PS SHIFT HANDOVER REPORT

CDU / VDU / SGRU / LTU / NTU / KTU

DATE 17 Feb 2009

.
SHIFT B NIGHT FIRE MARSHALL Hidir RSM Azhar Ahmad
DUTY PS Rozee ` PANELMAN M Nazir UNIT 21 Kamarul Ariffin
SPECIALIST PANELMAN M Fauzi UNIT 21 Ridzuan
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PROJECT TRNG PANEL UNIT24 Herman
UNIT 26/27/28 Sapian Rahim
Fadhi

Unit 21 : Crude Distillation Unit

PLEASE SAVE ALL SIPs IN THE Q:/PS H'OVER/AREA2/CDU2 SIPS
Feed Rate (m3/hr) 939.94 SIPS running number (CDU2/XX/mth/2009) 010
CDU Feed Thruput (MB) 141.89 141.89%

Feed Tank Online T-71205 syazahanisah

T-71204 T-71206 T-71207 T-71206
Feed Pump Online P-71201A DUB P-71201BDUB P-71201C P-71201D P-71201E
Crude Type Supplied IRH/RTW MAS/IRH/RTW MAS/SLOP/IRH/RTW ALT/SLOP/MAS MAS/SLOP/IRH/RTW
Crude Rate (M3/hr) 160.00 150.16 179.40 264.32 189.53
Crude Rate (MBPD) 24.15 22.67 27.08 39.90 28.61
Crude Rate (%) 17.02 15.98 19.09 28.12 20.16

PRODUCT MB HCK DHT MB

O/H Vapor (m3/hr) 4460.8 MB Kerosene (m3/hr) 107.5 16.23 HGO (m3/hr) 17.1 2.57
O/H Distillate (m3/hr) 206.10 31.11 LGO (m3/hr) 190.4 28.75 Atm Residue (m3/hr) 551.0 83.17
DHT bypass (m3/hr) 84.9 12.82 DHT FEED LGO + LVGO 285.6 43.11
Cell A Cell B Cell A Cell B
OTHER DATA Set point FG press F-21201 2.30 2.30 Arch Temp 841.5 740.4
Coil Outlet Temp (oC) 344.5 348.0 O/H Pressure (kg/cm3) 1.27 Diff. Temp 101.2
Top Temp (oC) 138.5 T-21201 Level (%) 47.4 K-21201 running
A B

LAB RESULT
Measure Routine FBP Spec Measure Routine Spec
O/H Dist 90% Distil (oC) 158.8 189.6 [ 155 / 190 ############ LGO 90% SIM 386.5 395 03-11-08 07:59
Kero Flash Pt (oC) 43.5 m 38 ############ HGO Pour Pt (oC) 33.0 n/a 12-09-08 08:28
Kero Freeze Pt (oC) -47.7 [ -47 ############ HGO 90% SIM 445.0 [ 390 11-02-09 07:59
Kero 90% Distil (oC) 251.0 [ 245 ############ HGO ASTM Colour 2.5 3.0 11-02-09 07:59
Kero Mercaptan 150.2 160 ############

Unit 21 : Vacuum Distillation Unit

FEED MB MB
Feed Rate from CDU (m3/hr) 551.0 83.17 Total Feed Rate to VDU (m3/hr) 590.6 89.16
Feed Rate of LSWR (m3/hr) - HOT COLD 12/02 @ 1000HRS 39.7 5.99 VDU Feed Thruput (%) 120.8

PRODUCT (m3/hr) MB
Off Gas (m3/hr) 189.50 MB MVGO 125 18.87 XHVGO (m3/hr) 10.0 MB
LVGO (m3/hr) 95.1 14.36 HVGO 102 15.35 Vac Residue (m3/hr) 189.1 28.54
TOTAL VGO + HGO 243.7 36.79 TOTAL VR + XHVGO 199.1 30.06

OTHER DATA Set point Cell A Cell B Cell A Cell B

Coil Outlet Temp (oC) 391.5 389.7 FG press F-21251 1.72 1.69 Arch temp 810.2 824.2
Top Temp (oC) 76.5 Wash Oil Rate (m3/hr) 109.9 Diff. Temp 14.0
VDU SW to U34 (m3/hr) -0.2 Vac Pressure (mm Hg) 16.21 FG Density 0.80

