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1.

Executive summary
This report focuses on the significant progress done during the 10 weeks internship period at Kuantan Compressor Station (KTNCS).The objective of the industrial training program is to integrate theories learned in university with on-hand experience in order to get clearer understanding of learning process. Being assigned to one of the world class oil and gas company, this will be the perfect chance to do so. Kuantan Compressor Station is one of the stations managed by Transmission Operation Department (TOD), and owned by PETRONAS Gas Berhad (PGB), which is one of the subsidiaries of Petroliam Nasional Berhad (PETRONAS). KTNCS main objective is to increase the pressure of the natural gas flowing from Kertih to Segamat with normal operational reliability of 99.90%. During 10 weeks of intern, Mr Ahmad Naim, Executive of Compressor Maintenance KTNCS, has been assigned as my supervisor. His wide experience in the company and serious approach to work has been exemplary to me. Others colleague has been a huge help too, I managed to blend well with them and able to gain much knowledge from them. I was tasked with an individual project and able to join their activities without any problem. Conclusively, the experience acquired during this industrial training especially in compressor, turbine and natural gas transmission is a lifetime opportunity.

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2. Acknowledgement
First and foremost, I would like to thank to Allah S.W.T, The Almighty for giving the strength and patience in completing 10 weeks Industrial Internship program, which starts from 9 July 2012 until 14 September 2012. Besides, thank God for giving me the chance to complete this final report. A special thank goes to my family and members who has been given a lot of support during my internship program. All of their efforts in ensuring me have been successfully undergone the program are really appreciated. Besides that, I would like to express my utmost gratitude and appreciation to PETRONAS Gas Berhad (PGB), for giving me an opportunity to do industrial training, great experience and knowledge in doing the internship program. Special thanks especially to my supervisor, Mr Ahmad Naim who has been an exemplary leader and mentor to me. Also I want to reserve special thanks for other KTNCS staffs for their guidance and cooperation in teaching me a lot of technical stuffs within these 10 weeks of practical training program. Last but not least, I would like to express my appreciation to my visiting lecturer, Miss Sitinoor Adieb Binti Idris for her continues support and efforts either directly or indirectly in helping me to successfully complete the internship program. The experiences obtained, be it sweet or bitter, will always become a guidance for me in pursuit of an ubiquitous oil and gas engineering student goal, which is to become an excellent engineer with full of integrity.

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3. Contents 1. Executive summary 2. Acknowledgement 4. Introduction 5. Process 6. Projects and activities 6.1 The safety valve project 6.2 Activities involved 6.2.1 Unit 4k and 8k running maintenance 6.2.2 Jom Sembang program 6.2.3 Site visit for new lube sampling point 6.2.4 Site visit schedule waste 6.2.5 Site visit to PETRONAS CUF Gebeng to collect Demineralized water 7. Problem encountered and ways overcoming it 8. Lesson learned 9. Suggestion 10. Conclusion 11. Reference 12. List of Appendices 30 31 32 32 33 33 33 23 24 25 28 11 1 2 4 9

