1

2008 Offsite & Interconnecting Piping Program Review

Presented by Tom Atkinson

The purpose of this program: To identify and repair piping that is clamped and/or impending minimum wall thickness

Safety and Environmental 2008 Budget and Committed Dock Road LPG Interconnecting Piping incident and path forward Clamp Removal Clamp prevention by identifying piping at or near retirement Future leak prevention Man Hours West Refinery Flare Lines Manpower efficiencies Post Outage Reports

2

2009 Safety & Environmental Record for the Offsite & Interconnecting Project

Safety & Environmental No Safety or NRC Recordable Incidents as of June 15th 2009.

Wyatt has worked 230 K man hours since inception of this program in May 2005 through June 15th 2009 with no Safety or NRC recordables.

3

2008 - Budget for the Base and Catch Up Programs through December 31st

Base Program $ 1,700,000

Committed $ 1,251,398

over/(under) budget $ (448,602)

   

Catch Up Program $ 4,500,000

Committed $ 4,410,787

over/(under) budget $ (89,213)

Overall Offsite & Interconnect Piping Program $ 6,200,000

Committed $ 5,662,185

over/(under) budget $ (537,815)

4

2008 – Base Program Budget Planned

Pulled out of scope Completed Lines Lines in progress Committed

Base Budget Lines - AFE H-28G01-077-240Line No.

No. of Clamps

Mitigated Leaks Budget SAP Committed

19-565-B-14" 0   $ 30,000 $ -

9010-842-B-8" 1   $ 35,300 $ 4,694

9065-20-B-3" 1   $ 35,000 $ 1,339

19-207-BB-6" 1   $ 75,000 $ -

19-5033-B-4" 1   $ 65,000 $ -

      $ 250,000 $ -

9010-831-B-6" 1   $ 35,000 $ -

9025-187-B-24" 1   $ 124,000 $ -

19-202-B-30" 8   $ 1,519,200 $ 247,496

 WFL Scaffolds WO 80037680       $ 9,903

 Polaris DWG’s WFL WO 80035781     $ 30,800 $ 11,658

Polaris DWG’s WFL Tie Ins WO 80037700 $ 66,876

WFL Long Lead Hot Tap WO 80038286       $ 71,812

Structural repairs 1 & 2 SRU & Beavon 0 $ 125,747 $ -

Yearly Rental Equipment WO 80038440 0   $ $ 9,701

33-1140-C-2" 1 7 $ 38,000 $ 15,878

9030-39-B-12"     $ 50,000 $ -

Subtotal Clamps 15 7 $ 2,413,047 $ 439,357

Total Base Program Committed $ 439,357

Total Unscheduled Committed $ 812,041

Total Committed $ 1,251,398

5

2008 –Base Program Unscheduled Repairs

Pulled out of scope Completed Lines Lines in progress Committed

Line No.No. of

ClampsMitigated

Leaks Base Budget SAP Committed 19-5116-BA-3" 1 1 $ - $ 23,918

9045-33-B-20" 1 23 $ - $ 165,827

19-547-C-4" 1 65 $ - $ 59,955

19-532-B-6" 1 1 $ - $ 17,792

WO 80037198 0 0   $ 1,860

9045-103-B-10" IST 0 2   $ 36,044

9045-105-B-12" IST 1 3   $ 82,611

9040-28-B-12" 1 3   $ 22,984

9045-107-B-14" 2 4   $ 20,535

9040-19-B-10" 1 4   $ 15,650

33-2003-B-16 0 4   $ 10,004

9045-104-B-12" 0 4   $ 5,208

9040-44-B-14" 0 4   $ 10,684

19-616-B-16"IH 0 4   $ 9,854

33-2304-B-6" 2 20   $ 133,771

9010-800-B-6" 0 4   $ 50,784

19-201-B-24”        $ 4,465

9030-4-B-36”       $ 16,678

33-2083–B-6” 0 6 $ 23,794

3308–2342- 24” $ 96,698

1604-4-B42” $ 2,925

33-1383-B-4” $

Subtotal Clamps 11 152

Total Clamps 26 159 Unscheduled Committed $ 812,041

6

Catch-Up Budget Lines AFE H-28K01-077-240

Pulled out of scope Completed Lines Lines in progress Committed

 No. of Clamps

Mitigated Leaks

Paint Complete Budget SAP Actual

19-667-C-3" 0     $ 17,800  33-1145-A-3" 1     $ 32,300 $ 377 9040-43-B-24" & 9045-

13-B-24" 7 102   $ 152,900 $ 46,818 9015-100-B-10" 0     $ 33,700  9020-041-B-6" 2     $ 29,000  7907-D-2821-B-3" 0     $ 33,800  1604-03-B-36" / 9045-

