers, and four Vessels for Hydroblasting. Also tendered were two Propane Treaters and two Butane Treaters which were to start one week prior to the main element of the Turnaround. Catalyst:
CR was awarded the task of unloading and reloading two Propane Treaters and two Butane Treaters under a normal atmosphere. Each Vessel contained approximately 55 drums of Mole Sieve and Inerts. All four Vessels were blinded, the top manways removed, and vacuum unloaded in series. The bottom manways were also removed from each Vessel to remove the Johnson screens and for scaffold to be erected for statutory inspections. Once the inspections were completed, it was discovered that the ceramic rope packing placed around the trays was incorrectly listed on the vessel drawings. Luckily, we were able to arrange suitable packing from our Bankstown Workshop and had it flown in to reduce the risk of costly delays. The Johnson screens were re-installed and the new ceramic rope was replaced on the outer edges between the vessel and the screens. New ceramics were loaded from the bottom manway to the correct outage. The bottom manway was then replaced and torqued to the required settings. The new sieve was then sock loaded to the required outage, mesh re-fitted, and ceramics also loaded. Once passed off by the client, the top manway was replaced and torqued to the required settings. This procedure was then repeated a further three times before the vessels were de-blinded and handed back.
Stage 1 Turnaround:
CR was required to work a 24hr timetable with the original scope of work scheduled for approximately 14 days. This schedule was then further compressed by the client to 8 days, resulting in additional personnel being required per shift to complete all the work within the new time frame. The work consisted of the following: Hydroblasting of the LP & HP flare separator, the slop oil tank, and the condensate recycle tank. All the works were carried out using a tank head. All the blinding and de-blinding as well as the manway removal and reinstatement was carried out by CR Personnel.
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Major Projects
Exchangers:
This originally consisted of eight Exchangers with an additional Exchanger added at a later date. The scope was to blind, disassemble, pull, inspect, and push the exchangers, then rebuild and de-blind. Cleaning of the exchangers was not a requirement; testing was done pre start-up.
PV-16.12 De Butaniser: The scope was to blind the vessel and remove all external manways, remove damaged trays, remove internal access panels and buff welds, reinstall internal access panels and replace damaged internals, replace external manways, and de-blind. WCCHMS were successful in tendering both jobs and work commenced on the Treaters in late April, followed by the other works one week later. Despite a number of unforeseen delays, the team completed the projects within schedule, without injury, and the plant successfully started up with no leaks or issues on any of the CR work fronts. The project presented a number of challenging circumstances for the team, but thanks to the hard work and efforts put in by all it was executed successfully. We look forward to working with Wesfarmers Kleen Heat Gas again in the near future.
Photo Torquing of manways
Columns:
PV-16.06 Absorber: The scope was to blind the vessel, open all external manways, remove de-mister pads and all internal access panels, buff welds for inspection, re-build, and de-blind. PV-16.08 De Ethaniser: The scope was to blind the vessel, open external manways, open all internal access panels, buff welds for inspections, and unload / reload random packing from bed one and two, re-instate all internals and de blind. PV-16.10 De Propaniser: The scope was to blind the vessel, open all external manways and internal access panels, buff welds for inspection, re-build and de-blind.
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Major Projects
by Mike Charles
In May 2012, Contract Resources mobilised personnel and equipment to the Woodside operated Karratha Gas Plant to assist in the Train 4 Shutdown and the TOT1 (Trunk line Onshore Terminal) refurbishment.
