2011 Capital Project Construction Review

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Safety 2010 Carry Over and 2011 Summary of Capital Projects 2011 P-6 Summary Schedule by Project 100 Day Plan Construction Schedule 2011 SVF Pie Chart and MH’s NDE Point SAR Heater in the News Media Fire Water Plan Accomplishments Opportunities

Agenda

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Recordable rate target = .50

Combined = 0.36

Hovensa = 0.43

Contractor = 0.31

TSCM = 0.21

Hovensa, Contractors & Turner St Croix Safety

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Projects1. Coker Grating2. Coke Drum 1 Support3. Coke Drum 2 Support4. Coke Handling System5. Dock Road Crossing6. Spent Cat Slab Pump Around7. Spent Cat Slab Catch Basin8. VER 1 Skid9. VER 2 and VER 3

2010 Carry Over to 2011

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2011 Tracked Capital Projects Summary   PIR AFE   Complete  

  # # Description To Date To

        Plan Actual Date

 

(N) (O) (Q)

1 3940   Curbing and Drainage 100.0% 100.0% 1.57

2 10-001   CHS Desal Line 100.0% 100.0% 1.48

3 09-037   Greenhouse Gas 100.0% 100.0% 0.92

4 10-028   West Stack Cameras 100.0% 100.0% 1.08

5 08-143   Firehouse Generator 100.0% 100.0% 0.90

6     OEL Piping 100.0% 100.0% 0.90

7 09-088   QC Lab Air Compressor 100.0% 100.0% 1.81

8 08-119   LEL Gas Detectors 100.0% 100.0% 0.99

9 08-008   Alky Caustic Sewer Stage II 100.0% 100.0% 1.01

10 4159   Blowdown Stack Silencers 100.0% 100.0% 0.84

11 4267   West SRU CEMS 100.0% 100.0% 0.92

12     GT8 Foundations 100.0% 100.0% 0.85

13 08-076   FB5 Stack 100.0% 100.0% 1.83

14     Figtree Ditch Brush Removal 100.0% 100.0% 1.22

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  PIR AFE   Complete  

  # # Description To Date To

        Plan Actual Date

 (N) (O) (Q)

15     4 DD Fire Repair 100.0% 100.0% 0.73

16 10-199   FCC MCB Pumps 100.0% 100.0% 0.79

17 10-199   West Benzene Seawater Piping 100.0% 100.0% 1.23

18 4027 H-28010 API STAGE II 100.0% 100.0% 1.19

19 4027 H-28010 API STAGE I 100.0% 100.0% 0.82

20 4027 H-28010 API STAGE II Post 100.0% 100.0% 0.81

21 08-021 H29Z02 GWR-Pipe Repair & Upgrade 91.6% 83.2% 1.01

22 08-109 H-31017 5 Crude Concrete Repair 100.0% 100.0% 1.09

23 09-013 H-29050 Desal Water Meter Project 100.0% 100.0% 1.47

24 10-039 H-30017 Warehouse Material Trailer 100.0% 100.0% 1.10

25 MNT 90472536 Area IV Control Room 100.0% 100.0% 1.26

26 3755 H-25720 SAR Converter Heater 100.0% 100.0% 1.05

27 PH1109 H-31T63 MC4700 Conveyor Structural 100.0% 100.0% 1.08

28 10-005 H-30005 Ultra Low Sulfur Distillates 100.0% 100.0% 0.92

29 11-005 H-31028 T-4761 High Level Switches 100.0% 100.0% 0.74

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  PIR AFE   Complete  

  # # Description To Date To

        Plan Actual Date

 (N) (O) (Q)