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4. Introduction

PETRONAS

PETRONAS Gas Berhad

PETRONAS Carigali

PETRONAS Dagangan

Plant Operation Division

Transmission Operation Division

Centralised Utilitiy Facilities

Technical and Facilities Development Division

Regasification Terminal Division

Facilities

Pipeline

Compressor

Metering

Technical

Maintenance

Figure 1 Petroliam Nasional Berhad

Figure 2 PETRONAS Gas Berhad (PGB) logo

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PETRONAS Gas Berhad (PGB) is a subsidiary of Petroliam Nasional Berhad (PETRONAS). There are five department under PGB, mainly known as Plant Operation Division (POD), Transmission Operation Division (TOD), Centralized Utilities Facilities (CUF), Technical and Facilities Development Division (TFDD) and Regasification Terminal Division (RGTD). Table 1 Departments in PGB Department Plant Operations Division (POD) Task POD operates the six gas processing plants in the state of Terengganu. The plants are divided into two complexes Gas Processing Plant A in Kertih and Gas Processing Plant B in Paka. With total combined sales gas processing capacity of over 2000 million standard cubic per day, these gas processing plants process natural gas into sales gas and other by-products such as ethane, propane and butane to be transmitted to PETRONAS customers in power and non-power sectors via PGBs Peninsular Gas Utilization pipeline network. TOD operates the Peninsular Gas utilization pipeline network by managing the supply of gas to PETRONAS customers throughout Malaysia and ensuring the reliability, safety and efficiency of operations. The Segamat Operation Center which houses the PETRONAS Gas Control Center acts as a mission control for the entire PGU network. CUF supplies a range of industrial utilities to the petrochemical business in Kertih Integrated Petrochemical Complex in Terengganu and Gebeng Industrial Area in Pahang. The industrial utilities include electricity, steam, industrial gases and other by-products such as liquid oxygen, liquid nitrogen, demineralized water, raw water, cooling water and boiler feed water, as well as effluent treatment. TFDD is the engineering and project management arm of PETRONAS Gas Berhad. Having in place a solid technical resume, TFDD also provides services to other companies within the PETRONAS Group such as PETRONAS Carigali Sdn. Bhd for the Sabah-Sarawak Pipeline project.

Transmission Operation Division (TOD)

Centralised Utility Facilities (CUF)

Technical and Facilities Development Division (TFDD)

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Regasification Terminal Division (RGTD)

The newly-formed RGTD is testimony to PGBs serious endeavor in transcending beyond its conventional business parameters. RGTD is currently responsible in overseeing the engineering, construction and commissioning of Malaysias first ever Liquefied Natural Gas (LNG) Regasification facilities in Sungai Udang, Melaka as well as the operations and maintenance of the facilities upon completion in August 2012. Three new subsidiaries under PGB Group, namely Regas Terminal (Sg. Udang) Sdn. Bhd., Regas Terminal (Pengerang) Sdn. Bhd., and Regas Terminal (Lahad Datu) Sdn. Bhd., under the purview of RGTD.

Kuantan Compressor Station (KTNCS) Managed by TOD PGB, KTNCS is located at Kg. Mahkota, KM19, Jalan Gambang, 26070, Kuantan.

Station A

Station B

Figure 3 KTNCS top view

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The main purpose of KTNCS is to increase the pressure of the natural gas flowing from Kerteh to Segamat. There are two stations, station A and B. Their differences are mainly on the operating conditions:

Table 2 Stations operating conditions Station A Unit Capacity (mmscfd) Conversion ratio 1,2,3 700 1:1.35 Station B 4,5 500 1:1.48

KTNCS has the flexibility of running either Station A or Station B or combination of them. Natural gas arrived from Kerteh at pressure between 3000-6000kPag and temperatures between 20 to 30C.It is boosted up to 6895 kPag maximum as export pressure. During 10 weeks of internship here, I was assigned to Mr. Ahmad Naim, Executive of Compressor Maintenance KTNCS and was trained as trainee engineer. Project that was assigned to me is The Safety Valve Studies, which is explained in details in project and activities section. The project is an individual assignment, it was done for the further reference of the station and I have carried it out successfully.

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Ismail b. Othman
Kuantan Regional Operation

Mohd Faiz b. Mohd Mustafa


Executive Compressor Operation

Ahmad Naim Abd. Rahman


Executive Compressor Maintenance

Mohammad Husni Muhammad Sani Executive Compressor


Maintenance Mechanical

Fazley Zulfikar b. Ismai


Technician (MT - Operation Compression)

Mat Ghani b. Mohd Salleh


Technician (MT - Process)

Norli b. Yajid
Technician (MT - Process)

Azmi b. Mamat
Technician (MT- Electrical)

Mohd Fauzi b. Mamat


Technician (MT - Mechanical)

Azanmudin b. Deraman
Technician ( MT - Mechanical Compression)

Matsaliniah b. Yusof
Technician (MT - Operation Compression

Mohammad Faizal b. M. Noor


Technician (MT - Process)

Ahmad Tawfik Fathir b. Muhammad


Technician (MT - Process)

Azizul b. Hosma
Technician (MT- Electrical

Tahir b. Shariff
Technician (MT - Mechanical

Nik Mohd Fauzi b. Sapian


Technician ( MT - Mechanical Compression

Mohammad Faris b. M Zayadi


Technician (MT - Operation Compression

Mohd Hashim b. Embong


Technician (MT - Process)