LAB RESULT K-21251 running A B

Measure Routine Spec
LVGO 90% SIM 373.0 395 11-02-09 07:59 Measure Routine Spec
LVGO Pour Pt (oC) 9.0 n/a 10-11-08 07:59 HVGO Colour 6.0 [ 6.0 16-02-09 07:59
MVGO 90% SIM 502.0 n/a 12-09-08 06:00 HVGO Asphaltenes 0.006 [ 0.008 11-02-09 05:59
HVGO 90% SIM 554.0 [ 565 16-02-09 07:59 U30 Filtered Feed
VR 10% SIM 551.0 > 550 11-02-09 05:59 HCK Total Metal 0.861 1.500 16-02-09 03:59
Feed Rate of VR (m3/hr) - ASPH HSFO DCU 189.1 28.54 16-Feb-09
Unit 24 : Saturated Gas Recovery Unit
K-24201 Feed Rate (m3/hr) 4981 K-24202 Feed Rate (m3/hr) 7747
PRODUCT
Butane 0.4
Fuel Gas (m3/hr) 7757.2 Light Naphta (m3/hr) 20.0
Untreated LPG (m3/hr) 24.7 Heavy Naphta (m3/hr) 286.8

OTHER DATA FIELD TESTS

Amine Circulation Rate (m3/hr) 39.8 Date Time Test Result
Sponge Oil Rate (m3/hr) 20.1 27-Aug 0600 H2S 100
Lean Oil Rate (m3/hr) 0.0
T-24201 Level (%) 4.0 Depropaniser (C-24203) on off
LAB RESULT
Measure Spec DCU LPG
Hydrogen Sulphide 30.00 [ 100 30-01-09 07:59 Measure SC 3272 Spec
FG C3 Content (mole%) 1.67 [ 3.0 13-02-09 07:59 LPG Tot C5+C6 (vol %) 0.42 [ 1.5 17-02-09 20:31
LPG Tot C3 (vol %) 41.95 44 17-02-09 19:59
LPG Tot C4 (vol %) 56.97 17-02-09 19:59 C24202 LPG
LPG Tot C5+C6 (vol %) 0.81 [ 1.5 17-02-09 19:59 Measure SC 2403 Spec
Sulphur Content (ppm) 72.00 [ 100 17-02-09 19:59 LPG Tot C5+C6 (vol %) 0.06 [ 1.5 16-02-09 07:59
Vapor Pressure, kPa 702.80 17-02-09 19:59

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 Unit 26 : LPG Treating Unit
FEED
LPG feed from SGRU (m3/hr) 24.7 Total Feed Rate (m3/hr) 34.4
LPG feed from DCU (m3/hr) 9.7 LTU Feed Thruput (%) 61.1

OTHER DATA
Amine Circulation Rate (m3/hr) 18.0 Oxidation Air Rate (m3/hr) 52.8
Caustic Circulation Rate (m3/hr) 4.0 Flow Rate (m3/hr)- TSN 0.47
Reformate

RATIO
Measure Actual Spec Measure Actual Spec
LPG Flow / Amine Circ. Rate 1.9 2 to 10 LPG Flow / Caustic Circ. Rate 8.6 7 to 20

LAB RESULT
Measure Routine Spec Measure Routine Spec
C2 Content (vol%) 0.12 [ 1.0 09-02-09 18:09 Cu Corr 1a 1A 23-10-08 13:39
LPG Tot C5+C6 (vol %) 0.08 [ 1.5 09-02-09 18:09 Weathering Test (oC) 0.6 -2.2~2.2 23-07-07 21:59
Sulphur Content (ppm) 116.00 [ 100 17-02-09 14:00 Residue in LPG (vol%) 0.00 0 05-08-05 09:59

CAUSTIC
Caustic Unit 26 (wt% free NaOH) <7.0 10.7 16-02-09 07:59 Lead Acetate Test No H2S Present
Latest Caustic Change-Out 11-Feb-2009 Shake Test No Colour Change
DSO (ppmwt) 576.8 13-02-09 07:59

Unit 27 : Naphtha Treating Unit

FEED
Light Naphta Flow Rate (m3/hr) 23.9 NTU Feed Thruput (%) 24

OTHER DATA
Caustic Circulation Rate (m3/hr) 22.3 Oxidation Air Rate (m3/hr) 7.1

RATIO
Measure Actual Spec Measure Actual Spec
Naphtha Flow / Caustic Circ. Rate 1.1 4 to 10 Naphtha Flow / Oxidation Air Rate 3.4 3.8 to 6.4

