REFINERY NEWS May 2012

MAY 2012
engen Refinery news May 2012 // 1

7 8 12
COVER: Control Systems Engineer, Neville Mshengu, Junior Process Control Technician, Ashlin Pillay and Process Control trainee, Andile
Mthiyane were at the forefront of installing new equipment cabinets in the PCC. Read story on pg3
Contents
Process Control Network upgrade 3
Rope Access services save Enref time and money 4
Engen Computer School changing lives 5
Long Service rewarded 6
Durban EMSS Programmes produce excellent results 7
Engen Relieves stationery burden 8
Engen opens new supplementary education centre 8
Contractor’s yard revamp 9
Caring for the elderly 9
New Switchgear for Refinery substations 10
Lee-Ann tackles Midmar Challenge 11
Competition 11
ECPP uplifts Bayview Community 12
6
This newsletter is produced by the Public Affairs Department of
The Engen Refinery.
Send comments and feedback to:
Thabisile Gumede
Tel: 031 460 3617 OR
E-mail: thabisile.gumede@engenoil.com
Layout and Design by
May Birthdays
Sudesh Sarjoo
1st Aniel Sahue
Ntuthuko Mabaso
1st Alistair Groom
Siphamandla Chili
1st Pule Molefe
Anesh Sewduth
1st Nelson Govender
Ray Bhagwandin
3rd Alfred Mhlongo
Brian Lloyd
4th Shabeer Mahomed
Musa Ndwandwe
4th Sandile Nzimakwe
Melvin Jansen
4th Zukisa Maya
Suren Ruthnum
4th Michael Sharp
Garry Pitman
5th Strini Moodley
Dhevan Naidoo
5th Mellanie Chetty
Rob Balfour
6th Patrick Canham
Links Govender
6th Thokozani Langa
Thabani Zondi
6th Chad Van Der Merwe
Steven Moodley
7th Dave Moodley
Learn Bhendane
7th Romeo Sibiya
Celeste Hudson
8th Vikash Devraj
Nokukhanya Dlamini 8th Vernon Mudaly
Ceshan Hanuvanth
9th Silindele Sithole
Cyprian Shezi
10th Jodie Peters
Segren Govender
10th Suren Naidoo
Justin Gunkel
10th Deveron Wagner
Phindile Ngcobo
11th Riaz Kajee
Lizwe Dube
11th Innocent Sekwaila
Reginald Gasa
12th Heather Seidle
Kurt Seidle
13th Cody Brauns
Avir Ramkissoon
13th Charles Koster
Jeeten Jagadis
14th Michele Padayachee
Thobelani Boyana
14th Famida Mohamed
Burtie Dercksen
15th Clairissa Padayachee
Siyethaba Maphumulo 15th Charmaine Xaba
Johnny Moodley
Musa Ndwandwe
Jerrold Lazarus
Silindile Mathe
Ronald Naidu
Service anniversaries
16th
17th
17th
20th
21st
21st
21st
21st
21st
23rd
23rd
24th
24th
24th
25th
25th
26th
26th
26th
27th
28th
28th
28th
28th
29th
29th
30th
30th
30th
30th
31st
5 Years
5 Years
5 Years
10 Years
20 Years
2 // engen Refinery news May 2012

