INDUSTRIAL TRAINING REPORT 2013

ACKNOWLEDGEMENT

I would like to take this opportunity to give my millions of thanks to all of the staff and worker in PFCE-BJW Engineering Sdn Bhd for helping me; give me lot of knowledge and unforgettable memories during my ten weeks industrial training in PFCE-BJW Engineering Sdn Bhd.

Other than that, I also want to send my appreciation to Owner / Project Manager of PFCE-BJW Engineering Sdn Bhd, Mr Roslan bin Sanip who willing to accept me as the practical student in PFCE-BJW Engineering Sdn Bhd. Besides, I would like to thank to my Supervisor / Executive, Mr Zulkifli bin Ismail for all the kindness guiding me to complete all my task assignment within this training. Meanwhile, I also would like to thank Mrs Nurhafiza Zainal Abidin from Human Resource Department who make a good arrangement in accommodation and familiarization program.

Once again, I would like to give a great big thank you to the all persons who are willing to teach me and give me guidance during my training program.

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ABSTRACT

All the undergraduate students from the Faculty of Mechanical Engineering, UMP are compulsory to attend 10 weeks Industrial Training during the period of their study. The purpose of this training is exposed the students to the world of careers and working environment and also offer a chance for them to applied all the theory which learnt in the lecture room during their training. The main goal of this industry training is to enhance student’s knowledge and their skills in their respective profession in line with the graduates with professional, ethical, skilled, creative and competent.

Besides, there also have several others objective of industry training such as to expose students to the environment and working conditions in their respective field, to use the knowledge of the Industry

Training and this might be useful in the study, to train students to interact and communicate effectively at all levels in the workplace and to appreciate the ethical values of their profession. During 10 weeks industrial training at the PFCE-BJW Engineering Sdn Bhd, the objective and the purpose of the training had been achieve successfully. Student had been implant suitable knowledge and also the ethic of engineering study. Besides, there are many training conducted at the company and the related knowledge will help the student and the staff of the plant execute the job more effectively. Meanwhile, the student also given a chance to get involved in the engineer daily job and this will be useful in the future. As a summary, the company was done well as playing an important role to guide the student in complete their internship.

COMPANY PROFILE

BJW Engineering Sdn. Bhd. is one of the PFCE Group of Company that focus on Oil and Gas Engineering work such as piping and fabrication work. Was located in Kerteh, Terengganu, and this company incorporate and registered as a registered company on 06 November 1998. Establish to handle many Petronas Gas Berhad (PGB) work such as Plant Rejuvenation and Revamp Project (PRR), mini shutdown/turn around and overall shutdown. Currently, BJW Engineering now involves on Plant Rejuvenation and Revamp Project 2 (PRR2) on Gas Processing Plant 2 (GPP2) under PGB plant and focus on piping and maintenance work.

BJW Engineering Sdn. Bhd. is owned by two directors. First is Mr. Roslan bin Sanip and second is Mr Bahrin bin Ariffin. These two directors have a lot of experience and knowledge in piping and Oil and Gas industries. Mr Bahrin bin Ariffin especially has extensive knowledge of the steel industry as he was formerly the Head of Department for Perwaja Steel Sdn. Bhd in Kemaman in 1984 – 2008. Mr Roslan bin Sanip has extensive knowledge of the steel and fabrication design and he also formerly the Head of Department for Perwaja Steel Sdn. Bhd in Kemaman in 1994 - 2008. Until July 2013, total employees of the BJW Engineering Sdn. Bhd are 150 peoples include work leader, welder, mechanical fitter and helper.

1.1.1

Company Vision and Mission
I.

To be the leading engineering services provider of choice

II.

To be the leading engineering solutions provider by understanding and working together with clients to resolves their problems and delivering exceptional
quality products and services on-time thereby creating long-term relationships with clients by supporting their growth

1.1.2

Company Health, Safety & Environment (HSE) Policy
BJW will, so far as reasonable, ensure that:
I.

Adequate resources are provided to ensure that proper provision can be made for health, safety and environment.

II.