11-B-36" 1 138   $ 258,200 $ 423,571 19-609-B-4 0 1 Yes $ 26,300 $ 17,824 9045-30-B-24" & 9045-

19-B-24" 3     $ 66,200 $ 8,752 33-1002-B-20" 0     $ -  multiple lines 0     $ 100,000          $ 40,000  9045-56-B-14" 1     $ 61,900  9045-10-B-24" 1     $ 67,400  9045-165-B-30" 0     $ 79,100  33-1154-C-4"       $ 51,400  31-57-B-6" 1 17 Yes $ 30,200 $ 51,801 Air Line on Docks       $ 12,500  7904-0711-B-6"       $ 35,000 $ 422

7

2008 Catch Up Program Budget Planned

 No. of

ClampsMitigated

LeaksPaint

Complete Budget SAP Actual

9010-411-B-18" 2     $ 43,000  1605-04-B-24" 1 4 N/A $ - $ -

9030-2-B-36" 1 0   $ 198,600 $ 105,155 Punch List Items       $ 50,000 $ 33-1007-B-4" 0 3 Yes $ 45,000 $ 13,927 9010-478-B-16       $ 50,000 $ 594

33-1255-C-6" & 33-1068-B-6"       $ 24,400 $ 56,544

33-1069-BB-3"       $ 35,000  7904-1519-BK1-8"       $ 35,000  9055-7-B-4" 1     $ 40,000 $ 9,267 1605-14-B-8" 1 1 No $ 75,000 $ 33,392 9010-187-B-24 2 1 No $ 35,000 $ 46,248

9020-090-B-8" & 9020-009-B-6" 1     $ 50,000  

33-1091-B-6"       $ 24,000  19-604-B-6" 0     $ 40,000 $ 7,106 19-550-B-10" 1     $ 45,000  

Pulled out of scope Completed Lines Lines in progress Committed

8

2008 Catch Up Program Budget Planned

Pulled out of scope Completed Lines Lines in progress Committed

 No. of

ClampsMitigated

LeaksPaint

Complete Budget Committed

33-30-BA-2"-IH   16   $ 40,400 $ 15,785

 SRU Cross Brace Demo       $ 155,972 $ 25,816

 Carry over from 2007         $ 207,845

 Casing Seals TK-7408/9   0 N/A $ 8,328 $ 10,120

9030-1-B-42" 4 18 Yes $ 223,000 $ 354,393

9030-3-B-42" 2 0   $ 293,700 $ 67,525

Subtotal 33 301 $ 2,639,100 $ 1,503,282

Catch up Planned Program Committed $ 1,503,282 Unplanned Committed $ 2,907,505 Total Committed $ 4,410,787

9

2008 Catch Up Program Unscheduled Repairs

Pulled out of scope Completed Lines Lines in progress Committed

Line No.

No. of Clam

psMitigated

Leaks

Paint Complet

e Catch up Budget Committed12-17-B-8" 1 1 Yes   $ 2,525 19-5058-BR-2" 2 2 Yes   $ 95,205 9030-88-B-4" 4        9040-28-B-12" 0 1 Yes   $ 7,448 19-5058-BR-2" 3       $ 246,711

60-110-B-24" 0  

By Others??

??   $ 1,202 9040-33-B-36" 1 7 Yes   $ 147,894     0 N/A   $ 15,681 8700-1401-B-14" 1 7 No   $ 56,998 9010-874-B-10" 1 1 Yes   $ 30,076 33-1115-B-12" 2 22     $ 221,840 Deiso Btms Line South

ofArea 2 Control room  0 3 No   $ 16,855 Deiso Btms Line TF13 0 43 No   $ 22,889 Deiso Btms Line UOP

Corn  1 1 No   $ 43,518 9045-105-B-12" IST     N/A   $ 842 9020-047-B-6   4     $ 28,472 9030-2-B-36" 0 242     $ 485,711 19-1047-C-4" 2 50      $ 926,432 LPG WO 90342519          $ 40,404 LPG 1 WO 90343981          $ 4,703