3011-022 H-31023 TK-7535 Level & Alarm System 100.0% 100.0%

0.82

31 08-076 H-30039 FB5 Ladders and Platforms Cems 53.4% 64.6% 1.20

32 08-023 H31006 9 DD Hydrogen Optimization 99.6% 83.1% 1.10

33 08-109 H-31002 2 Vac Concrete Restoration 100.00% 100.00% 1.61

34 08-109H H-31040 4DD CRP 100.00% 100.00% 1.69

35 08-120 H-31011 West Refinery LP&HP Flare 100.00% 100.00% 1.03

36 09-013 H-29050 Desal Water Meter Stage II 100.0% 100.0% 2.11

37 10-054 H-31033 FB5 Soot Blower Cntrl Panel 99.97% 62.35% 0.96

38 11-085 H-31044 AutoDrainValves on C2201C 100.0% 100.0% 1.48

39 08-095 H-31007 W Sulfur Pit Vent System 100.0% 100.0% 0.83

40 08-021 H-29Z02 GWR Wells 100.0% 100.0% 0.78

41 09-013 H-29050 Desal Water Meter Stage 3&4 100.0% 100.0% 1.32

42 08-109 H-31042 Sulfolane CR 100.0% 60.8% 1.29

43  90482927 Reverse Osmosis 100.0% 100.0%

1.1

4408-109 H-31003 Penex Concrete Restoration 100.0% 39.7%

1.2

4508-109 H-31041 3 Amine Concrete Restoration 100.0% 69.5%

1.9

      TOTAL  

0.97

2011 P-6 Summary Schedule

2011 P-6 Summary Schedule

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IFC received

WBS for engineer materials & tracking

% of Bulk Material ordered, bagged & tagged

Estimate & construction schedule

Man power forecast

Work release

100 Day Plan Construction Schedule

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100 Day Plan Construction ScheduleBase Load Capital Remainder of 2011 & 1st Quarter fo 2012 Construction Schedule

 

Project Names and Numbers  Dec Jan Jan Jan Jan Jan Feb Feb Feb Feb

  Pro 27 2 9 16 23 30 6 13 20 27

108-023 Maint/Cap Cross Refinery Hydrogen Phase 1 1.10

50 23 23 23 Paint          

1st IFC in 6/30 - IFC in 8/25 - 1st Est out 8/5 - Sch out 8/12 - Rel 9/26- WBS for Eng Items 100% - Bulk Ordered 100% - Bagged & Tagged 100%

2 08-076 FB5 CEMS 1.20

10 10 14 4 Paint Paint        

E&I IFC in 9/14, 9/21, 9/23 - Estimate Out 10/14/11, Schedule out 10/20 - Rel 9/15 - WBS for Eng Items & tracking 100% - Bulk Mat Ordered 75% Bulk Mat Bagged and Tagged 50%

3 10-054 FB5 Sootblower Panels 0.96

15 15 15 Paint Insul          

IFC in 7/15 - Est out 9/14 - Sch out 9/14 - Rel 9/15 - WBS for Eng Items 100% - Bulk matreial 100% - Bagged and Tagged 99% - Need 1 breaker

4 08-095 Sulfur Pit Vapor Recovery System 0.83

10 10 Paint              

IFC in 8/30 - Est and Sch out 9/20 - Rel 10/7 - WBS for Eng Items & tracking 100% - Material Ordered 100% - Bagged & Tagged 100%

511-105 Maint Manifold # 2 Oil Water Sewer/BTX  

16 16 10 10 15 5        

Scope in 10/27, Estimate & Sch out 10/27, Rel 10/27, Bulk Material Ordered & Bagged and Tagged 100%

6 08-109 Concrete Repair Program Sulfolane 1.29

6 6 6 6 6          

Scope in 10/6 - Est & Sch out 10/19 - Released - Bagged & Tagged 100%

708-109 Concrete Repair Prog Penex, 3-4-5 Amine 1.53

12 6 6 6 6 6 6 6 6 6

Scope in 2/28- Est & Sch out 3/14 - Released - Bagged & Tagged 100%

8 Maint RO Unit SSW Offsites 1.11

  4                

Working Plans Submitted 11/09/11 - Est. and Sched out 11/23/11 - Eng. Items 100% - Bulk bagged and tagged 100%

