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Proprietary 1
WIB 39906 Industrial Training
ESSO MALAYSIA BERHAD
PORT DICKSON REFINERY
• Khairoul Afeeq Jamaludin
• 50213108284
• Bachelor of Engineering Technology (Hons) in Mechatronics
Proprietary 2
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
Proprietary 3
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
Proprietary 4
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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Proprietary 6
Port Dickson Refinery
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Port Dickson Refinery
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Port Dickson Refinery
• 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
Proprietary 11
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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PDR Process Overview
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.
PDR Process Overview
Proprietary 14
PDR Process Overview
Figure 4 – Single Buoy Mooring Figure 5 – Vessel anchored to SBM
Figure 6 – Picture of Tanks Figure 7 – Floating Roof
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PDR Process Overview
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
PDR Process Overview
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PDR Process Overview
Figure 9 & 10 – Pictures of LPG Sphere
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PDR Process Overview
Figure 11 & 12 – Pictures of products tanks
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PDR Process Overview
Figure 13 – Picture of TTLR Figure 14 – Picture of LPG Bottling plant
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PDR Process Overview
Figure 15 – Picture of a vessel loading/unloading products at Esso Jetty
Proprietary 21
PDR Process Overview
Figure 16 – Pictures of a Marine Loading Arm
Proprietary 22
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.
Proprietary 23
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)
Proprietary 25
Maintenance and Construction
Figure 18 – Maintenance workflow
Proprietary 26
• 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
Proprietary 27
Role and Responsibility
Proprietary 28
• 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
Proprietary 29
Jobs/Tasks/Assignments
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
Proprietary 30
Jobs/Tasks/Assignments
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
Proprietary 31
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.
Jobs/Tasks/Assignments
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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
Jobs/Tasks/Assignments
Figure 19 – Picture of H.I. Volt Meter Figure 20 – Picture of reference anode
Proprietary 33
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.
Jobs/Tasks/Assignments
Proprietary 34
Jobs/Tasks/Assignments
Connect the +ve clip here
Proprietary 35
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.
Proprietary 36
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,
Jobs/Tasks/Assignments
Figure 21 – Pictures Temperature Gun Figure 22 – Pictures of vibration probe
Proprietary 37
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.
Jobs/Tasks/Assignments
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Jobs/Tasks/Assignments
Drive end side Non drive end side
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Jobs/Tasks/AssignmentsMotor NDE side Motor DE side
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Jobs/Tasks/Assignments
• Motor Bearing (NDE side) • Motor Bearing (DE side)
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Jobs/Tasks/Assignments
Readings of P-91B
Proprietary 42
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.
Jobs/Tasks/Assignments
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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.
Jobs/Tasks/Assignments
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E-1164 In-Situ HPWJ cleaning
Activity : 1. To drop Channel cover, Shell cover and Floating Head cover.
Jobs/Tasks/Assignments
Lifting Lugs
Channel cover Shell and Floating Head cover
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E-1164 In-Situ HPWJ cleaning
Activity : 1. To drop Channel cover, Shell cover and Floating Head cover.
Jobs/Tasks/Assignments
Picture of HEX after channel cover have been removed
Picture of channel head
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E-1164 In-Situ HPWJ mechanical cleaning
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.
Jobs/Tasks/Assignments
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E-1164 In-Situ HPWJ mechanical cleaning
Activity : 2. To perform In-Situ HPWJ cleaning of tubes.
Jobs/Tasks/Assignments
Picture of HPWJ machine Picture of E-1164 tubes (clogged)
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E-1164 In-Situ HPWJ mechanical cleaning
Activity : 2. To perform In-Situ HPWJ cleaning of tubes.
Jobs/Tasks/Assignments
Picture of HPWJ nozzle Picture of tubes before and after HPWJ cleaning
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E-1164 In-Situ HPWJ mechanical cleaning
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.
Jobs/Tasks/Assignments
Proprietary 50
E-1164 In-Situ HPWJ mechanical cleaning
Activity : 3. To re install Channel cover, Shell cover and Floating Head cover.
Jobs/Tasks/Assignments
Pictures of tube sheet gasket` Pictures of girth flange gasket
Proprietary 51
E-1164 In-Situ HPWJ mechanical cleaning
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.
Jobs/Tasks/Assignments
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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.
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