Systems of work are provided and maintained that are safe and without risks to health and environment.

III.

All accidents, incidents, injuries, spills and releases are preventable.

IV.

All employees are provided with such information instruction, training and supervision as is necessary to ensure their safety and health at work and the safety of others who may be affected by their actions

V.

Health, safety and environmental performance will be measured and continuously improved.

1.1.3

Company Job & Scope
I.

ENGINEERING PROJECTS & MANAGEMENT
a) Basic and detailed engineering design
b) Total Turnaround Management
c) Engineering, Procurement and Construction
d) Project Management Consultant

II.

MAINTENANCE
a) Maintenance workshop and facilities
b) Provision of Mechanical and Engineering Services
c) Commissioning
d) Turnaround Execution
e) Minors Projects
f)

III.

Tie-in works

CONSTRUCTION
a) On-Site and Pre-Fabrication works
b) Heavy Structure Fabrication
c) Pre-commissioning and commissioning

1.1.4

Company Project Experience

Table 1.1 Company experience

1.2

COMPANY ORGANIZATION

PFCE – BJW ENGINEERING SDN BHD

Figure 1.1 Company Organization Chart

1.2.1

KEY PERSONAL

Table 1.2 Key Personal

1.2.2

MANPOWER LOADING

Table 1.3 Manpower involve

CHAPTER 2

COMPANY ACTIVITY

2.1

INTRODUCTION

The purpose of this chapter is to provide a review of company activity that related to Mechanical Engineering. A hot works like grinding, welding, drilling and hot tapping majorly use on preparing and fabricate spool. Cold work activity like work in height, painting and cold cutting also use on plant activity. Other work that related to the Mechanical Engineering concept and theory is like testing and inspection, safety and health and also ability to read drawing, determine piping system and instrument that involved in process. All of this is related to what I learn at UMP now.

2.2

PREPAIRING AND FABRICATE SPOOL

For PRR2 Project at GPP2, BJW Engineering Sdn. Bhd preparing a piping, touch up painting and Joint Inspection Testing (JIT) work only. Other work like electrical, painting and blasting, mechanical and insulation work is done by other company. BJW Engineering Sdn. Bhd only focuses on piping work. Piping work includes of preparing spool, fabricate spool and conduct Non Destructive Testing (NDT) like Hydro Test or Radiographic Test (RT).

A spool is an assembly of fittings (elbow), flanges and pipes that may be prefabricated. It does not include bolts, gaskets, valves or instruments. A spool sheet is an orthographic drawing of a spool drawn either from piping GA or from an ISO sheet. Each spool sheet shows only one type of spool. Spool will be fabricated based on ISO drawing from Piping Test Package. Each package has different drawing depend on working area or work line. Piping Test Package is a guide sheet to do work at plant. Every modification and renovation of spool will be mark up to drawing. Work Leader has to survey the area or line that renovation and spool changing works want to do before proceed to open a Piping Test Package.

Fitting Elbow

Rating Flange

Spool which already fabricate will paint with grey in colour. It will use the International Paint (IP) to standardize the colour of all spools in plant. After paint, spools have to be test and inspect. The purpose of the testing is to avoid leak at flange and test the strength of pipe. Non Destructive Testing (NDT) will be conduct and it is involved the Leak Test (Hydro Test) and Radiographic Test (RT). For Radiographic Testing (RT), only authorize person can doing this testing. RT is purpose to test strength of welding joint. After RT, Leak Test will be conducted. Finally, after pass both of the testing, spools can be load to plant for activity.

Figure 2.1 Spool prepares and fabricate

2.3

NDT – LEAK TEST

Figure 2.2 Leak Test Preparation

CHAPTER 3

STUDENT SELF ACTIVITY

3.1

INTRODUCTION

In this 10 weeks industrial training, I have been given suitable trainings and site learning. During that period, I was also involved in work and activity on Oil & Gas plant to make sure understand well about the running of the process and activity at gas processing plant. Knowledge gained in the training is very useful and will ease the student get familiar in the engineer’s works in future.