The Scopes of Work Contract Resources were engaged in included: LNG4 Driers Catalyst Changeout LNG4 Rescue Crew and Rescue Plan Facilitation LNG HPW / Cleaning of Fin Fans / Exchangers and Vessels TOT1 Capturing of Magnetite Sludge with potential Mercury Contamination TOT1 Decontamination of ~300 tons of Steel including 157 valves ranging from 2 to 42 to allow the steel to go to recycling Emergent Work: TOT1 Isolations under Breathing Apparatus TOT1 removal of stuck plug on the main Isolating Beach Valve under BA Overall the shutdown was very successful for both Contract Resources and Woodside with the timeframe for LNG4 being bought in 7 days ahead of schedule. At the completion of the shutdown the following comments were sent though by the Woodside Shutdown Leader in appreciation of the service we had provided: I would like to provide some feedback on Contract Resources support which contributed to the success of this milestone. Contract Resources provided a high level of assistance during the LNG4 SD, with the Catalyst Handling work, High Pressure Water Jetting, Rope Rescue, Emergency Response and general vessel support providing an invaluable service. Contract Resources approach to tasks at KGP was very professional, thorough and timely which was noticed by several members of the KGP shut down team The project Managers fitted in to the shutdown routine at KGP and provided excellent leadership throughout the event supported by a great team with the typical Contract Resources can do attitude. With this said I look forward to working with Contract Resources again on Frac 2 and LNG2 SD in September. On behalf of Woodside I would like to thank all contributing Contract Resources staff for the support during the KGP LNG4 SD. Contract resources completed in excess of 12,700 man hours of Catalyst Handling / Mechanical, Rope Rescue, HPW, and decontamination without any injury to personnel or damage to equipment. Thank you to all involved for a great shutdown and continuing to grow our relationship with Woodside.
Photo Tia Campbell and Ken Murphy swinging Blinds under the watchful eyes of Woodside Operators.
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New Equipment
ACT156 Twin Drum Decanter
by Philip Richards
A third twin drum tipper has been manufactured to meet increased demand for catalyst handling work. The new asset design is based upon the existing drum tippers currently available (AG424 and AG514), but with upgrades based upon user feedback.
The hydraulic power pack has been upgraded from 1.1kW to 2.2kW and the tipping cylinders changed from single acting to double acting. As the new cylinders had different strokes to the old units, all the geometry has been re-calculated to ensure they are capable of lifting 2x 500kg drums through 115 degrees. In line with the modifications made to the other drum tippers in the last 18 months, the new asset is telescopic and fits within a shipping container. The side ladders have been redesigned to collapse and extend in-line with the platform raising and lowering. The collection chute has also been redesigned to allow it to be stored on top of the rollers during transport.
Photos above Finished Manufacture Photos left Finished Design
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New Equipment
AUGUST 2012
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New Equipment
AT179 Tautliner Truck for High Pressure Pump Unit AHP075 by Ian Pearce
The Adelaide workshop has recently completed the installation of a Jetstream 20k HP pump (AHP075) onto a Nissan UD 4x2 tautliner truck (AT179). This is the first time the company has utilised a tautliner for the purposes of housing a HP pump. The curtain-sides have the advantage of enabling both sides to be fully opened when operating; greatly improving ventilation around the engine and pump, providing good access to all equipment, and excellent lighting for operators. Careful consideration to ergonomics has been given to the layout; with retractable stairs for safe and easy access, all water connections located below tray level, a large storage cabinet for loose items, as well as specific storage space for hoses, signs, and a second pump head.
Photo above left Designed for easy access with ample storage for all equipment.
Mounted in the roof is a small girder trolley and chain hoist to reduce manual handling when changing pump heads. A 1,000L poly water tank is mounted at the front. With new curtains fitted displaying the company logo this unit looks impressive and should boost our company image wherever it goes.
Photo above AT179/AHP075 with new curtains proudly displaying the company logo.
Photo far left Sections of frames in the Adelaide workshop Photo left Completing final works on a frame
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New Equipment
Q: How many boilermakers does it take to use an extraction system? A: Only one, as long as it can reach. Welding fumes are always a problem, especially when the item you are welding is too big to place near the designated welding bay and its localised fume extraction system.