Process Control Network Upgrade
Above: Before upgrade
Above: After upgrade
In with the new, out with the old. This is exactly what has happened in the PCC where five spanking new computer cabinets
have replaced old cabinets that are no longer suitable for the Process Control computer equipment currently in use.
The Process Control Network and
Infrastructure Upgrade which is currently
underway at the PCC was born of the
need to improve the reliability of Process Control
network systems. This not only meant upgrading
the servers, but also introducing new cabinets
to house and protect the computer equipment
effectively and neatly.
Control Systems Engineer, Neville Mshengu says
the new cabinets provide better network cable
management whereby cables are neatly tied and
the cabinets provide better cooling for equipment
and save space. Up to 42 units can now be installed
in a cabinet whereas previously, only a maximum
of five units could be installed per cabinet.
“The three-phase project began with upgrading
of the Historian (PHD) and Advanced Control
old and smaller equipment cabinets have been
upgraded with Dell D4220 cabinets to ensure
security of the control network cables and higher
reliability thereof,” he says.
Subsequent to this will be the engineering of the
Process Control Network domain and installation
of the firewall between the Business Information
Network and Process Control Network for better
domain administration and management and
Process Control network data security.
Neville adds that although the project has not
been without its fair share of challenges, it was
well worth it. “The biggest challenge we have had
is ensuring that while the project is underway that
no disruptions occur to the control network as well
as minimizing loss of data from the servers during
upgrade.”
(RMPCT) servers. Now in its second phase, the
Above: Junior Process Control Technician, Ashlin Pillay says being part of
this project was a great learning experience
engen Refinery news May 2012 // 3

Rope Access Services save Enref
time and money
In these tough economic times every cent counts, which is why Enref is delighted to have saved more than
R14m on scaffolding costs during the refurbishment of over 23 storage tanks.
The contracting company - Acumax (Pty)
Ltd, supplied Engen with a comprehensive,
cost-effective, safe and environmentallyfriendly
solution for Ultra-high pressure Water
Blasting, Grit blasting and protective coating
utilizing Rope Access Services on above-ground
storage tanks.
To date, Acumax have UHP blasted/ grit blasted
and painted a total of 41361m2 of tankage
surfaces and used a total of 24817 Litres of paint
with a total of 64 800 man hours at the refinery.
Plant maintenance Deputy Manager, John
Naidoo says the benefits of rope access include
minimal impact on structures and surroundings,
including traffic flow and pedestrian access,
in comparison to the use of scaffolding, which
makes substantial cost savings and minimal
downtime possible. “Acumax has not only saved
the Refinery money but during the year that they
were contracted (between 2010 and 2011) they
completed over 23 above-ground storage tanks
utilizing Rope Access Services with zero lost-time
incidents and zero near misses,” says John.
Acumax was established in 2006 and is run
by highly experienced, South African, expatriate
management teams who have worked abroad
providing maintenance and inspection services in
the oil and gas industry.
In 2011, Acumax was acquired by The SGS
Group which is the largest inspection, verification,
testing and certification organization in the world.
Being part of the SGS Industrial Services global
network has provided Acumax with massive
growth and expansion opportunities and the
prospect of supplying additional services to
companies such as Engen and other significant
industry participants in Southern Africa.
4 // engen Refinery news May 2012

Above: Eighty-two graduates were presented with certificates for successfully completing a basic computer course at the Engen Computer School
Engen Computer School changing lives
Refinery Call Centre Operator, Nokukhanya
Dlamini thought she knew all she needed
to know about computers until she heard
about the Engen Computer School run by the
Added Advantage Academy which is operated on
the Refinery’s behalf.
Enrolling in the course was easy; the challenge
was finding time to attend the day course as
Nokukhanya works shifts at the Call Centre.
Determined to complete the course she chose to
work night shifts for six months for the duration
of the course.
“It was not easy working night shifts every
day but I knew that my sacrifice would lead to
success. The course exceeded my expectations
and I learnt many new skills. The facilitators are
very knowledgeable and we all forged life-long
relationships,” says Nokukhanya.
She is one of 82 Engen Community Computer
Training Centre graduates who received their
certificates at a recent certification ceremony held
at the Refinery.
Five pensioners who also received their
certificates proved that one is never too old to
learn. Retired Wentworth Councillor, Derrick
Parsons (75) says he was inspired to do the
computer course when he saw people sitting
at an internet café. “I looked at them and they
seemed to be having fun and I thought this is an
interesting challenge – I must learn how to use a
computer.”
More than 500 students have acquired new
computer skills since Engen embarked on the
partnership with Added Advantage in 2009. These
have included added proficiency with a personal
computer mouse, the keyboard and general
competence at using Microsoft programmes like
MS word, Excel and PowerPoint as well as emailing
and logging onto the internet.
Director of the Programme, Sheryll Cassalis says
over 120 students who were unemployed before
taking up the course are now employed. She
believes that this can partly be attributed to the
computer literacy as well as business skills they
have learnt at the Training Centre.
Above: Call Centre Supervisor, Brenda Ndlovu and Public Affairs Manager,
Thandeka Cele congratulate Refinery Call Centre Operator, Nokukhanya
Dlamini (centre) on her achievement
Right: Refinery Fire Fighter, Jabulani Sithole (left) who also
attended the course to enhance his computer skills, encourages
other Refinery employees to attend the course
engen Refinery news May 2012 // 5