10

2008 Catch Up Program Unscheduled Repairs

LPG 32-206c-4”WO90344074 LPG Line       $ 4,700 $ 4,703 LPG 33-1011c-4”WO-90343095         $ 33,300 $ 39,352 Benzene Line TF20Hurricane Emergency

leak       $ 9,100 $ 9,029 33-2079-B-4"   3   $ 36,000 $ 25,629 33-2117-B-8"       $ 272,000 $ 203,788         $ (900,000)  19-677-C-3“ LPG       $ 275,000  EquipmentWO-80038441        $ 2,500 $ 2,500 Boiler Feed Water

Line WO 90342383        $ 65,506 $ 74,586 33-1161-C-4“ LPG    8   $ 175,000 $ 157,215

Subtotal 17 395 $ 2,349,857 $ 2,907,505

Total 50 696Unscheduled Committed $ 2,907,505

Pulled out of scope Completed Lines Lines in progress Committed

11

East–West LPG Interconnecting Line Incident at Dock road

LPG leak incident at Dock road lead us to multiple unknown LPG line repairs. East-West LPG Interconnecting Line 700’ of 4” at #6 Crude (Near miss that lead to the

shut down of #6 crude). Interconnecting spools at #6 Crude and the #2

LPG. 3” LPG Interconnecting lines in the West Plant that

tie into the 4” LPG East-West Interconnecting Line that run to the Tall Frac

12

Offsite and Interconnecting Root Cause and Operation and T/A Action

Inspection and Repairs of Interconnecting lines have been neglected.

I contacted Bobby Loe in early November 2008 to identify all interconnecting lines that were associated with Unit outages in early 2009.

Bobby Loe provided a list of Interconnecting lines that were associated with Units that would be in T/As in early 2009.

Bobby Loe also separated the Interconnecting lines that could only be repaired during T/A’s.

Sent the prioritized list to Inspection in late November 2008 for the 2009 January, February, and March T/A’s.

Inspection started giving Maintenance inspection results according to the T/A order in 2009.

13

Paint failure areas caused lines to fail in 2nd half of 2008

These are lines that have been repaired before 12” Bunker Line on the Docks 4” LPG line in Area 1 16” #5 CDU Charge Suction in TF #13

14

Clamp Prevention by Identifying Piping At or Near Retirement

Total of Clamps Clamps Total Potential Actual Potential Potential areas that

to Remove Removed Clamps to Mitigate Clamps Mitigated could be spot painted

Base Program 15 1 7 7 50

Unscheduled Repairs 11 11 152 136 150

Sub-Total 26 12 159 143 200

Catch Up Program 33 13 301 183 75

Unscheduled Repairs 18 7 405 405 200Sub-Total 51 20 706 588 275

Base and Catch Up

Sub-Total 77 32 865 731 475

15

2008 Potential Savings from Mitigated Clamps

Clamp installation cost $5,000+ Cost to remove a clamp on a line $80,000+

Average cost to mechanical mitigate 1 clamp during a clamp removal $1,500 Delta installation and mitigation $83,500

731 Clamps mitigated – Credit 1/3 to Savings Potential savings from clamps mitigated 363 X $83,500 = $30,901,500

Potential savings from repaired failed paint 156 X $83,500 = $13,026,500

2008 Total potential savings from future clamp mitigation $43,928,000

Priority ActivityLead

Abatement Complete

Touch Up Paint Complete

Forecast or Schedule

Completion Date

Actual Completion

DateCrital Path and top Priority

1 24" Premium Base Suction 3308-2342-B-24"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

2 8" Regular Base R/D 3308-2117-B-8"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

3 42" Crude Line at Dock # 4 no no     We need this lead abatement ASAP

4 36" Crude Line at Tk Field #59 no no     We need this lead abatement ASAP

5 8" 2 Oil Line South of the UOP corner

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

6 36" #6 Oile Line East of Dike #4

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

7 6" Sour Naptha Line yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

8 8" Bunker Line to Dike #5 yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