Basically the trainings given are related to the operation of the Oil & Gas plant and also some problems identification. I also have been equipped with training schedule during the ten week training. The training schedule is made on discussions with supervisors and has been agreed upon. The planning are;

i.

Expose to the concept of plant and piping drawing; P & ID and GA drawing.

ii.

Able to understand and know the terms in piping drawing, plant

process and work; spool, line number and pipe schedule.
iii.

Expose to the work in Oil & Gas plant; observation and
inspection with QC Coordinator.

iv.

Attend NIOSH and CIDB course to be able to enter the plant and doing work at plant.

v.

Documentation and office work; GPP2 Control Sheet, Workers Time Sheet, Fit-up and Visualization report.

vi.

Involve and learn about Non Destructive Testing (NDT) like Leak Test and Radiographic Test.

3.2

TRAINING SCHEDULE (GANTT CHART)

3.3

i.

SUMMARY OF ACTIVITY / TASK ASSIGN
WEEK 1 ( 01/07/2013 – 04/07/2013 )

Register as an Industrial Training student in PFCE Human Resource Department. Registration and industrial training placement are managed by Pn Nurhafiza bte Zainal Abidin. I was placed in BJW Engineering Sdn Bhd and be supervise by BJW Engineering Executive, Mr. Zulkifli bin Ismail. Mr Zulkifli briefed a little bit about the company and introduced me to staff and start talking about the tasks to be performed by me during the training industry.

On first week, I was introduced to piping drawing; ISO Drawing, Piping and Instrument flow Diagram (P&ID) and General Arrangement Drawing (GA). Piping isometrics (ISO Drawing) allow the pipe to be drawn in a manner by which the length, width and depth are shown in a single view. Isometrics are usually drawn from information found on a plan and elevation views. The symbols that represent fittings, Valves and flanges are modified to adapt to the isometric grid. Because ISO are not drawn to scale, dimensions are required to specify exact lengths of piping runs.

Pipe lengths are determined through calculations using coordinates and elevations. Vertical lengths of pipe are calculated using elevations, while horizontal lengths are calculated using north-south and east-west coordinates. A pipe into an isometric view is always drawn by a single line. This single line is the centreline of the pipe, and from that line, the dimensions measured. This is example of GPP2 ISO drawing for package number of G2-600-03-PI-P-001 and G2-730-03-PI-CWR030.

Figure 3.1 Piping ISO Drawing

P&ID is a schematic illustration of functional relationship of piping, instrumentation and system equipment components. P&ID shows all of piping including the physical sequence of branches, reducers, valves, equipment, instrumentation and control interlocks. The P&ID are used to operate the process system. A P&ID should include:

I.

Instrumentation and designations

II.

All valves and their identifications

III.

Process piping, sizes and identification

IV.

Miscellaneous - vents, drains, special fittings, sampling lines, reducers, increasers and swaggers

V.

Flow directions

VI.

Control inputs and outputs, interlocks

VII.

Equipment rating or capacity

Figure 3.2 Piping & Instrument flow Diagram (P&ID) Drawing

General Arrangement drawings for piping systems and equipment are developed by piping designers. These drawings indicate the locations of main equipment in the plant. The main piping items, valves, and fittings are also indicated in the General Arrangement or GA drawings. Most often the piping is indicated using a top-view. Sometimes a side view of the pipe rack is also presented on the GA drawing.

General arrangement drawings are also developed for individual equipment. These drawings present the main dimensions of that equipment using 2D views,
top-view, side-view and sometimes front-view. All the nozzles for concerned equipment are indicated on the equipment General Arrangement or GA drawing.

For a green field engineering project, equipment location drawings are prepared at the proposal stage by piping designers. On commencing the project work, these drawings are used as first basis for development of piping layout. Depending on the feasibility of the piping layout arrangement, often the equipment locations are revised and updated. The changes to equipment location can sometimes be substantial in order to have the desired piping arrangement.

Thus piping layout arrangement and development of piping general arrangement or GA drawings is dependent on reference sources developed prior to the piping arrangement work and modifications required to those references to allow for the desired piping layout arrangement.