LAB RESULT
Measure SC2703 Spec CAUSTIC
Mercaptan Sulfur (ppm) 8.11 <5 17-02-07:59 Caustic Unit 27 (wt% Free NaOH) 8.13 13-02 07:59
Dr Test Positive - ve 17-02 07:59 Latest Caustic Change-Out 14-Feb-09
RVP 215.0 < 180 17-02 07:59 Caustic Unit 27 (Deg Baume)-Use 20Baume
215 max as planner
Unit 28 : Kerosene Treating Unit
FEED
Kerosene Feed Rate (m3/hr) 116.6 Kerosene Thruput (%) 123.9

KTU DATA Set Point

Oxidation Air OP (%) 45 Caustic Circulation Rate (m3/hr) 12.0
Oxidation Air Rate (m3/hr) 50.3 47.5 (m3/hr) 28PC-001 Reading (kg/cm2) 5.7
Wash Water Rate (m3/hr) 11.0 T-28201 Level (%) 101.4
Caustic Make-up, P-28203 Stroke (%) 60

RATIO
Measure Actual Spec Measure Actual Spec
Kerosene Flow / Oxidation Air 2.3 3.33 Kerosene / Wash Water Flow 10.6 10
Kerosene / Caustic Flow 9.7 10

LAB RESULT
Measure SC2809 Spec Measure Routine Spec
Mercaptan Sulfur (ppm) 63.9 max 50 17-02-09 19:59 Dr Test Negative + ve 22-10-07 09:59
Saybolt Colour (filtered) 17 m 12 17-02-09 16:00 Particulate 0.35 <1.0 17-02-09 07:59

Next Recausticization (every Sunday)

Caustic Unit 28 (wt% free NaOH) - 3-5wt%' 2.92 16-02-09 07:59 Latest Recausticization 16-Feb-09
Total Alkalinity (wt% NaOH) -M 5.18 16-02-09 07:59 Caustic change-out 22-Jan-09
Spent Caustic Unit 28 (wt%) - 44% Salt Top-Up 13-Jan-09

Unit 28 : Caustic Neutralisation Unit

CNU DATA current ############
V-28251 Level (%) Spent Caustic 70.60 73.46 -2.85 P-28251 Stroke (%) A B 80 %
V-28252 Level (%) H2SO4 19.17 23.46 -4.29 CNU status- Down
CNU pH Control -DCS 8.43 6~8
Running

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 Others

CONDITION / CORROSION MONITORING

Measure Routine Spec Measure Routine Spec
V21201A Effluent H2O -pH 6.20 6.5-7.5 11-02-09 05:59 CDU Overhead - pH 5.5 5.5-7.0 11-02-09 05:59
V21201A Effluent H2O -Oil&grease 36.40 [ 200 11-02-09 05:59 CDU Overhead - Chloride (mg/L) 20.0 [ 50 11-02-09 05:59
V21201B Crude Out. - Salt (ptb) 0.79 [ 0.7 11-02-09 05:59 CDU Overhead - Iron (mg/L) 0.84 [ 3.0 11-02-09 05:59
WHB - pH 10.1 9.5-10.5 13-02-09 19:59 VDU Overhead - pH 6.8 5.5-7.0 17-02-09 14:00
WHB - Conductivity (lS/cm) 85.4 [ 1000 13-02-09 19:59 VDU Overhead - Chloride (mg/L) 16.0 [ 30 11-02-09 05:59
WHB - Phosphate (mg/L) 43.5 10-40 13-02-09 19:59 VDU Overhead - Iron (mg/L) 0.40 [ 3.0 17-02-09 14:00
WHB - Silica (mg/L) 1.3 [2 13-02-09 19:59

