STUDENT INDUSTRIAL TRAINING (SIP)

PRESENTATION 23rd July, 2019

Title of SIP Project:

PLANT RELIABILITY MODEL FOR PETRONAS
SECOND REFINERY – 1 (PSR1) & MELAKA
GROUP 3 (MG3)

UTP Supervisor: AP Ir Dr Mokhtar Che Ismail

Host Company Supervisor: Mr. Wan Bin Wan Hussain

Presenter:
Muhamad Shukri Bin Hassan
22856 ME student, UTP
OEX Department
 6. Conclusion
and
Recommendati
on.
5. Result
1. Background
and
Study.
Discussion.

PRESENTATI
ON OUTLINE

2. Objectives. 4. Challenges.

3. Q&A
Methodology. SESSIO
N
Background Study
 The importance of plant performance in MRCSB.

MRCSB core business:

 To refine indigenous crude oil into high

value petroleum products for domestic
and export markets.

MRCSB responsibility:

 To ensure the performance of refinery

complex in excellent condition.
 To deliver the customer’s demand within
the agreeable time. FUTURE
 To operate the refinery complex in a
sustainable and safe manner.
 To achieve the targeted business profit. Comparison of MRCSB with other
refineries in MALAYSIA
 MRCSB Annual KPI:

Strictly avoiding major accident.

Plant Reliability Model will be one of Zero major HSSE

company’s tool to gain the targeted PU accident.

Plant Utilization (%)

Refinery plant achieve

Plant Utilization (PU) above
83%
Gain beyond RM300 million profit
before tax

Profit Before Tax (RM million)

TERAS 2019
 The definition of RELIABILITY, AVAILABILITY and
MAINTAINABILITY.

What is reliability?

The probability that the item will perform its required function under given
conditions for the time interval
What is availability?

The probability that a system is performing its required function at a given point
in time or over a stated period of time when operated and maintained in
prescribed manner.
What is maintainability?

The measure of the ability of an item to be retained in or restored to specified

condition when maintenance is performed by personnel having specified skills
level, using prescribed procedures and resources, at each prescribed level of
maintenance and repair.
Objectives
Methodology
 Project activity process.

* Plant Reliability Model not

cover until component level.
MRCSB
REFINERY
PLANT SELECTED UNITS
IN PSR-1 & MG3:
1. CDU-1
MAIN EQUIPMENT
2. CRU-1 - Rotating
3. U18 1. Pump
2. Compressor COMPONENT
4. U19 1. Blade
- Static 2. Bearing
1. Column 3. Mechanical Seal
2. HEX 4. Tube bundle
3. AFC 5. Channel head
4. Vessel 6. Fan belt
5. Furnace
 General Methodology for Reliability Analysis

1. Setting objectives

2.1. Definition of system 2.2. Definition of failure

3. Data gathering

4. Exploratory analysis

7. Recommendation for
5. Distribution analysis
Operation and Maintenance
improvement.
6. Estimation of
Reliability Measure
Challenges
 Result
and
Discussion
 Conclusion
&
Recommendations
Summary from the Plant Reliability
Model results for unit level.
Ranking of units based on reliability
simulation (BlockSim)
 Ranking of root causes in CDU-1
according to the weightage of FCI and
DTCI
Top 10 critical items in CDU-1 which
need to be aware by company.
 Recommendations:

3
1
2
3