Figure 3.3 General Arrangement (GA) Drawing

ii.

WEEK 2 ( 07/07/2013 – 11/07/2013 )

For the second week, I was introduced to the test package. Test Package is a guide to doing work at plant. Test Package is a drawing sheet that include ISO drawing and P&ID. Every package is control and approve by Planner and the survey of the work to do are responsible by Superintendent, Supervisor or Work Leader. Every Test Package is named by one specific name like G2-460-P1101-02, G2-75012-SV-002, G2-600-02-PI-P-011 and G2-930-03-PI-HF-041. Each abbreviated numbers and letters on the test package has the specific purpose represent line number, area, processing plant and joint. For example;

G2-460-P1101-02

G2 = represent that this package doing work at Gas Processing Plant 2 460 =
represents the area where the work is done
P1101 = represent the line that spool is loading and work is done. 02 = represent the number of joint like spool joint, flange joint or valve joint.

Other abbreviations as HF, CWR, SV and PIC represent the name of device, condition or measurement. For example like SV is stand for Safety Valve, CWR for Cold Water Tank or PIC for Pressure Indicating Controller. From Test Package, we also can define and know the bill of material that use for spool, the measurement and schedule of pipe, NDT that involve and joints like elbow, flange or gasket. All of he details are completely shown in the Test Package.

Material description, measurement and quantity.

NDT reference like pressure use, insulation and fabrication specific.

Line number Painting code and colour.

Figure 3.4 Test Package detail description

Drawing number and
revision.

I also have been sent by the company to attend the Safety and Health course (NIOSH) and take the Oil & Gas Safety Passport (OGSP) examination. The
purpose is to get an OGSP card and to allow me to enter the oil & gas plant. Through this course, I also gained knowledge about the rules for work in plant, legislation occupational safety and health for worker, accident causes and prevention, hazards present in the oil & gas and prevention measures and many more knowledge about work safety in the plant. This course is useful as a preparation before I was allowed to work and enter the plant.

Other tasks that assign to me including prepare and help technical clerk complete daily report like GPP2 Control Sheet report, Fit-Up and Visual Inspection report. GPP2 Control Sheet is a documentation work that record and monitor the progress of work based on selected Test Package. Other documentation work like prepare Time Sheet for workers and copy the Test Package for Supervisor and Project Engineer use.

Figure 3.5 Fit-Up and Visual Inspection report

iii.

WEEK 3 ( 14/07/2013 – 18/07/2013 )

For the third week, I have been introduced and expose to the procedure to work in plant. I have been introducing to the Permit To Work (PTW). By following the Work Leader apply the PTW throughout the week, I thus know and understand what the PTW is and its importance. PTW will be applied as early in the morning before work is done in the plant. Each of the works and equipment to be brought into the plant must be applied for prior approval by the representatives / persons responsible for approving them. Work Leader is responsible person for applying the PTW. Daily activities and work to be done in the plant, Work Leader should apply for PTW a day earlier before doing the work and enter the plant.

PTW are always applied generally divided into two; Hot Work Permit and Cold Work Permit. Hot Work Permit is a permit for employees to perform hot work involving sparks and connectivity in welding and cutting. Cold Work Permit is a permit for employees to doing cold work which not involving spark and
cutting work. Example of hot work is hot cutting/welding, grinding, drilling and hot tapping. Example of cold work is like painting, working at height and calibration.

The objective of PTW is;
a. to ensure worker safety, property and the environment
b. ensure that procedures are followed and approvals obtained for: I.

routine work, but in certain circumstances

II.

non-routine work

c. to ensure that the arrangements made to that all risks are, and appropriate hazard control measures were taken before work starts. d. ensure that the owner / asset aware of all the work done in the area under its responsibility

Through this exposure, that I know all the activities and the work to be performed in the plant require approval and several major documents. Not all employees can do the work in the plant without the skills and evidence such as certificates and documents to verify eligibility. Major documents to do jobs in the plant are:

a. Permit To Work (PTW)
b. Support certificate;
I.

hot work in hazardous areas

II.

enter a confined space

III.

electrical work

IV.

gas inspection

V.

excavation work

VI.

heavy lifting

c. other supporting documents;
I.

