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WIB 39906 Industrial Training

ESSO MALAYSIA BERHAD

PORT DICKSON REFINERY

• Khairoul Afeeq Jamaludin

• 50213108284

• Bachelor of Engineering Technology (Hons) in Mechatronics

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Introduction

• Location of Industrial TrainingESSO Malaysia Berhad,Port Dickson Refinery,1 ½ Miles,Off Jalan Pantai,71009 Port Dickson,Negeri Sembilan.

• Supervisor• University : Mr Abdul Rahim Omar• Company : Mr Zulkafli Abdul Halim

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Introduction To Host Company

• Esso Malaysia Berhad is a subsidiaries company of ExxonMobil (Malaysia).

• Esso Malaysia Berhad have 3 core business in Malaysia: 1. Refining2. Supply3. Marketing

• The registered address for Esso Malaysia Berhad is:

Level 29, Menara ExxonMobilKuala Lumpur City Center50088 Kuala LumpurMalaysia

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Port Dickson Refinery

• Located in Port Dickson, Negeri Sembilan, PDR is the first Refinery Plant in Malaysia.

• With an initial investment of RM50 Million, PDR first commission it plant in 1963 with production capacity of 25kbd.

• PDR has undergone a number of expansions and upgraded projects to increase its processing capacity. Currently, PDR production capacity is 88kbd.

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• PDR is located on 500 acres of land, of which 70% is underdeveloped. This vast area of underdeveloped land buffers the Refinery from neighbouring communities.

• In result, the impact from accident could be minimize.

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PDR Organization

Chart 1 – PDR organization Chart

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Maintenance Department Organization

Maintenance Superintendent

Mr. Zulkafli Abdul Halim

Maintenance Engineer

Mr. Wan Rosmadey Wan Yaakob

Mechanical Engineer

Mr. Nursharulhamir Johari

Maintenance Planner Onsite

Mr. Celestin A. Anthony

Mr. Yusof Said

Maintenance Planner Offsite

Mr. Hj. Mustafa Mahbut

Mr. Hj. Samsudin Buyadi

Sections Front Line Supervisors

University Trainee

Khairoul Afeeq Jamaludin

Instrument

Mr. Mohd Talib Jaafar

Metal

Mr. Rashid Hassan

Rotary

Mr. Teoh Boon Haw

Electrical

Mr. Robert Foo Dai Hing

Maintenance Scheduler

Mr. Syazwan Othman

Chart 2 – Maintenance Organization Chart

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PDR Process Overview

• PDR is a hydro skimming refinery with two powerformer units for gasoline, naphtha and kerosene hydrofiners.

• Product from PDR :-• MoGas(UL95 & UL97)• ADO (Diesel & Bio-Diesel)• LPG • Kerosene(JetA1)• Fuel oil • LSWR

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Figure 3 Process overview

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1. Crude oil from ship/tanker/vessel is transferred to refinery via pipelines from sea shore to PDR. • Crude will be transfer from vessel to Single Buoy Mooring before being

feed to 30” pipeline

2. The crude received will be stored at Crude Tanks before undergo a further process.• Crude from tank will be feed to furnace for pre-heating process before

being heated at distillation tower. • Crude then will be heated up to 400°C for fractional distillation.• Product will be produce after hydrofining, deethenizer/stabilizer and

stripper/splitter process.


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Figure 4 – Single Buoy Mooring Figure 5 – Vessel anchored to SBM

Figure 6 – Picture of Tanks Figure 7 – Floating Roof

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Figure 8 – Distillation Process

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3. Products will be stored in tanks.• LPG stored in Sphere Tank before bottled into LPG cylinder• Petrol, Diesel, LSWR and Kerosene stored in Tanks

4. Products distribute to Stations and Industry Customer.• Product will be transfer to PDT (Port Dickson Distribution Terminal) for

distribution process• MoGas and Fuel oil – Distribute using Tank truck and vessel• ADO – Distribute using Tank truck and vessel• LPG – LPG’s cylinder distribute using truck• LSWR – Exported to Singapore using vessel• Kerosene – Transfer to KVDT via pipeline.