Update: 12/29/2011

119 90 74 49 27 11 6 6 6 6

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2011 BLCC NDE Records  TOTAL     TOTAL    

MONTH BUTT. WELDS REJ. REJ.% SOCKET WELDS REJ. REJ.%

JANUARY. 2011. 93 0 0% 2 0 0%

FEBRUARY. 2011 98 0 0% 0 0 0%

MARCH. 2011. 183 2 2.40% 4 0 0%

APRIAL. 2011. 29 0 0% 142 0 0%

MAY. 2011 226 0 0% 146 0 0%

JUNE. 2011 127 0 0% 33 0 0%

JULY. 2011 66 0 0% 55 0 0%

AUGUST. 2011 99 0 0% 36 0 0%

SEPTEMBER. 2011 79 2 2.53 9 0 0%

OCTOBER. 2011 24 0 0% 46 0 0%

NOVEMBER. 2011 91 2 2.19% 194 0 0%

TOTAL 1115 6 0.54% 667 0 0%

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2011 SVF Pie Chart Bid Omission

Contractor Error

Engineering Error

Equipment not Ready

Field Condition

Fab Error

Holiday

Material

Negative SVF

Other Contractor

Operations Delay

Other

Permit Delay

Equipment Issues

Scope Change

Weather

Work Stoppage

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2011 SVF Man Hours Bid Omission = 2,668.00

Contractor Error = 62.00

Engineering Error = 793.50

Equipment Not Ready = 1,606.50

Field Condition = 1,518.50

Fabrication Error = 36.00

Holiday = 1,128.00

Material = 1,516.00

Negative SVF = 5,609.00

Other Contractors = 498.00

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2011 SVF Man Hours Operations Delay = 1,514.00

Other = 181.50

Permit Delay = 225.00

Equipment Issues = 51.00

Scope Change = 29,767.00

Weather = 1,219.00

Work Stoppage = 1,096.00

2011 Total SVF MH’s = 49,489.00

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Capital Project Construction is in Point

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SAR Heater / Capital Projects made the News Media

HOVENSA COMPLETES FOURTH QUARTER MAINTENANCE

Fourth quarter turnaround included several projectsto improve reliability and environmental performance

CHRISTIANSTED, U.S. Virgin Islands, December 6, 2011 — HOVENSA has completed its scheduled fourth quarter maintenance activity including several projects to clean and replace components and piping to ensure the refinery runs safely, reliably and environmentally friendly. An additional capitol project was conducted during the turn-around to improve environmental performance.

The capitol project included installation of a new start-up heater at the refinery Acid plant with the best available technology. The addition is to improve environmental performance by eliminating permit exceedances when starting up the unit.

HOVENSA operates a 350,000 barrels per day refinery. The refinery encompasses 2,000 acres on the south shore of St. Croix and employs approximately 2,000 direct and contract employees.

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Fire Water Repairs We Coordinated with the Chief to organize a six month

proactive Fire Water Repair Plan and schedule. This plan includes the cross over lines on Dock Road and a couple of valves in the 1st quarter needed to execute the three month schedule in the 2nd quarter.

We have created a list of all emergency repair material for fire water. We have given this information to the Ware House and the Chief in 2011.

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2011 Accomplishments Developed 100 day construction plan

MH’s Earned V/S Actual Spent

P-6 Schedules

Implemented SVF procedure

Point

Weekly reporting on each project

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Community Involvement I worked the volunteer week end preparing and painting all

the fire hydrants in the Hovensa neighborhoods with the Fire Brigade

Continue to give to Shrine Club International and direct it to the burn center in Galveston, TX

Continue to give to the local Churches we visit

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Opportunities

Continue safety meetings and observations Continue productivity audits Spend more time on constructability reviews Post lessons learned about the cost of each project discipline

and adjust the estimate format to reflect on future estimates New procedure to capture all final red lines from revision

drawings and RFI’s in one turn over package Upload P-6 Schedules into the Hovensa P-6 System in 2012