Khairul Anuar b. Mamat


Technician (MT - Process)

Zamri b. Embong
Technician (MT - Mechanical

Ariffin b. Sulaiman
Supervisor Administrator

Figure 4 KTNCS organization chart

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5. Process
Kuantan Compressor station (KTNCS) was opened on 1993 with initial three units, 1,2 and 3. This is known as Station A. Further renovation to the station occurs with addition of Station B with 2 new units, 4 and 5, effective in 2010. Overall, KTNCS undergoes clean process flow with no reaction occur. Natural gas flow only undergoes increase in pressure through the compressor. The gas is a composition of nitrogen, CO2, methane, ethane, propane, i-Butane, n-butane, i-pentane, n-pentane, n-hexane, nheptane and water. The composition is constant throughout the system as the process is at steady state with no reaction occurring. The summary of composition is stated in the table below: Table 3 Composition natural gas Material Composition Lean Composition 80% isentropic

Nitrogen CO2 Methane Propane i-Butane n-Butane i-Pentane n-Pentane n-Hexane n-Heptane Water

0.004049 0.040647 0.910743 0.028511 0.009277 0.002939 0.000880 0.000440 0.000420 0.000190 0.000316

0.008720 0.022521 0.869046 0.069902 0.020331 0.003100 0.001450 0.000730 0.000320 0.000060 0.000000

Relate with Component Continuity Equation, with its general equation and taking methane as subject:

Moles of methane flow into the system

Moles of methane flow out of the system

Rate of formation due to reactions

Time rate of change of mole of methane in the system

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Then, knowing that: No reaction occur Process at steady state

Cancellation causes the equation to become: Moles of methane flow into the system Moles of methane flow out of the system

This applied throughout the system, so the composition of methane is constant throughout the system.

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6. Project and activities 6.1 The safety valve study


a) Introduction The project was handed out by supervisor, Mr. Ahmad Naim, on 28 July 2012. Scope of the project includes: i. ii. Gathers required data regarding PSV and PRV at KTNCS Locate each safety valves in the drawings

After lengthy discussion, it is known that the safety valves can be found at station A, station B and Fire Water Pump. Station A and B is located at the process area and Fire water Pump is at non-process area. Heres a closer look at the safety valve. A safety valve is a valve mechanism which automatically releases a substance from a boiler, pressure vessel, or other system when the pressure or temperature exceeds limit. It is one of set of pressure safety valves (PSV) or pressure relief valve (PRV) which also includes relief valves, safety relief valves, pilotoperated relief valves, low pressure safety valves and vacuum pressure safety valves. PSV and PRV differ from each other, PSV have manual lever that open valves in case of emergency. Pressure relief valve is an auto system actuated by the static pressure in a liquid-filled vessel. It specifically opens proportionally with increasing pressure. Pressure safety valve in the other hand is an auto system that relieves the static pressure on a gas. Usually open completely with popping sound. KTNCS safety valves consist mainly of PSV type. One of the PSV model used is Farris Series 3800 by Farris Engineering. Its operating principles can be summarized in four sentences below: i. Pressure in the protected vessel is sensed through a pressure tap (remotely connected or to the main valve body). The pressure tap is piped to the pilot control sensing line port. The vessel pressure is transmitted to the dome from the pilot control dome port. When vessel pressure is below pilot control set pressure, the relief seat of the pilot control is closed. Inlet pressure of the main valve is equal to the dome pressure (smaller) and the dome area (larger) guarantees the main valve to be closed. When the vessel pressure reaches set pressure, the pilot control relief seat opens instantaneously with the closing of lower seat. The pilot control

ii.

iii.

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iv.

relieves the dome pressure to the atmosphere. The force of the pressure in the inlet of main valve causes the piston to lift from its closed position to relieve excess vessel pressure. The relationship between the down ward force on the main valve and vessel pressure is illustrated in Figure 1. When vessel pressure reaches re-seat pressure (typically 95% of the set pressure), the spring forces overcomes the pressure force on the lower seat of the pilot control. The relief seat closes instantaneously with the opening of the lower seat. Pressure re-enters the dome and develops the force to move the main piston down and close the main valve. In Figure 2, the lift of the main valve piston is plotted against vessel pressure.