Some of the long service award recipients for 2012
Long Service rewarded
In March the Refinery recognised and paid tribute to employees who have passed various long service
milestones ranging from five, to 40 years service.
Refinery GM, Kamal Bahrin Ahmad,
personally thanked each individual for
their contributions and loyalty to the
organisation often sacrificing time with families
when the Refinery needed them.
Certificates were handed out for five, ten, 15, 20,
25, 30, 35 and 40 years. Most of the recipients were
cheered and applauded as they went up to receive
their certificates.
At the top of the list was Clean Fuels Process
Manager, Dave Laurence who has been with the
Refinery for 40 years. Dave is one of the more
jovial personalities at the Refinery, and has a knack
of making people laugh with his entertaining
anecdotes. Dave joined the refinery as a Junior
Chemical Engineer and has seen the Refinery go
through both good and bad times. He started
working at Engen when it was still called Mobil
and still considers Engen to be one of the best
companies to work for. Now Dave is using all
his acquired knowledge to give direction and
guidance of how all fuel specifications will change
into the future in his assignment to the Clean Fuels
project.
Others who have spent most or all of their
working life at the Refinery for 30 years and above
include HSEQ Manager, Lynne Hanekom who
never shies away from a challenge regardless of
how daunting the task. She started off as an agile
engineer and has a vast knowledge of Refinery
operations and is always willing to share her
knowledge with others around her.
Refinery Security manager, Nicholas Ngubo
takes the safety and security of every individual
at the Refinery very seriously and has a high level
of commitment to his work. The same goes for
Laboratory Supervisor Francis Mkize who started
off at the lab as a junior technician and worked his
way up to becoming a supervisor,
a position he has now held for
the past 12 years. He is a very
knowledgeable and hands
on person when it comes to
his work. These two
gentlemen are
just two out
of 16 refinery employees who received certificates
for completing 30 years of service.
Another familiar face around the Refinery is IS
System Support Specialist, Roger Crawley who
speaks fondly about the past and the people
who joined the company at the same time as him
35 years ago. Roger is also one of nine refinery
colleagues who have completed 35 years at Engen.
6 // engen Refinery news May 2012