9 Ole 2 Oil Suction South of Tank Field # 20

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

10 #1 Vac Line between TF 8 and 9

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

11 2" Caustic Line to # 1 Beavon Phase # 2

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

12 #1 Vac Make Up Line yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

13 Regular Base Suction Line in TK Field #7

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

14 # 5 & #6 CDU Slop Line yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

15 Deiso BTMS Line south of Area 2 Control Room

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

Priority ActivityLead

Abatement Complete

Touch Up Paint Complete

Forecast or Schedule

Completion Date

Actual Completion

DateCrital Path and top Priority

15 Deiso BTMS Line south of Area 2 Control Room

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

16 Deiso BTMS Line at TK Field 13

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

17 #2 V/B R/D Line @ 7413 Dike Wall Insulation

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

18 6" Header @ TK-6840 yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

19 LPG Condensate Line West of 7416

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

20 20" #2 Oil Line under dock road

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

21 #2 CDU 6 Oil R/D line at TK - 6814

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

22 2 V/B R/D Line @ 7413 Dike Wall

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

23 #1 Vac R/D Line @ 7413 dike Wall

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

24 Coker Gas Oil Line @ 7413 Dike Wall

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

25 HVGO to #6 DD Line @ 7423 Dike Wall

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

26 MFP R/D Line Tank Field #6 yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

27 6" Old Water Line yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

28 East - West 4" LPG Transfer Line new tie-ins

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

29 East Plant #5 Crude Slow Down 4" LPG line

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

30 East Plant #1 LPG 4" LPG line Repairs

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

Priority ActivityLead

Abatement Complete

Touch Up Paint Complete

Forecast or Schedule

Completion Date

Actual Completion

DateCrital Path and top Priority

31 West Plant 4" LPG Transfer Line Replacement

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

32 West Plant 3" LPG line repairs yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

33 Deethanizer Off Gas Line #33-1184-B-4"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

34 OHD to 3 LPG Sweet LPG line #33-1155-C-4"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

35 # 4 Plat Cold Charge Line #33-2067-B-8"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

36 #2 Visb R/D Line #9045-105-B-12" IST

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

37 36" 6 Oil Line #9045-11-B-36" yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

38 6" R/D Header at Tk-6841 yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

38 36" Crude Line #9030-2-B-36" to DK 3/4

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

39 6" #5 CDU Kero R/D Line #33-1091-B-6" @ South Departure

Rack

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

40 8" #5 Jet T/D Line #31-130-B-8" to storage

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

41 4" Slurry Line #85-7064-BA-4" to DCU

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

42 TK-7412 header Spool 9040-37-B-30"

yes yes   4/23/09 We need to paint these repairs and touch up paint paint failure areas of the line.

43 TK-6841 3308-2374-B-12" yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

44 TK-6841 3308-2375-B-12" yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

45 TK-6841 3308-2379-B-12" yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

Priority ActivityLead

Abatement Complete

Touch Up Paint Complete

Forecast or Schedule

Completion Date

Actual Completion

DateCrital Path and top Priority

46 TK-6841 3308-2372-B-20"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

47 TK-6841 3308-2416-B-8"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

48 TK-6841 3308-2415-B-12"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

49 TK-6841 7907-0-0819-B-6"

yes no     We need to paint these repairs and touch up paint paint failure areas of the line.

20

Man Hours – Base and Catch Up Program

TypeOriginal

Budget man- Hours

Man Hours Committed

Man Hours Under Reason

Base & Catch Up 83,650 69,345 14,305 We were under 14,305 Man Hours because of budget cuts.

21

2008 Phase #1 Jumper Design Engineering Chronology

Activity Completion Date

Preliminary red line Plot Plan, P&ID & ISO’s 30 Aug 08

Request MOC approval 15 Sep 08

Detail design of the P&ID & ISO DWG’s 30 Nov 08

22

Phase # 1 Jumper Execution Status

Scaffolds are erected to take thickness readings for all hot taps and stopples

Wyatt is currently laying out all the hot tap and stopple areas in the field so the Inspectors can document the thickness readings for the hot tap and stopple approval – Projected completion 2 Feb 09

Inspection will start taking thickness readings on 26 Jan 09 – Projected completion 16 Feb 09

Engineering will review the inspection thickness findings for hot taps and stopples starting 2 Feb 09 – Projected completion 23 Feb 09

Wyatt will start fabricating the pipe jumpers on 9 Feb 09 – Projected completion 17 Apr 09

Triangle will start installing all the hot tap and stopple fittings on 16 Feb 09 – Projected completion 30 Mar 09 TISI will start cutting all hot taps 9 Mar 09 – Projected completion 20 Apr 09

TISI will install stopples according to the future flare repair schedule

Wyatt will start installing the Jumpers on 23 Mar 09 – Projected completion 29 May 09