Over the next few months the Adelaide workshop will be building a pigging container for DDT. This project requires a 40ft Hi-Top container to be extensively modified to become a self-contained pigging module. There will be a requirement for a great deal of welding to be done in, around, and on top of this container. As the only place to put the pigging container is in the working bays (its too large for the welding bay), we needed a way to remove the fumes being generated in this area to ensure a safe work environment. By utilising existing extractor arms removed from our old premises, modifying, and mounting them on mobile stands, we have created a system that can be set to any height from ground level to the top of a Hi-Top container. The extraction system has the coverage of 3 of the 4 work bays, which means we can safely work two sides of a container or anywhere in between. This innovative solution will be well utilised not only for welding activities, but also diesel engine exhaust extraction and other tasks conducted in the work bays.
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General News
New Emlpoyees
Bianca Boucher
Workshop Administrative Assistant
Bianca has recently commenced working with Contract Resources in the role of Workshop Administrative Assistant as part of the WCEIS Team and is located in the Perth Office. Bianca is originally from South Africa and has worked extensively in Administration and Customer Service before joining Contract Resources. As a Workshop Administrative Assistant, Biancas primary role is to monitor equipment throughout our order management system, stock control, and replenishment of general workshop items. She also assists with the preparation of equipment for various projects and maintaining registers for Lifting, Breathing Apparatus, High Pressure Water, and Project Equipment.
Photo Bianca Boucher
Monique Bretones
Hayley Kinnane
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CATALYST 15
PAGE 38
New Employees
Robert Comerford
Zaid El Sheekhly
Adriana Heikkinen
Receptionist
It is with pleasure I introduce Adriana Heikkinen to the role of Receptionist. Adriana is part of the ECEIS Team and is located in the Sydney office reporting to Surita Alyono. Adriana has been working with Contract Resources on a contract basis since September 2011 and is now joining us on a permanent basis. Adrianas primary role is to provide professional and courteous reception services and assist with all general office administration and accounts tasks to facilitate the smooth running of office operations. She will also provide administrative support to Surita, ensure all purchase orders and invoices are processed in accordance with set procedures, and archive records as needed.
Photo Adriana Heikkinen
Saurabh Jain
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New Employees
Carol Overy
Ian Sayers
Vacuum Specialist
Ian commenced in the role of Vacuum Specialist in March 2012. He is part of the Plant, Equipment, & Reliability Team reporting to Neil Morris and is located in the Sydney Office. Ian is from Sydney and has previously been working within the oil and gas and heavy industries before joining Contract Resources. Ian is responsible for ensuring all vacuum equipment and accessories are in service, operable, and compliant, as well as ensuring the effectiveness, appearance, innovation, and best practice of vacuum equipment. Ian is also tasked with maintaining diligent maintenance programs and improvements, ensuring databases and documentation is up to date, and providing vacuum equipment and operation technical support
Photo Ian Sayers
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CATALYST 15
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New Employees
Deepak Pranosh
We have been joined by Deepak in the Abu Dhabi office. Deepak is currently working as a Junior Engineer on our Quality Assurance/Control, and Administration. His background as a Mechanical Engineer will no doubt be of use to us in the future.
Murtuza Khan
Murtuza has joined CR in the last month as Accounts Administration, assisting Syed. This will hopefully not require Syed to be in the office until midnight any more. Murtuza has 4 years experience in accounting and works from the Abu Dhabi office.
Nithin Rao
Nithin is taking over as Operations Coordinator in Abu Dhabi, as Tim Smith is returning to New Zealand. Some of you may have already met Nithin as he led a team of Middle East Technicians on the NZRC and BP shutdowns. Nithin has a huge amount of knowledge in the catalyst industry, with 12 years experience in catalyst handling and a background as a Mechanical Engineer.
Ravi Kaul
Ravi has joined CR as a Project Manager and has already managed and executed a couple of projects for CR, including a shutdown offshore at ADGAS and onshore at ENOC Refinery, Dubai. Ravi is based in Abu Dhabi and is a Mechanical Engineer, with 6 years experience in the catalyst handling business.
Souad Zerhouni
Souad Zerhouni has joined us recently in the Abu Dhabi Office. She is currently undertaking the administration of all aspects of the business, including coordinating operations in the other Middle East Countries.