Job Safety Analysis (JSA)

II.

Risk analysis

III.

Lifting plan

IV.

‘Spading’ list,

V.

Rescue plan and others

iv.

WEEK 4 ( 21/07/2013 – 25/07/2013 )

I have successfully received my card OGSP and this has allowed me to enter the PGB plant. However, to do the work and make the activity in the plant, I must follow the Construction Industry Development Board (CIDB) course to get a CIBD authority card. However, since I've had OGSP, I do not need to pursue the CIDB course but only need to apply through the documents provided. The process of obtaining the card takes three days. I successfully obtain my CIDB authority card on that week.

I was sent by the company to follow safety briefing organized by HyundaiPFCE and working at height courses organized by the PGB. Besides having OGSP and CIDB, other conditions that enable employees to work at the plant are pursuing safety and working height place course. This two day course (22/07/2013 – 23/07/2013) taught me a lot about the safety measures in the plant, and equipment use when working at heights and working in plant regulation. I was also given guidance on Personal Protective Equipment (PPE) and how to use it properly. The knowledge that I gained through this course is risks associated with working at height, fall protection; harnesses and scaffolding and PPE.

a) WORKING AT HIGH
Risks associated with working at height:
1. People fall
I.

From the height / depth into. Example: Scaffolding, ladders, tall structures, places and equipment, into the groove / hole dug.

II.

at the same level (collapsed)

2. Falling objects
I.

falling objects when in use or not kept

II.

scaffolding collapses

b) PROTECTION FROM FALLING
I.

Scaffolding

II.

Ladder

III.

Safety net

IV.

Body Harness

c) PROTECTION AGAINST FALLING: HARNESS
I.

Harness must be worn when working at height (two meters or
more).

II.

Harness must have two lanyards, one of which must be fastened at all times.

III.

It should be inspected before use and should be a good
maintenance and care.

d) BODY HARNESS COMPONENT
I.

Life Rope

II.

Snap hook

III.

Karabiner

SNAP HOOK

LIFE ROPE

BODY HARNESS
Figure 3.6 Body Harness Component

v.

WEEK 5 ( 28/07/2013 – 01/08/2013 )

After obtain my OGSP, CIDB, ID Pass and Working at High briefing card, I finally have authority to enter GPP2 Plant. With supervise by QC Coordinator; I was taken to the working area in the GPP2 plant. I was also
taught how to interpret drawings contained in ISO drawings and P & ID refers to the actual situation in the plant.

During the week, I was given guidance to identify areas of work done on the selected Test Package, brought to see the work done in the plant such as painting, changing the spool, cutting and welding spool and bolting debolting work. In this week, a lot of things related to the work of the plant that I can learn and see even just looking and observing. Entrusted by the Supervisor and QC Coordinator to work and act as a QC Coordinator assistant to doing work as drawing controller, line checker and helper.

Figure 3.7 Work at plant

vi.

WEEK 6 ( 04/08/2013 – 06/08/2013 )

As usual, follow QC Coordinator observes and see the progress on plant. Taught more detail about the tasks as Line Checker. Line Checker task is to examine and review the progress in a line. Every progress made by the workers will be recorded by the line checker to revise ISO Drawing (Mark-up) on the Test Package prior to submission to the Hyundai Engineering Department for drawing update. For the week, the task assigned to me is to help QC Coordinator checking line and see progress of work.

I also introduced quite a bit about Pipe Support. Pipe Support is the holder or directions guide of a pipe. Pipe will be held by the support to ensure it does not shift or move away from the course. Pipe support is divided into 3 type; Support Guide (SG), Normal Support (SH) and Support Anchor (SA).

Figure 3.8 Piping Support Guide

vii.

WEEK 7 ( 13/08/2013 – 15/08/2013 )

Given a task by a supervisor to help store man and learn the names of the tools and methods of inspection tools in the workshop. Tools or equipment such as generator sets, slings belt, chain blocks and lever block are often used and brought into the plant for use. Other tools and equipment like spotlight, grinder, quiver and welding cable have to be inspecting at least once a month before it was allowed to be brought into the plant.