Durban EMSS Programmes
produce excellent results
For most learners being 35km from a
classroom would be more than sufficient
reason to skip lessons.
Not for Nqobile Hlongwane. She was a pupil at
Mqhawe High School in Inanda (about 35km
North of Durban; on the extreme opposite side
of the city to Umlazi). Nevertheless she went to
great lengths to make sure she was able to attend
the Engen supplementary education programme
at Mangosuthu University of Technology (MUT),
not just occasionally, but every day.
Nqobile, with help from a caring and generous
teacher made sure that distance was not an
obstacle to attending the supplementary tutorials.
Their efforts were handsomely rewarded when
Nqobile passed all her matric subjects with
distinctions. She was fortunate that a grade 11
teacher at her school, Mrs Shabane recognised her
potential and each day, used her own car to drive
Nqobile from Inanda to Umlazi and back to attend
the extra tuition. The reward for this extraordinary
dedication and sacrifice: Nqobile romped home
81% for English, 81% for Physical Science and 86%
for Mathematics in her matric exams.
Not only that. Nqobile was the only matriculant
to achieve distinctions in all her subjects at Mqhawe
including Zulu, Life Science and Accounting.
That has left here well placed to fulfill her dream
Above: Fairvale Saturday school programme learners and educators
of becoming a chartered accountant. She is now in
her first year of studies for a B.Com in Accounting
at the University of the Western Cape. “I found
Physical Science very challenging but the Engen
programme, through its tutorials, provided the
support that I needed.”
Hard work and dedication has paid off for over
100 learners who attended the Engen Maths
and Science School (EMSS) Programme. An
awards ceremony was held that the Refinery to
recognise and reward these learners for passing
their supplementary programme subjects with
distinction. The successful students received
vouchers for each relevant distinction. The
vouchers will help pay further education costs.
The Fairvale group notched 22 As and 43 Bs
while the Mangosuthu group achieved 62 As
and 84 Bs. Learners in the programme from both
the Mangosuthu and Fairvale Saturday school
programmes have again done Engen proud by
achieving top matric marks in Maths Physical
Science and English subjects.
The extra-curricular tutorials for learners
attending schools in the Bluff, Wentworth and
Merebank areas are hosted at the Fairvale
Secondary school while lessons for learners in the
Umlazi district are hosted at the MUT.
Engen relieves stationery burden
As ever there was widespread excitement
when schools reopened for the 2012
year. But some youngsters faced the
new term with trepidation. They didn’t have, and
could not afford, the exercise books, pens, rulers
and other stationery necessary for their lessons.
Their families cannot afford school fees let alone
high-priced stationery for the children. As part of
the CSI outreach programme, Engen has extended
a helping hand to two schools in the neighbouring
community - Settlers Primary School and Nizaam
Road Primary by providing stationery for learners
from indigent families. At Settlers ten learners
are benefitting from the stationery and another
ten at Ocean View Primary School. Settler’s
Primary principal, I.Y Naidoo says he is extremely
grateful to Engen for providing this much needed
contribution. “It will go a long way to assist these
learners to participate in everyday educational
activities.” The Refinery has also donated stationery
to the community through the local councilor,
Aubrey Snyman who distributes it to a broader
spectrum of the needy in the community.
Top Right: The Refinery has also donated stationery to the community
through the local councilor, Aubrey Snyman.
Right: Refinery CSI Coordinator, Paul Makhanya with some of the learners who
received stationery at Settlers primary school.
engen Refinery news May 2012 // 7

Above: EMSS unveiling L-R Engen Corporate Affairs GM Natie Maphanga, DoE HOD Dr Nkosinathi Sishi, Cllr
Speaker Logie Naidoo, Engen Refinery GM Kamal Ahmad, Refinery Public Affairs Manager Thandeka Cele
Above: Principal of Ganges Secondary Deena Reddy, Lamontville Cllr Sthembiso Nzuza, Engen GM Corporate
Affairs Natie Maphanga and Refinery GM Kamal Ahmad adress learners in the Saturday programme
Engen opens new Supplementary
Education Centre
“Thank you Engen for playing and active role in the development of our youth in preparation for their future careers
by making mathematics and science a priority thereby contributing to the future economy of our country”.
This was the glowing commendation lauded
upon Enref by HOD of the KZN Department
of Education, Dr Nkosinathi Sish. Sishi
made this statement during a keynote address at
the opening, in the Durban
South Basin (DSB),
of the third Engen
Maths and Science
Supplementary (EMSS) education programme at
Ganges Secondary School in Merebank. The other
facilities are currently at Fairvale Secondary School
on the Engen Refinery fence line and Mangosuthu
University of Technology (MUT).
Engen constantly strives to be at the forefront
of the drive to enhance educational standards and
bridge skills gaps, especially in our surrounding
communities. Now the 232 learners enrolled at
Merebank will no longer have to travel to Umlazi
or Wentworth for special tuition in mathematics
and physical science. Fairvale has 318 learners,
whilst Mangosuthu has the highest enrollment of
over 750 learners.
The hugely successful EMSS offers learners in
grades 10 to 12 three hours of mathematics and
physical science on Saturdays (and daily in the case
of MUT) throughout the year. A life-skills element
is woven into the curriculum to help prepare
youngsters for life after they have left school.
The Ganges programme is facilitated by six
educators and headed by Principal of Ganges
Secondary, Deena Reddy, with the assistance of
one administrator.
Above: Ganges opening being addressed Dr Nkosinathi Sishi HOD KZN
Department of Education
Above: EMSS unveiling Education HOD, dignitaries, SDB Community stakeholders
8 // engen Refinery news May 2012