Pilot dome Main valve Pilot discharge Relief seat Piston

Figure 5 Main valve close

Figure 6 Main valve open

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Figure 7 Downward Force on Main Valve Piston versus Pressure

Figure 8 Main valve piston lift versus pressure b) Findings Studies on plant station A, station B and also Fire Water Pump system is conducted. First, the manual documents of each station need to be found. The manual contains data provided by the manufacturer earlier during the design and building of the plant. Fortunately, all the manuals are placed in tidily on shelves, so finding the right ones is not a tough job. The manual documents are very specific, and it helps a lot as most of the data can be found there. Next, related P&IDs are analyzed in detail in order to determine the valves locations. The P&IDs are quite complicated at first, but with the help of experienced colleague, understanding the piping and instrumentation flow become easier. We then go to the site to check out each valve and also visit fire water pump. The Fire Water Pump uses PSV on its diesel engine, to relieve the excessive head on the pipe. Another PSV found is PCV-2120. Although the tagging indicates it is

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regulator valve (pressure control valve), but its function resembles safety valve. Thus it is regarded as one of the safety valve. The findings can be summarized below:

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Table 4 Pressure Safety Valve Station A


Orifice No Tag no. Equipment Serial no. VA 004779 2 VA 004779 2 98/3870 6 VA 004703 1 VA 004702 5 VA 004702 6 VA 004702 8 VA 004703 1 Manufactur er Model Inlet Outlet Type (in) Set Pressure (KPAG) Relieve temperature (C)

Drawing no.

PSV 1011

FILTER SEP. V1010

CROSBY

2H3-JOS-45-A

2'' X 600 # ANSI RF

3" X 150 # ANSI RF

CONVENTI ONAL

0.785

7585

64.3

CM202-020-D0006 (1)

PSV 1021 PSV 1031

FILTER SEP. V1020 FILTER SEP. V1031

CROSBY

2H3-JOS-45-A D050HS120AK S1100

2'' X 600 # ANSI RF 2'' X 600 # ANSI RF

3" X 150 # ANSI RF 3" X 150 # ANSI RF

CONVENTI ONAL CONVENTI ONAL

0.785

7585

64.3

CM202-020-D0006 (2)

ANDERSON

0.785

7585

64.3

2223-110-001

PSV 1051

FUEL GAS FILTER

CROSBY

ID2-JOS-45-A

1" X 600 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.11

7585

64.3

CM202-020-D0013 (1)

PSV 1061

FUEL GAS FILTER

CROSBY

ID2-JOS-45-A

1" X 600 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.11

7585

64.3

CM202-020-D0013 (1)

PSV 1081

AIR RECEIVER

CROSBY

3L4-JOS-15-A

3" X 150 # ANSI RF

4" X 150 # ANSI RF

CONVENTI ONAL

2.853

1380

85.7

CM202-020-D0015 (1)

PSV 1019

POWR GAS DEHYDRATOR

CROSBY

ID2-JOS-45-A

1" X 150 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.11

7585

64.3

CM202-020-D0019

8 9

PSV 1013

FUEL GAS SKID FUEL GAS SKID

CROSBY CROSBY

11/2 G 2 1/2JOS-35-A

11/2" X 150 # ANSI RF

21/2" X 150 # ANSI RF

CONVENTI ONAL

0.503 0.503

3272 3272

35 35

CM202-020-D0013 (2)

PSV

VA

11/2 G 2 1/2-

11/2" X 150 #

21/2" X 150 #

CONVENTI

CM202-020-D-

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1014

004703 1 VA 004703 1 VA 004703 4 VA 004703 4 VA 004703 6 VA 004703 8 93E 00079 KA2319 3 KA2318 4

JOS-35-A

ANSI RF

ANSI RF

ONAL

0013 (2)

10

PSV 1015

FUEL GAS SKID

CROSBY

11/2 G 2 1/2JOS-35-A

11/2" X 150 # ANSI RF

21/2" X 150 # ANSI RF

CONVENTI ONAL

0.503

3272

35

CM202-020-D0013 (2)