Get guidance and explanation from Inspection Coordinator, I was given the task of inspect the workshop tools such as grinder size 4 "and 9", welding cable and sling belt. For example sling belt, it has a colour code where each colour represents a length and load that can be borne by the belt sling. It is important to know the colour code to avoid accidents and safety during lift spool work performed.

Figure 3.9 Sling Belt

Before an inspection on possible tools, tools or equipment to be inspected will be issued in a form called Request for Inspection checklist (RFI). This RFI will then be submitted to the inspection team of Hyundai and PGB for them to come make a second inspection before issuing permits and authorize stickers stating the tools or equipment safe and can be used in plant. For example, all electrical and mechanical equipment should be checked every month and expiry dates use these equipment in the plant is a month before the RFI issued. Each tool shall be issued a day earlier before the expiry date. However, tools such as a tank of gas argon, oxygen or Acetylene not examined by month. It just changed to a new one after expiry of its use. Each tools or equipment that has been checked to be recorded into a checklist called the Portable Equipment Inspection Checklist. This week I was involved in the preparation of RFI and inspection tools in the workshop. No activity in the plant work and documentation.

viii.

WEEK 8 ( 18/08/2013 – 22/08/2013 )

This week there is a request from the Hyundai to do a hydro test on two spool of completed fabricate. This is to ensure the spool is safe and complies with safety standards at the plant before installation. I had the opportunity to see, learn and help provide a spool for hydro test conducted.

A hydrostatic test is a way in which pressure vessels such as pipelines, plumbing, gas cylinders, boilers and fuel tanks can be tested for strength and leaks. The test involves filling the vessel or pipe system with a liquid, usually water, which may be dyed to aid in visual leak detection, and pressurization of the vessel to the specified test pressure. Pressure tightness can be tested by shutting off the supply valve and observing whether there is a pressure loss. The location of a leak can be visually identified more easily if the water contains a colorant.

Strength is usually tested by measuring permanent deformation of the container. Hydrostatic testing is the most common method employed for testing pipes and pressure vessels. Using this test helps maintain safety standards and durability of a vessel over time. Here is the core of a procedure (other than the table of contents, reference documents, safety, equipment lists, etc.) work for hydro test work.

1. Hydro test preparation
Request for inspection (RFI) notification shall be informed by construction supervisor to quality assurance/quality control (QA/QC) department when a piping system is ready for testing. Verification of all materials, test and mill certificates are compiled and documented by QA/QC department and traceable for each component, fitting and pipe applied to each spool or line number. All required non-destructive examination (NDE)

results shall be verified to conform to Hyundai general specifications prior perform hydro test. The BJW QC inspector and Hyundai representative shall together check visually in detail for the piping network prior to test. The checking shall include of:

i.

Compliance with drawing and battery limit of related subsystem

ii.

Welded or flanged joints

iii.

Secure and correct bolting

iv.

Pipe routing and slope

v.

Pipe support, permanent and/or temporary

vi.

Temporary spading or blinding

vii.

Pipe painting and colour coding

The piping supervisor will be responsible for conducting preparation and execution of pressure test and shall take coordination with QC inspector. Additional material for close the spools such as blind flange shall be available on test site and tighten properly prior hydro test (check correct rating). Pressure gauges and recorder shall be in Bar or Psi unit. Full gauge range (indicated span) of pressure test gauges are to be selected in such a way that the test pressure will be in between 50% to 80% of the full range. A minimum of two pressure gauges shall be required for the test. The gauges shall be installed at predetermined locations with one at the highest elevation point and one at the lowest elevation point wherever possible.

2. Hydro test Execution
For hydrostatic test, the pressure is applied by means of a suitable test pump (hydro test pump shall be equipped with PSV as safety devices if used during pressure test) and gradually built up to 35% of the test pressure and held for at least 15 minutes to uniform stress along the piping network. Pressure then shall be applied until 70% of test pressure and, again, held for 15 minutes. Thereafter, once the required pressure reaches (1.5 design pressures) test pressure, piping network shall be isolated from the pressure source.