23

Phase #1 Jumper Installation

24

Phase #1 Jumper Resources

25

Phase #1 Jumper Preliminary Estimate

HOVENSA L.L.C. St. Croix USVITurnaround Estimate Summary

West Flare Jumper/Hot TapsBy : L. Chappell H-29K01-077Date :Jan. 16, 2008AFE No: : H-29K01-077 ESTIMATE SUMMARY REV 1Estimate:

WBS Non-Wyatt Wyatt Non-Wyatt Wyatt Wyatt Total Detail Description M/Hrs. M/Hrs. M / L / E $ Labor $ Mat'l $ Dollars

240 Piping 5,042 11,471 255,816 1,349,916 41,296 1,647,028250 Valves - Replace 0 0 0 0 0 0

Above The Line ==> Directs 5,042 11,471 255,816 1,349,916 41,296 1,647,028

Field Supervision 0 2,519 0 90,684 4,534 95,218 Field Support 119 320 4,653 11,520 0 16,173 Consumables 0 0 13,752 0 14,310 28,062

Logistics 1,715 0 72,000 0 0 72,000 Major Equipment 0 0 0 0 0 0 Equipment Rentals 0 0 85,600 0 0 85,600 Environmental - Waste Disposal 0 0 0 0 0 0

Indirects 1,834 2,839 176,005 102,204 18,844 297,053

SUB-TOTAL 6,876 14,310 431,821 1,452,120 60,140 1,944,081

999 Contingency ............ 0.0% -$

TOTAL BASE AMOUNT $1,944,000

26

West Flare Repair/Replacement Schedule Status

24” High pressure line 75% complete – Projected completion 02 Mar 09

Waiting on the subcontractors to supply estimates and timelines for the 24” Hydro-chem – Line Mole and Chemical Clean Veolia - Line Mole and Chemical Clean TISI – Drill, Hot Tap, and Set Stopples Triangle – Weld all Hot Tap and Stopple Fittings

30” Low pressure line 0% complete – Projected completion 04 Sept 09 (This repair will be included in the 2010 budget)

27

Material Status

TISI Hot Tap/Stopple fittings are on site. $107,975 08 Budget

Material for the hot tap jumper fabrication are on $288,500 08 Budget site.

Long lead material for Phase # 2 repairs on the $84,100 09 Budget high pressure flare line to be purchased no later than 13 Apr 09.

Long lead material for Phase # 3 repairs on the $160,600 09 Budget low pressure flare line to be purchased by 28 Sep 09

28

Environmental MOC Concerns

Environmental Department is in possession of the MOC.

MOC has not been approved because of Subpart JA regulation concerns.

Next slide shows the typical red line P&ID tie-in Subpart JA regulation concern. The environmental concern is the area we plan to tie the jumper into the flare header inside the battery limits valve. Our P&ID’s show the flare header starts at the discharge side of the relief valve. Environmental and Legal say we need clarification on this issue before moving forward because EPA could interpret the flare header starting inside the battery limits valve.

29

30” Low Pressure Flare Header

30” Low Pressure Flare Header

24” High Pressure Flare Header

24” Existing Jumper

8” Existing Jumper

Proposed Jumper

V-1 V-2

Battery Limits

Legend

=24” High Pressure Flare

=30” Low Pressure Flare

=30” Low Pressure Flare (Area #1)

=Unit Example

=Proposed Jumper

30

RR&E for Offsite/Interconnecting Manager, Planners and Schedulers

Receive marked up DWG’s from Inspection Receive marked up P&ID, blind list, de-inventory plan and Champ or

MOC from Operation Walk down the job and draw up a detailed repair plan Order all materials Build time line Schedule and Estimate Fabricate in the shop and execute the job in the field

The Offsite/Interconnecting group is not using Engineering and they generate their own replacement in kind DWG’s directly from Operation/Inspection. Operation/Inspection is working closely with us to make sure repairs on all these lines are executed according to the current standards and specification!

31

Equipment Plan Efficiencies

Lease to Own Delivery by October 2008 Received in 2009

Vacuum Truck Transfer Pump Wench truck Water truck Trailer and Piggy back Forklift

32

2008 Post Outage Report for Offsite and Interconnecting Piping Repairs

Files are located in the T/A Building.

All pertinant files are being downloaded into “Live Link” by the Planners.