• Products distribution using vessel were transferred from Refinery using Marine Loading Pipeline to Jetty

• Kerosene distribution to KVDT using Multi Product Pipeline


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Figure 9 & 10 – Pictures of LPG Sphere

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Figure 11 & 12 – Pictures of products tanks

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Figure 13 – Picture of TTLR Figure 14 – Picture of LPG Bottling plant

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Figure 15 – Picture of a vessel loading/unloading products at Esso Jetty

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Figure 16 – Pictures of a Marine Loading Arm

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PDR Safety Practices

• Safety is number one priority in PDR. Each and every task planned is to be completed with safety as the main concern.

• PDR management believe that compliance with safety regulations and planning for excellence in personal safety, industrial hygiene, environmental performance and operation of the refinery will ensure PDR is a safe and secure workplace.

• As result, PDR currently on a record of 7 consecutives year without Lost Time Incidents

• Esso practices Loss Prevention System (LPS).• LPS is a system to prevent or reduce incidents by using behavior-based

tools and proven safety management techniques.

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PDR Safety Practices

• Seven LPS tools & techniques:-1. Safe Performance Self-

Assessment (SPSA).2. Job Safety Analysis (JSA).3. Root Cause Analysis Flow Chart

(RCAF).4. Loss Prevention Observation

(LPO). (UCUX)5. Near-Loss Investigation (NLI).6. Loss Investigation (LI).7. Stewardship.Figure 17 – LPS pyramid

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Maintenance and Construction Section

• Maintenance section is the biggest unit under Mechanical Division.

• Maintenance section work scope is to maintain and upgrade all the equipments and instruments in the PDR to be in perfect and well maintain condition to avoid from production set back.

• Maintenance section is divided into 4 core units:-1. Instrument – to maintain all the instruments (PLCs, Sensors, Electro-

Pneumatic valves)2. Electrical – to maintain all the electrical equipments (Lamps, Motors,

Relays, Transformers)3. Rotary – to maintain all the rotating equipments (Pumps, Compressors,

Fin Fans)4. Metal – to maintain all the static equipments (Tanks, Drums, Heat

Exchanger, Piping system)

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Maintenance and Construction

Figure 18 – Maintenance workflow

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• There is 2 types of maintenance in PDR :-1. Routine Maintenance

• Simple, small-scale activities associated with regular (daily, weekly, monthly, etc.) and general maintenance equipments.

• Example : - • Cathodic Protection Reading (Once in every 2 months)• Critical motors/pumps temperature and vibration analysis (Everyday)

2. Schedule Maintenance• Scheduled maintenance to an equipment to ensure that an equipment is

operating correctly and to therefore avoid any unscheduled breakdown and downtime.

• Example:-• Wind Speed Monitoring device installation.• Thermocouple Hot spot monitoring project.• Heat Exchanger INSITU HPWJ Mechanical cleaning.

Maintenance and Construction

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Role and Responsibility

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• Divided into 2 phase :-1. Planning, Scheduling and Engineering (Technical)

• To learn from engineers, planers and scheduler on how to prepare a maintenance planning, scheduling, documentations, budgeting and chairs a meeting.

2. Hands-On Task and On field Practical• To applied practical knowledge and skill to complete the given task.

Jobs/Tasks/Assignments

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Planning, Scheduling and Engineering (Technical)No. Task Detail of task Assign by Status

1 Time on tools To prepare time on tools report

Mr. ZAH Complete

2 Work start delay To prepare a work start delay record

Mr. ZAH Complete

3 OSS-2 Upgrading To calculate and compare the quotation

Mr. NSJ Complete

4 SQUAT 2012 •To organize a kick off meeting

•To prepare MOM

•To prepare SQUAT 2012 Work list

Mr. NSJ Complete

5 Motor Vibration Analysis

•To prepare an analysis record from report prepared by SKF

Mr. MKNI Complete

6 Cathodic protection potential Survey

To prepare a workscope for bidding document

Mr. ZAH In progress

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Planning, Scheduling and Engineering (Technical)No. Task Detail of task Assign by Status