11

PSV 1023

UTILITY GAS SKID

CROSBY

1E2-JOS-15-A

1" X 150 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.196

825

46

CM202-020-D0014

12

PSV 1024

UTILITY GAS SKID

CROSBY

1E2-JOS-15-A

1" X 150 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.196

825

46

CM202-020-D0014

13

PSV 1025

UTILITY GAS SKID

CROSBY

11/2F2-JOS15-A

11/2" X 150 # ANSI RF

2" X 150 # ANSI RF

CONVENTI ONAL

0.307

250

21

CM202-020-D0014

14

PSV 1071 PSV 1001 PSV 112-1 PSV 112-2 PSV 112S RL
PSV 112SIL

ODOURIZER POT STN DISCH HEADER PIPELINE RECEIVER PIPELINE LAUNCHER

CROSBY

1E2-JOS-15-A 4731281010/SI 26 GC 13-140A10 26 FC 13-140A-10

1" X 150 # ANSI RF 8" X 600 # ANSI RF 11/2" X 600 # ANSI RF 11/2" X 600 # ANSI RF

2" X 150 # ANSI RF 10" X 150 # ANSI RF 21/2" X 150 # ANSI RF 2" X 150 # ANSI RF

CONVENTI ONAL

0.196

690

21

CM202-020-D0014 CM202-020-D0006(1)

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FARRIS FISCHER (FARRIS) FISCHER (FARRIS)

PILOT CONVENTI ONAL CONVENTI ONAL

N/A

7240

50

16

N/A

6895

N/A

0516-33-008

17

N/A

6895

N/A

0516-33-008

18

PIPELINE RECEIVER PIPELINE LAUNCHER

3288961-A10/R 3288962-A10/R

TELEDYNE (FARRIS) TELEDYNE (FARRIS)

26 GC 13-130

1.5" X 600 # ANSI RF 1.5" X 600 # ANSI RF

2" X 150 # ANSI RF 2" X 150 # ANSI RF

CONVENTI ONAL CONVENTI ONAL

N/A

6895

N/A

0516-33-008

19

26 FC 13-130

N/A

6895

N/A

0516-33-008

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Table 5 Pressure Safety Valve Station B


Serial no. Manufactu rer Orifice (in) Set Pressure (KPAG) Relieve temperature (C)

No

Tag no.

Equipment

Model

Inlet 1" x 600# ANSI RF 8" X 600# ANSI RF 1" x 600# ANSI RF 1" x 600# ANSI RF 1" x 600# ANSI RF 1" X 150# ANSI RF

Outlet 2" x 150# ANSI RF

Type

Drawing no.

PSV2010

FILTER SEP V-2010

0640359

CROSBY

1D2-JOS-E45-J

CONVENTIO NAL 0.11

7585

311.36

8022-KN-DR-PR007(1)

PSV2016 2

DISCHARGE SIDE VALVE

0640378

CROSBY

44312T810/ S1

10'' X 150# ANSI RF

PILOT 26

7240

50

8022-KN-DR-PR007(1)

PSV2020 3 FILTER SEP V-2020

0640360

CROSBY

1D2-JOS-E45-J

2" x 150# ANSI RF

CONVENTIO NAL 0.11

7585

311.36

8022-KN-DR-PR007(2)

PSV2030 4

FUEL GAS FILTER SEP V2030

0640361

CROSBY

1D2-JOS-E45-J

2" x 150# ANSI RF

CONVENTIO NAL 0.11

7585

313.19

8022-KN-DR-PR011

PSV2040 5

FUEL GAS FILTER SEP V2040

0640362

CROSBY

1D2-JOS-E45-J

2" x 150# ANSI RF

CONVENTIO NAL 0.11

7585

313.19

8022-KN-DR-PR011

PSV2061 6 UTILITY GAS

0640363

CROSBY

1D2-JOS-E15-J

2" x 150# ANSI RF

CONVENTIO NAL 0.11

825

25

8022-KN-DR-PR012

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PSV2062 7 UTILITY GAS

0640364

CROSBY

1D2-JOS-E15-J

1" X 150# ANSI RF 1" X 150# ANSI RF 1" X 150# ANSI RF 1" X 150# ANSI RF 2" X 300# ANSI RF 2" X 300# ANSI RF 1" X 600# ANSI RF