Contractor’s Yard revamp
Enref is in the process of re-asserting its control of the contractor’s on-site fabrication yard and offices. That means
that contractors doing business with Enref will have to operate from their own external bases.
Over the years the contractor’s yard has
been used by both Enref and third party
companies- some of the more than 14
third party companies have had bases on site for
over 15 years.
However, after an extensive re-assessment
of the pros and cons in terms of the business
processes the engineering department decided
that a change was needed.
Deputy Engineering Manager, Sibusiso Zulu
says the concept of removing contractors from
the Refinery came about when Engen realised
that having contractor’s on site was becoming an
increasing HSE risk in terms of added responsibility
for Engen controlling the yard.
“We considered the cost involved in keeping
the contractor’s on site as well as the image the
yard was creating for Enref and weighed this
against cost saving on these logistics.”
As a refinery we were spending a lot of money
on constant supervision, security (badging, theft,
and confidential info), controlling traffic and
personnel movement, property damage.
“Our research showed substantial savings in the
long term and we devised an engineering control
plan,” says Sibusiso. This plan includes discussions
with relevant contractors and revisiting our
current workflow processes to manage risks.
Relocating from site, however, does not
excuse contractors from complying with Engen
regulations as safety audits will still be conducted
regularly by appointed Engen staff. If contractors
do not comply with regulations they will be
instructed to stop work until deviation is corrected.
Above: The contractor’s yards in the process of demolition
Caring for the elderly
Recently, CSI Co-ordinator Paul Makhanya along with Refinery Events
co-ordiantor Heather Seidle visited Old age homes in Lamontville,
Wentworth, Bluff and UMlazi to show them love and appreciation in
their respective communities.
The elderly patrons of four old age homes could not contain their excitement
when Paul arrived unexpectedly to give them a variety of clothing.
Above: Refinery Social Investment continues to build a caring brand image and positive perceptions.
engen Refinery news May 2012 // 9

Above: Some of the team members involved in the refurbishment L-R: Keith Charlton, Ravi Moodley, Donovan and Andrew. Other team members that made this project a huge success were Mohammed Ayoob,
Francis Perry and Mike Hancock.
New Switchgear for
Refinery substations
The Refinery has taken a giant step forward in terms of reducing the risk of
trips triggered by power outages. The refurbishment of five substations in the
Combo, South Complex and Alky units should go a long way towards ensuring
uninterrupted power supplies to these sections of the plant.
Project Manager, Steven Moodley says
the refurbishment of the substations will
ensure that we are better equipped to
manage equipment failure, handle power outages
and pin-point the failure causes earlier.
The refurbishment which was completed in
four weeks, involved the replacement of obsolete
switchgear – some of which had been in the
Refinery since the Refinery’s early days.
These challenges should be a thing of the past
as the new switchgear should be much more
reliable and it incorporates a fast fault clearance
time. This means that in the event of a fault the
state-of-the-art features speed up detection and
resolution of problems. The substation equipment
is also protected from catastrophic damage.
As part of this electrical infrastructure upgrade
substation T, which supplies the majority of power
to the Alkylation plant is now equipped with two
sources of supply where it was a single source
supply in the past. “This will increase the reliability
and availability of Substation T substantially,” says
Steven.
Safety is our first priority and the teams involved
must be commended for executing this high risk
project without a Lost Time Injury or Medical
treatment Case and just one First Aid injury.
Over and above that, the strong technical
support and team commitment resulted in the
project being completed on schedule, with
minimum deviations and a significant cost saving
in excess of 40% achieved by utilizing in-house
Engen personnel for the project.
Senior Reliability Electrical Engineer, Ravi
Moodley says the project was “a complex project
involving a lot of hard work, but dedication and
commitment from the team, made this project a
success”.
Above: The substations after refurbishment
10 // engen Refinery news May 2012