7 SQUAT 2012 – Equipment Data

To prepare a data book contains equipment involve in SQUAT

Mr. NSJ Complete

8 SQUAT 2012 – Misc Piping

•To prepare a Job Specification Sheet

•Schedule Lump sump price

•To prepare piping worklist

Mr. NSJ Complete

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Hands-On Task and On field Practical1. Routine Maintenance

• Cathodic Protection Reading.• Critical Motors/Pumps temperature and vibration analysis.

2. Schedule Maintenance• Jetty’s Wind speed monitoring devices installation.• Furnace hot spot temperature monitoring.• Heat Exchanger InSitu HPWJ mechanical cleaning.


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Cathodic Protection Reading

Objective : To take reading, record and assessment of Cathodic Protection system.

Equipments : High Impedance Volt Meter, Records form,

Reference anode (Copper/Copper Sulfate


Figure 19 – Picture of H.I. Volt Meter Figure 20 – Picture of reference anode

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Cathodic Protection Reading

Procedure : 1. Go to any Test Point of Cathodic Protection System. (Example – TP#1 CS Shed)2. Open the Test point box.3. Reference anode cable connect to –ve terminal of voltmeter.4. Reference anode put on the ground5. Turn ON the volt meter6. Put clip from +ve terminal of voltmeter to the test point cables.7. Saved the reading taken.8. Move the +ve clip to the other cables inside the Test point.


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Connect the +ve clip here

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Jobs/Tasks/AssignmentsWO:

MONTH:

ESSO CATHODIC PROTECTION

OVERLAND

JETTY

MOV SHED (JETTY / SHORE)

JALAN LAMA

BRIDGE (JETTY)

BRIDGE

(REF)

SHELL

RAILWAY

SHELL (BIFUR)

SHELL GATE

KG TEK RAIL-X

KG TEK SHED

ACS SHED

PUMP SLAB

CCB #10 CCB #8 TS #8 TS #7 TS #6 TS #5 TS #4 TS #3 TS #2 TS #1

6" SLOP

6" LPG RETURN

10" LPG

10" KERO

10" ULG

CCB #9 CCB #7 CCB #4 CCB #3 CCB #1

10" ADO

16" LSWR

20" ABANDON

30" CRUDE

4" INERT GAS

TRANSFORMER RECTIFIER UNIT

MCB GAS POINT #1 MCB GAS POINT #2 TEL SHED FLARE FIRE H2O

NEB STATION

IDEAL SKIM POND FIRE WATER UNPORT PROTECT UNPORT PROTECT

LOCATION

VOLTAGE

AMPERE V AMP

SKIM POND 22.3 42.0

REMARK: ACS SHED 22.5 30.0

JETTY 7.5 190

RHS 10 50

TESTER: Original signed by:

VERIFIED BY: Original signed by:

DATE:

ZY:rmk, I:\Refining\ME\ZY\NZY007-02

Wrote the reading according to the test points and cables.

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Critical motors/pumps temperature and vibration analysis

Objective : To take temperature and vibration readings, and record the readingsEquipments : Temperature gun, Vibration probe, and Records form,


Figure 21 – Pictures Temperature Gun Figure 22 – Pictures of vibration probe

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Critical motors/pumps temperature and vibration analysis

Procedure:1. Go to any critical pump or motor [Example – P-91B (Crude pump)]2. Put the vibration probe to the motor side (Drive end or Non drive end)3. Adjust the vibration probe orientation (vertical, horizontal and axial)4. Get the reading from vibration probe before write the reading onto form.5. Take the bearing temperature by pointing the gun laser pointer to the bearing.6. Get the reading from temperature gun before write the reading onto form.7. Repeat the above steps (4,5,6) to obtain the pump data.