2" x 150# ANSI RF

CONVENTIO NAL 0.11

825

25

8022-KN-DR-PR012

PSV2070 8

INST. AIR RECEIVER V2070

0640365

CROSBY

1E2-JOS-E15-J

2" x 150# ANSI RF

CONVENTIO NAL 0.196

1380

441.3

8022-KN-DR-PR013

PSV2080 9

BUFFER AIR RECEIVER V-2080

0640366

CROSBY

1E2-JOS-E15-J

2" x 150# ANSI RF

CONVENTIO NAL 0.196

1380

441.3

8022-KN-DR-PR013

PSV2090 10

UTILITY AIR RECEIVER V-2090

0640367

CROSBY

1E2-JOS-E15-J

2" x 150# ANSI RF

CONVENTIO NAL 0.196

1380

441.3

8022-KN-DR-PR013

PSV2101 11 FUEL GAS

0640368

CROSBY

2H3-JOS-E35-J

3.2" X 150# ANSI RF

CONVENTIO NAL 0.785

3450

30

8022-KN-DR-PR011

PSV2201 12 FUEL GAS

0640369

CROSBY

2H3-JOS-E35-J

3.2" X 150# ANSI RF

CONVENTIO NAL 0.785

3450

30

8022-KN-DR-PR011

PSV1080 13 FUEL GAS SEP. V-1080

0640370

CROSBY

1D2-JOS-E45-J

2" X 150# ANSI RF

CONVENTIO NAL 0.11

7585

64.3

CM202-020-D0013(1)

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Table 6 Pressure Relieve Valve for Fire Water Pump


N o Orifice (in) Set Pressure (KPAG) Relieve temperature (C)

Tag no. PSV2120 PCV2120

Equipment

Serial no.

Manufacturer ANDERSON GREENWOOD CROSBY

Model 324JLT-JOS-EOR15-J

Inlet

Outlet

Type

Drawing no. 8022-KN-DR-PR019 8022-KN-DR-PR019

DIESEL ENGINE RECYCLE TO TANK

07-20505

N/A

N/A

N/A

N/A

1600

N/A

705-108-3

SINGER VALVE INC

106-XX-PR

N/A

N/A

N/A

N/A

1100

N/A

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c) Conclusion By referring all the tables, station A, statin B and Fire Water Pump contains 19, 13 and 2 pressure safety valves respectively. Type of valves varies with each position and requirement and model used were Crosby, Anderson, and Farris. The safety valves mainly can be separated into two types, pilot and conventional. Pilot typed valves usually found at the station discharge header and for others, conventional valves are usually used. All PSV locations can be spotted on its individual P&ID by referring the drawing number provided. The drawings are compiled in the appendix section. The project was completed on 25th July, one week after.

Figure 9 Farris safety valve, pilot typed valve

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Figure 10 Conventional safety valve

6.2 Activities involved


Throughout the internship period, a lot of activities are planned at KTNCS. By joining these activities, a lot of experience and knowledge regarding PETRONAS Gas Berhad and KTNCS were gained. Being friendly and freely volunteer is important remarks in joining these activities. Among the activities are: 6.2.1 Units 4k and 8k running hour maintenance

As the unit has continuously running for about 4000 and 8000 hours, a routine maintenance needs to be done. These maintenance standard procedures in ensuring the turbine well serviced and detect any abnormalities in its process. The procedure includes: a) Filter change for lube oil system and dry gas seal system Change of filter in the oil that acts as both lubricant and coolant for the turbine. Routine maintenance is done by the mechanical technician in order to enhance turbine operating life. The turbine uses duplex filter system, where one run and the other are on standby. The filter has capability of filtering component up to 5 micron. Steps during filter change include isolate, drain line, change filter, online with control system, and perform bleeding.