drop/min Stroke ppm drop/min Stroke ppm ppm

10O BE Fresh Caustic - P21224A/B 150.0 0 23.6 EMB 2W801 - V21201 Air pump 40.0 stop 6.3
Philplus 5K2S - P-21261 - Corr inh-VDU 6.0 5.5 EMB 2W151 - E-21201 Air pump 30.0 4.0
Philplus 5K1 - P-21223 - Corr inh-CDU 16.0 13.1 EMB 2W151 - V-21201 pace satter 30.0 4.0
Thermoflo 7R64 -P-21221- Crude Feed 42.0 6.6 Phosphate HP 54707 - P-21219 - WHB A 45
Amine Neutralizer 4H5 - Air pump - CDU O/H 15.0 12.3 Citric Acid - Air pump - V21201A off
Ammonia - P-21214A CDU NH3 60 Proshele 61N - Air pump - Secondary Loop off
Ammonia - P-21214B VDU 4H5 60 Proshele 61N - Air pump - Primary Loop stop
Ammonia - Air pump OFF 0 Anti Oxidant U27 10cm/min betz
* CDU and VDU NH3 injection stroke will be adjusted accordingly to match the pH paper checking in shift basis. * chemical update 17-Feb-2009
* To calculate ppm vol = (drop inch/min x 2.46 mL x 60 min)/ (feedrate.eg 21FC062/21FC065/21FC001( (m3/hr)).* 5.0 wt% = 7.4 Deg Be. Pls refer Betz sheet at chemical tank. C1V1 = C2V2 OR drop/min=y ppm x crude Flow /146.7
CONTROLLER STATUS
DATE
1 21UC591 - u/stream & d/stream valve closed 08-Dec-08

Checked previous shift's Panel Handover Report Checked previous shift's Field Handover Report

Furnace Efficiency
F21201 F21251
Excess O2 (%) 1.46 Excess O2 (%) 2.82
Draft pressure (mmH20) -3.55 Draft pressure (mmH20) -1.17

Catalyst / Ammonia / H2SO4 Inventory

AQUEOUS AMMONIA H2SO4

Received new load 31-Jan Received new load 29-Jan
Current T-21251 level (%) 36.22 Current V-28252 level (%) 19.17
Initial T-21251 level, Lo (mm) 37.97 Initial V-28252 level, Lo (%) 23.46
Li - Lo (mm) 1.8 Li - Lo (mm) 4.3
Total load (kg) Total load (kg) 9360
ARI-100L
Received new inventory 06-Feb-09 one pallet
Available onsite (drum) 5 drums 06-Feb-09
Available at PSR-2 Chemical Store 0

EQUIPMENT STATUS
Equipment Qty Status Equipment Qty Status
LEL Meter 1 MSA ORION A4-1565 H2S Badge 11 no battery

RADIO NUMBER AS 10-02-09 Status Owner REMARKS.

1 PPMSB-0182 OK PS MTP750
2 PPMSB-0187 OK panel MTP750
3 PPMSB-0186 OK opr MTP750
4 PPMSB-0184 OK opr MTP750
5 PPMSB-0185 OK opr MTP750
6 PPMSB-0188 OK opr MTP750
PPMSB-0189 OK opr MTP750
SIPS UPDATE
CONTROL NO TAG NO & SERVICE STATUS
1 CDU2/29/2007 26UZA061 converted to CAF

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 ACTIVITIES
HSE & SAFETY ITEMS
1 Audit of cap/drain continues.Pls continue swing blind and close end flange.
Awaiting another batch of 3/4"caps ordered ( refer Ehsan ).
Pls continue the pending items plus housekeeping tonight as audit will be conducted tomorrow 13-2
2 Lightning arrestor at C-21251 top slip from the stand and hanging at the coloumn.
The dome already taken away by electrical (10-Feb) and the job will continue after evaluation regarding the others lightning arrestor coverage.
3 Pls empty out thedrum at U27/28 that contains liquid for tomorrow housekeeping.

UNIT 21
1 Crude feed maintains at 140MB.
2 MVGO and HVGO routed back to HCK feed tank.
3 V-21251 Recovered Oil - 100% to DHT and fully close to LSO
4 V-21251 RV bypass closed.
5 V-21254 - draining system suspected clogged, pls drain using LPS drain point.
6 VDU sour water routed to desalter as U34 train #2 shutdown. 4H5 injected to P-21214 replacing NH3 to VDU.