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New Employees
Sujith Alva
HSE Officer
Amith Kumar
B.A/Technician
Balakrishna Pillai
Mechanical /Technician
Praveen Kumar G
B.A/Technician
Giridhara Pojari
B.A/Technician
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New Employees
Mike Dillon
Piripi (Pip) Phillips has joined the Taranaki branch in New Zealand. Pip has a background in Industrial Services and his happy nature is much appreciated by staff.
Sam Prestidge
Technician
Sam Prestidge has recently joined the Taranaki branch in New Zealand. His electrical background has already been an asset to the branch.
Taki Munro
Technician
I employed Taki when I was with Interclean in 2008. I tried to take him with me to Transpacific but he decided to stay. I was however successful in bringing him into Contract Resources as a Technician in the Kawerau branch. Taki has a very close family bond and he brings this into his daily work. I have found him to be honest, hard working, and he is always willing to learn. With Taki having his Class 4 licence he has been a big asset to the Kawerau branch with the transportation of vehicles around the country and being able to mobilise in our immediate area as well. Taki is the only permanent employee in Kawerau so far but we are both working to get more on board.
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General News
Employee News
Indy 800 Go Karting
by Samuel Whitaker-Mills
On Friday the 30th of March the Bankstown Workshop organised a Go Karting night with a BBQ and drinks. Thanks to the organisers Ian and Adrian, it was an incredibly successful night.
It consisted of 3 ten minute rounds where the 3rd round was a final. There were spills and thrills over the three races with people spinning out and some being nudged onto the grass or even into the tyre barricade. There were a couple of challenging corners that managed to get a few drivers. The hairpin and hammerhead gave the drivers the most difficulty, resulting in neck and neck passing. The competition was fierce with no holds barred in the slagging department. It was all fun and games in the end with everyone in cheerful spirits and good times all round. Congratulations to Mark who took out the number one spot in the final and posted a speedy 52.18 seconds for his last lap. Thanks to Indy 800 Go Karting who put on the BBQ and drinks and provided a very safe and extremely exhilarating night. Thanks again to all that were there and hopefully see you at the rematch.
Photo The Go Karting participants and spectators Photo Starting blocks for the first practice race of the evening.
Photo All ready for the start of the third race. The Final!
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Employee News
AUGUST 2012
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General News
HOW TO ENTER
Your entry needs to be on an A4 sheet of paper, and have a topic relating to Health, Safety and/or Environment. We have three age categories Under 5s, Under 10s, and Under 14s (as at 1 October 2012). The best artwork in each age category wins a $100 Toys R Us, bookshop, or EB Games voucher the winner gets to choose! All entries will receive a prize for entering.
Entries close
No later than close of business on Monday, 1 October 2012. Winners announced in Catalyst Magazine 16 in December.
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CATALYST 15
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General News
Maddison Jordan
AUGUST 2012
PAGE 47
General News
Rob Old
Rob Old is a Project Supervisor/Manager. Hes based in Hervey Bay in Queensland, Australia and moves predominantly between the Sydney and Brisbane offices.
How long have you been with CR and where did you start? 11 years Ive been with CR; I started at Caltex Lytton on a Cracker shut back in 2001. Where did you grow up? Noosa Heads on the sunshine coast. What do you like to do in your time off? Fishing, hunting, a bit of bike riding and jet skiing. What is your most treasured possession? Thatd have to be my dirt bike. Its a KTM 500 EXC 2012 model; got a bit of grunt. What is your favourite holiday destination? Top end, up Darwin way. What was the most memorable project or job youve done and why? Id say Shell Clyde 2008; a Cracker re-fit. It lasted about 6 months through all the units and across all our disciplines. It was major, massive. What was the most difficult project or job youve done and why? A Tank demolition up in Phosphate Hill [Queensland Mine]. It was a brick removal and rubber strip on a HF Acid Tank up there. That was pretty crazy; we were using brand new equipment that wed never used before so we were sort of making it up as we went. There was Ultra High stuff, we Cold Cut the roof off it, then we jack hammered all the bricks out with a remote controlled machine called a Brokk. Then we High Pressure Water Blasted all the rubber and remaining brick out of it, all with remote controlled machines. What has been the most interesting country to work in and why? Id say PNG. Its like a step back in time compared to what were used to over here. What has been your most valuable lesson learnt with CR? Dont travel light.