The test pressure shall be maintained 2 hours for holding time as per Company specification However this holding time can be prolonged to allow sufficient time for inspection. QC Inspector and Hyundai representative shall carry out a detailed inspection of weld joints and connections for any leak, attention shall also be paid for dislocation or movement of the supports or distortion. In case of pressure test is performed in the sunny day, the pressure gauge and temperature indicator shall be monitored to prevent undue pressure increase due to thermal expansion In order to avoid excessive pressure the system may be depressurized down to the required test pressure.

3. Limit of Test Pressure
Hydro test pressure shall be 1.5 times of design pressure and hydro test pressure shall be indicated in the drawing, lower limit of the test pressure shall be not less than test pressure specified. Upper limit is 5% of the test pressure, if during hydrostatic test the test pressure increased by more than the upper limit, the test pressure shall be released or bleed off to the specified test pressure. If during hydrostatic test the test pressure is decreased to a pressure lower than the specified test pressure and there is no evidence of leakage, the line shall be pressurized back to reach the specified test pressure and held for two hours.

4. Inspection During Hydro test
Upon reaching the desired holding time, the test pressure shall be reduced to a pressure not less than the test pressure by QC Inspector and the Hyundai representative shall be carry out visual examination at this pressure. Examination for leakage shall be performed by QC Inspector at all welding joints and connections. Leakage is not allowed at time of the required visual inspection, except for leakage that might occur at temporary test closures for those openings intended for welded connections and leakage from temporary seals (gaskets). Leakage and damages found during the test shall be repaired and rectified. And retest shall be performed.

5. Pressure Release
After the pressure test, pressure shall be released at a rate so as not to endanger personnel or to damage equipment by drawing test medium off the line.

Pressure released slowly until the pressure drop to 70% then

holding for 15 minutes, release again until pressure drop to 35% then holding for 15 minutes. Pressure released again until gauge shown 0 bar, all vent shall be opened before the system is drained and shall remain open during draining prevent pulling vacuum on the system.

Upon completion of hydrostatic testing, BJW QC inspector shall de-water the pipeline. BJW QC inspector shall begin the drying operation only after all testing activities are complete and accepted by Hyundai and PGB. Water shall be moved ahead or disposed of after de-pressurized. Blowing some dry air inside the pipe spool to ensure that inside pipe is completely drained. Close the spool with proper closure before continue to other process, which is painting or installation.

Figure 3.10 Hydro Test

ix.

WEEK 9 ( 25/08/2013 – 29/08/2013 )

No new tasks assigned by supervisor. Just make a daily routine such as help QC Coordinator doing progress inspection in plant, assist Inspection Coordinator examines tools and equipment and apply RFI and some documentation work in the office. This week task more focus at workshop work; repairing and doing inspection on tools and equipment.

Figure 3.11 Workshop work; repairing and inspection

x.

WEEK 10 ( 02/09/2013 – 05/09/2013 )

There are several problems occurring at the plant involving work tools and equipment. Cases 1 is the leakages on the welding cable and suddenly emit sparks. PGB has issued a notice to the welding cable removed and not allowed its use in the plant. PGB also requested that we re-examine all the welding cable and RFI reapply in order for the welding cable can be reused in the plant. I was given a task by the Inspection Coordinator to inspect all of our company-owned welding cable and repair if there is any damage to the welding cables. Upon inspection there were six welding cable that was leaked and tear on the cable. With the help of Store Man and Material Controller, all welding cable can be repaired. Next procedure is to apply back RFI for inspection by inspector from the Hyundai and PGB. Successfully completed the task well and welding cables leak problem had been solved.

The second case is the loss of electrical generator entry permit into the plant or called PETI. PETI is a short of Portable Equipment Temporary Installation. PETI is important to allow electricity generators are used in the plant as a supplier to supply electricity to devices. Equipment such as welding machines, grinders and spot lights need electricity to start it. PETI is the same concept as applied PTW, only PETI require a permit for surveillance and observation of the PGB. PETI is specifically applied only for supply electricity equipment. Have some issue about PETI which is not endorsing by Work Leader and have missing request from PGB. Given guidance by Work Leader on how to re-apply PETI and the procedure.