Lee-Ann tackles Midmar Challenge
Above: It was a cold morning at Midmar and Lee-Ann and her friend Lara put on plastic bags
to keep warm before the race
When Refinery Quality Systems
Coordinator, Lee-Ann Olsen is not at
the Refinery, you can be sure to find
her in her bikini doing laps in a swimming pool
or a local dam. No swimming challenge is too
daunting for Lee-Ann and she proved it when
she entered this year’s 39th Midmar Mile along
with over 17 000 swimmers who participated in
what has been hailed the world’s greatest open
water swimming race. This being her first Midmar
Mile, Lee-Ann says it was very challenging and
she finished in 36 minutes
and 44 seconds. “I would
have liked to do better
but it was very crowded in
the water and the weather
conditions were not good
and as a result the water
was choppy making the
swim harder.” Despite these
challenges, Lee-Ann says
it was a great experience -
enjoyable yet challenging
and she is looking forward
to next year’s Midmar race.
Lee-Ann started swimming
in September 2010 at the gym just to have fun
and to keep her body fit. Seeing her growing
passion for swimming, a friend suggested that
she enter swimming competitions to challenge
herself further. When she came
across an advert in the paper
encouraging swimmers to
enter the 1Kilometre Capital ‘K’
swim she rose to the challenge
and completed the swim in 24
minutes. She was then motivated
to enter more swimming challenges and she
entered the 1km challenge at Albert Falls and the
Golden Mile. Seeking a greater challenge Lee-Ann
then began entering 3km swim challenges.
Now an avid swimmer, Lee-Ann trains four
times a week to remain in tip-top shape. This year
she is gearing up to enter 5km races and no doubt
she will add to her collection of six medals she has
clinched from all the races she has swum.
If swimming is a bug, Lee-Ann has been infected
as she says: “Every time I enter a swimming
race I get excited about the next race and I am
encouraged to enter another race.”
Left: Lee-Ann proudly holds
up her six medals
engen Refinery news May 2012 // 11

ECPP Uplifts Bayview Community
Above: The Bayview club runs successful school development programmes with a vision to build a drug free society. Pictured is the Bayview United
FC Under 15 team which won the SAFA Chatsworth 2011 Knock-out Cup and the league with their trophy
Uplifting the community is something that is close to the heart of the Refinery. This is why Engen has supported
Refinery Laboratory Quality Chemist, Gary Moodley’s Bayview United Football Club through the Employee
Community Partnership Programme (ECPP) for the past five years.
The Bayview United Football Club founded
11 years ago is committed to the upliftment
of soccer and through the support of
the ECPP funding; the club has managed to
assist youngsters in the Bayview community by
providing them with free soccer kit.
As part of their community soccer development
last year, the club gave away 15 sets of soccer kit
to various underprivileged primary schools in the
Bayview area. The club also runs successful schools
soccer development programmes and a Bayview
united schools Knockout Cup.
Over the years, Gary says the club has
recognised the need to focus more on community
projects because strong, disciplined families
build strong communities. The club has initiated
a schools outreach programme and adopted
eight underprivileged children from eight
primary schools in the Bayview area and
sponsored them with school uniforms.
The programme has also been extended
to three Secondary schools in the area.
“We decided to extend the
programme to learners in high schools
because they are also experiencing
many problems such as those related
to drug and alcohol abuse, poverty,
and lack of parental guidance. By
providing them with food hampers,
uniforms and introducing them to
sport we believe we can make a
difference in their lives,” says Gary.
The Club completed a successful
soccer season last year and continues to do what it
can to turn its vision of a better future for Bayview
community youngsters into a reality.
Right: The Bayview United Football Club committee
during a school outreach programme
12 // engen Refinery news May 2012