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General News
Paul Thew
Job Title - West Coast Catalyst Handling & Mechanical Services Manager Present CR Office and Location - Perth Office
What does your role at CR involve? Looking after the Catalyst Handling and Mechanical Services business stream on the West Coast of Australia; the Northern Territories and WA. Sourcing work, pricing it, coordinating the crews and equipment, overseeing the jobs to completion and invoicing. Basically seeing the jobs through from start to finish.
How long have you been with CR and where did you start? I attended an inert entry training course at the Panmure Fire Station in Auckland [New Zealand] in July 94. From there I went on to my first job in Malaysia pretty soon after that. Where did you grow up? Im not sure I have yet, but geographically, in South Auckland. What do you like to do in your time off? Time off is probably pretty much similar to most of the guys; golf, fishing, and because Im fairly new to Perth Ive only been here 12 months I enjoy just having a drive around and checking things out if you like, seeing whats around. When Im not doing that its spending time with family, and if Im not doing that, playing guitar. What is your most treasured possession? I can probably say my family would be. They are the reason why I do what I do, but I know theyre not possessions, so if were talking strictly possessions Ive got a nice Fender Stratocaster guitar that I pretty much love. Its a 1962 Sunburst Strat. Ive had it tweaked with Texas Special Blues pickups. What is your favourite holiday destination? I struggle to name any one place. Id probably say travelling in general. Rachelle and I went on a Mediterranean cruise a couple of years ago. We went through Italy, the Greek Isles, Greece, Egypt, Turkey, then on to England France and home via Hong Kong. Italy and Turkey really stood out for me. Just doing the cruise thing was a holiday in itself, a really good way to travel.
Photo An example of what not to do when working at heights
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What was the most difficult project or job youve done and why? The first time I supervised, Gray told me I was going to run the project at a fertilizer plant in Tauranga and I had pretty limited experience. After he went away I had some photos of how the equipment all went together so I worked it out and put it all together. Id just like to have a video of the look on my face when he told me. But you know how it is; we just did it and its all part of the history now. What has been the most interesting country to work in and why? Weve worked in a lot of countries and I keep thinking back to Thailand. It just seems to have so much going on, the people are just really beautiful, and the food I like my food and Thai foods my favorite. Theres just always something to see, even going to work in the morning youd see things that you dont see anywhere else through Asia. At work things would crop up; snakes on site and all that sort of thing. Going home from work theres just always something interesting to see. Ive got a lot of good memories of Thailand. What has been your most valuable lesson learnt with CR? Theres so much to learn, every day I pretty much take something away, I learn something. Thats through work learning about life as well because of the contact with the people. People are not just at work, they live as well so that side all blends through it and that interests me and excites me. If I had to nail down whats the biggest thing Ive learnt its probably what my brother taught me, to check everything; never assume anything and thats probably saved my bacon more times than I can count. If I ever try to take a shortcut then I hear his voice telling me and I feel the kick as it bites me, because whenever I dont check theres always something that pops up. If someone said to me: What would be your best bit of advice? it would be that; never assume anything, check everything Everything!
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CATALYST 15
AUGUST 2012
Contributions
Thanks for reading this issue of CATALYST This magazine is to keep you informed of what is happening within Contract Resources and the changes and developments that are taking place. If you have items of interest for Australia, please forward them to Sandra at the Adelaide office. For all other items, please send to Josh at the New Zealand office. See you next issue... Contact: Sandra Arch Email: sandy@contractresources.com Phone: 08 8186 9900 Contact: Josh Smith Email: josmith@contractresources.com Phone: 09 265 2083 ext 815
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