CHAPTER 4

CONCLUSION

4.1

INTRODUCTION

Sufficient useful knowledge and working experience gained after ten weeks of industrial training. During this period, company had provided a platform for the student to get involved in the engineer daily job. Meanwhile, company also organized work related training program to staffs and also student. This kind of program will let the staff know more detail in Oil & Gas plant operation without forget safety issue which is a very important and highly emphasized here and thus make the work become more efficient.

In normal day, workers will doing maintenance and renovation job by follow instruction of executive and also planner. All the jobs require discussion and cooperation between each other to complete it. From the daily jobs, it is learned that the time management is very important to the engineer. Since even a small problem will affect whole production line, so that as an engineer, how to fully utilized the time to optimized the job always in first consideration.

In order to have better understanding of the engineer daily job and also have a chance to apply knowledge that learn from the university, some task were assigned to student. The tasks involved understood the concept of working in the plant which involves piping drawings reading skills; learn the spool assembly and modification work and some documentation work. To complete the task, student

went to site and take related dimension which will be used in design purpose. Besides, student also needs to know the causes of the problem happening at plant and learn how to overcome from experienced workers there.

For sure site learning is very important for practical student in order to get clear understanding. Same goes in BJW Engineering Sdn Bhd, student went to the plant and also workshop for learning purpose. Normally, all the workers and the mechanical staff will assemble for Toolbox briefing every day morning to get further instruction of the job. The job assign to the workers was prepared by the executive or the planner.

Last but not least, thousands of appreciation sends to all staff and worker in BJW Engineering Sdn. Bhd. Due to helpful and guidance of them, so that this industrial training can be done smoothly and successfully. All the staffs and worker are willing to share their precious experience and knowledge when the problem facing and their explanation always lead us to the better understanding.

CHAPTER 5

RECOMMENDATION

5.1

INTRODUCTION

Industrial training experience here is very pleasant and got a good reception from the staff and workers here. Cooperation of the entire staff and workers make every task can be solved with better than to get new knowledge of each assignment. In addition, the knowledge that is taught is also very useful for the work especially for students who are interested in working in the oil and gas industry someday

5.2

RECOMMENDATION FOR FUTURE WORK

For those who are interested to learn and gain knowledge in the field of oil and gas, this company is the suitable company for industrial training as; Has a long experience in the oil and gas industry, particularly in the work of piping and piping maintenance. Heavily involved with Petronas Gas Berhad (PGB) projects starts from 2008 until now and involve substantial cost projects. Staff and employees are individuals who have been long in the field of oil and gas pipelines and very friendly and easy to ask questions and gain knowledge. Companies willing to issue capital to send Industrial Training students attending courses involving oil and gas such as NIOSH, CIDB and Petronas Safety Briefing as long as the student shows good persistence and progress.

Supervisors who monitor; Mr Zulkifli Ismail, is a very helpful and not overly emphasize the concept of work but more than communication and requirements in the pursuit of knowledge which is very important when working later Not only focus on the inspection work in the plant only, students are given the opportunity to work as helpers if they have qualifying certificates do work such as welding, fire fighter and fit spool and will be paid according to the worker rate.

However, there are some of my recommendations for improvements to the company from time to time; Prepare permits for camera for intern to be able to take pictures of the work in the plant to use for Industrial Training report. Too strict training schedule makes students could not understand certain tasks perfectly.

Continue to send trainees to attend courses related to safety and skills in the field of oil and gas in preparation and additional knowledge in applying for jobs in future.

REFERENCES
http://myone1way.blogspot.com/2011/04/piping-hydrotest-procedure.html

http://www.wermac.org/documents/isometric.html

http://www.engineeringtoolbox.com/ndt-non-destructive-testing-d_314.html

http://www.pids-a-drafters-perspective.com/index_PIDSymbols.htm

APPENDICES