CHEMICALS/OIL
* New chemical being used due to unavailability of the previous chemical after MOC. 7R64 replaced with 3F18, 5K1& 5K2S replaced with 5K7.
Anti Oxidant U27 - 3F28.
1 61N - BETZ fully monitor 61N injection rate. Operation responsibility is to monitor pump perfomance and stock at site.
2 Wetting agent pump was found not pumping. The pump was replaced by 61N pump.Notif raised.
3 Ammonia Haskel pump B awaiting for material for the rectification job.
4 P-21222A (main) removed out for rectification job under Betz. One spare unit installed at site but still failed as it causing pace setter to trip.
18Dec P21222B rectified by Elect(motor) and able to pump. Now injection back 16'/min to E201 and 16"/min to Desalter. Pls monitor
5 Mech AMT will replace RV of the 3F28 once the material arrive.

UNIT 24
1 Unit in steady condition. -
2 V-24208 RV bypass open.
3 24LC027 - reading faulty - RM to AMT. Inst plan to convert 24LI026 into 26LC026. OE to work for the CAF.
4 New LPG line from Unit 23 to C24202 reflux return under N2 blanket.
5 C-24203 online but no butane draw.

UNIT 26
1 Unit in steady condition.
3 Pls regularly check and compare the LG vs LI of U26 level.

UNIT 27
1 Unit in steady condition.

UNIT 28
1 Unit in steady condition.
2 Pls follow the instruction from OE regarding brine issue at V28203 and V-28202.
V28202 water wash changeout done once per shift. Do not drain until kero comeout at bottom drain as to ensure consistent water wash flow vrs kero as of Mericam.

CNU
1 Unit in steady condition.
2 Pls regularly check pH (litmus paper) versus analyser.
3 28UZA111 leaks at packing. Notification raised.
Tight-off valve located at top of the vessel is failed. To plan on next opportunity once V-28252 empty and plan for acid delivery properly.
Pls do not order the acid and let the vessel empty for UZ repair.
4 Currently both analyser is reliable and drained to OWS and isolation at suction pump was closed.

EQUIPMENT RELIABILITY
1 P-28255 under CRG.
2 P-21254B leaks at inboard seal 10 drops per minute. Switched to A as IMI advised. Highlighted to CRG and awaits for material. Till then pump A maintain on st by.
3 P21203A steam quenching line cold. IMI has checked and requested AMT to unclog. Pls liase with AMT.
4 P-21253A seal pot level loss severely and need to top up within shift. IMI to verify. Notification to raise.
5 P-21258A badly leaks thru quench steam drain. Mech seal suspect leaks. Notif raised to IMI @11Jan.
6 P21259A RV leaks at body. Pls arrange AMT to rectify. To rectify when B pump online.
7 P21259B- tested and found pump problem ,tomorrow AMT will rectified.
8 P-21202A - Under CRG for repair. Will be back on 23Feb 09.
9 K-24201- local panel display m/function, notification 20894716
Buffer gas filter element to replace.
10 K-21251B - suspected gear oil pump malfunction , pls closely monitor for filter cleaning tomorrow.

PROCESS CONCERN
1 RECAUSTICIZING OF U28 should be executed every Monday.
2 Both P-21209 A & B can be run to cater high AR flow.
3 Two strainers had been installed at outlet of V-28201.
4 Mudwash to be performed at night on daily basis for 1/2 hour duration.
5 It is advised to reduce desalting water to 3 % during crude tank switch to avoid water carry-over.
6 F-21251& F21201 :
Pls visually monitor hot spot and maintain as it is if possible.
7 Pls use separate pump for NH3 transfer from T21251 to T21207 (NH3 day-tank) and scrubber.
8 To identify steam tracing lines leak and related isolation valves, only then raise notifn.In progress.
9 Off gas from unit 19 was introduced into pipeline to PSR-1 via U21/24. PC-405 auto at SP=4.9 (OP=45%) and PC-407 at MAN fully shut.
Upstream and downstream valves of PC-407 isolated.
10 21RV-003 - still reliable as AMT but to have close monitoring by operation.

PROJECT
1 Revamp activity on going in Unit 21/24/26/27/28.

GENERAL ISSUES
1 Pls aware to inform area planner and not to raise notification for - belt wobbled/clean strainer.
2 File for bicycle maintenance record available at PS rack. Pls update in/out item.
3 Meeting
Production & Maintenance - every Tuesday @ 1030 hrs.
Maintenance backlog & planning - every wed @ 1030 hrs or refer to Ehsan, Area 2 Planner.
4 New Info: Sampling bomb is under our custodian but fittings (repair) are under lab. IF damaged mark it and send to lab.

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