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Drive end side Non drive end side

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Jobs/Tasks/AssignmentsMotor NDE side Motor DE side

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• Motor Bearing (NDE side) • Motor Bearing (DE side)

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Readings of P-91B

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E-1164 In-Situ HPWJ cleaning

Objective : 1. To drop Channel cover, Shell cover and Floating Head cover.2. To perform In-Situ HPWJ cleaning of tubes.3. To re install Channel cover, Shell cover and Floating Head cover.4. To conduct Hydro Test at both shell and tube sides.


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E-1164 In-Situ HPWJ mechanical cleaning

Activity : 1. To drop Channel cover, Shell cover and Floating Head cover.

Equipments : Spanner, Copper Hammer, Cranes,

Procedure : The activity begin after the equipment have been isolated, piping have been blinded, scaffolds have been erected and remaining liquids have been discharged. 1. Loosen and remove all the nuts at channel cover side except for 4 nuts.

(For lifting purposes)2. After the crane sling cable have been placed at lifting lugs, the remaining

nuts can be loosen and removed.3. Place the channel cover at covered area.4. Repeat the above steps to remove the Channel head, floating head cover

and shell cover.


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Lifting Lugs

Channel cover Shell and Floating Head cover

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Picture of HEX after channel cover have been removed

Picture of channel head

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Activity : 2. To perform In-Situ HPWJ cleaning of tubes.

Equipments : HPWJ machine.

Procedure : The activity can only begin after the area have been covered with canvas.

1. Start up the HPWJ machine and make sure the pressure rating is correct (15K psi)

2. Point the HPWJ nozzle at the clogged tube.3. Clean the tube one by one by inserting the nozzle inside tubes.


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Picture of HPWJ machine Picture of E-1164 tubes (clogged)

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Picture of HPWJ nozzle Picture of tubes before and after HPWJ cleaning

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Activity : 3. To re install Channel cover, Shell cover and Floating Head cover.

Equipments :Cranes, Spanner, Copper hammer

Procedure :1. Install new tube sheet gasket and girth flange gasket.2. Re install floating head cover with new bolts and nuts followed by floating head

gasket and channel cover.


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Activity : 3. To re install Channel cover, Shell cover and Floating Head cover.


Pictures of tube sheet gasket` Pictures of girth flange gasket

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Activity : 4. To conduct Hydro Test at both shell and tube sides.

Equipments :Pressure gauge, pressure water pump

Procedure :The hydro test can only begins after all covers is closed.1. The hydro test begin at tube side first.2. Water pumped into the tube side via tube nozzle using pressure water pump.3. Pressure in the tube side will be built according to the manufacturer’s hydro test

pressure.(575 psi)4. Pressure will be hold for the hydro test. (Inspector will check and monitor the pressure

for 30 minutes)5. The water in the tube side will be drain first before hydro test at shell side performed. 6. Water pumped into the tube side via shell nozzle using pressure water pump.7. Pressure in the shell side will be built according to the manufacturer’s hydro test

pressure.(385 psi)8. Pressure will be hold for the hydro test. (Inspector will check and monitor the pressure

for 30 minutes)9. Water in the shell side will be drain out.


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From the 16 weeks spent at PDR,I have found out that :-• PDR is a challenging place to perform InTra because the working

environment (pace of the work, knowledge level, communication ability and the high expectations of the work produce)

• I also believe that intense learning (Theory and Practical) at UniKL MFI have helped me to fit in at PDR. (I’m able to work independently and managed to applied the knowledge that I have learned)

Conclusion

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I would like to recommend that :-• PDR is a tremendous place for students to perform their InTra because

the amount of knowledge and experience could be gained by working with world’s largest oil and gas company.

• I also would like to recommend that InTra durations should be extended to few more weeks. I believed, in my case, I could have benefits in term of knowledge and experience gained. It would help me to boost my career opportunity in the oil and gas industry.

Recommendation

my intra slides

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cathodic protection

situ hpwj

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critical motorspumps

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