Tank

Pump: Backup Pre/post Main line

Fin fan (lube oil cooler)

Duplex filter

Engine bearings

Figure 11 Lube oil sequence

Compressor is connected to turbine by coupling, radial bearing, thrust bearing, radial bearing and gas seal. All of them are connected with each

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other on a shaft. Bearing main objective is to support the shaft. It requires lube oil to operate smoothly and if not isolated properly, it will mix with the gas flowing through the compressor. This is where gas seal work. The dry gas seal contains two inlet (refer appendix), buffer air and gas. The buffer air reduces oil from bearing side enter the compressor and gas on the gas flowing side. Both use labyrinth, a mechanical seal that provides a tortuous path to help prevent leakage. The dry gas is the most important part in ensuring quality of the gas discharged.

Figure 12 Bleeding process b) Turbine blade wash The turbine can be regarded as the core element in the gas process here. The complex structure of the turbine itself requires professional handling and regular maintenance. Its efficiency highly depends on the blade condition. So, routine cleaning is required for each unit of turbines in order to maintain the turbine performance and condition. The cleaning process also provides opportunity for the maintenance team to observe whether any part has worn out and needs attention.

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Figure 13 Turbine blade

Figure 14 Turbine blade

c) Air intake pre-filter change In addition to normal 4k maintenance procedure, the 8k requires operator to check unit control panel any determine any abnormality on its process. If any abnormalities occur, the technician needs to open the related parts and fix it. If the turbine is well maintained, these abnormalities will be a rare case. Air intake filter consist of two parts, pre and final. Pre-filter is a component made of fiber-glass, placed before final filter. The final filter is component that is box-typed; contain series of alternating aluminum sheet and fiber sheet. The change is done by Salutary Avenue, the company that provides the filter to PGB itself. This is convenient as they have expertise in their own product.

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6.2.2

Jom Sembang program at Kuantan Regional Office (RO)

Program initiated by TOD of PETRONAS Gas to help close gaps between top management and staff. This program provides opportunity for staff to issue any problem regarding their department to the top management. Besides, the program also provide platform for both parties to mingle with each other. The agenda includes briefing of current performance of TOD and interactive games. The briefing was conducted by Mr Noranizar B. Ali Amran, the Senior Manager (SM) of TOD. Briefing section create chances for staff to forward any questions regarding PETRONAS and TOD especially. All of the questions were answered directly by SM. Among the question raised was the staffs pay system, about the incentives given by PETRONAS to its loyal workers. The interactive part was even better, the staff and the top management combines and form groups to play the classic snakes checkers (dam ular). The game turns out to be interesting and funny, as all of the eager to finish first. All of the players enjoy quality time together, and in turn help release their daily working stress.

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Figure 15 Game winners

Figure 16 snake checkers on floor tiles 6.2.3 Site visit for new lube oil sampling point

In addition to existing sampling point, new lube oil sampling point is needed to monitor and maintain lube oil quality. Existing lube oil tapping sample is taken before the oil enters it filter. By consulting its very own Group Technical Solutions (GTS), they wanted to know where other samplings can be made. Dr. Chew has been assigned to this task. He has conducted studies on the Segamat Operation Center first prior coming to KTNCS. The assessment take two days, first day is entirely briefing regarding the choices that available for sampling and the discussions with responsible engineers and technician. Here he explained that there are four choices available:

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a) First is just maintaining the current sampling point (tapping) and added tapping point to the return line. This option is simple but the result will be unsatisfactory and seems lazy. b) Second option is to maintain current tapping, add another tapping after filter at the feed line and another at the return line. This seems reasonable and will make the job easier. c) The third choice is same as the second, but for the return line, each bearing (five all of them) will have its lube oil sampled. This is more accurate and better but depends on accessibility. d) The final option is to have sampling at all equipment that lube oils passed. This will be the most accurate method, but the sampler will have a torrid time collecting all the sample and it will be time consuming. It is agreed that the sampling will be either between options two and three, depending on the accessibility at the turbine. That takes us to the second day, where the line tracing is done. Line tracing using P&ID of lube oil will help the team to have far better view of the situation. Station A and B have different arrangement, so line tracing will be conducted at each one of units of the station. For station A, the team takes quite long time to determine the sampling point as the accessibility and the turbine arrangement is quite complicated. But for station B, which are more modern in design, the line tracing and the decision is made in short time. The line tracing only reveal possible sampling points but the final decision is at the hand of GTS. The result will come in after about one week.

Figure 17 return line for lube oil (station A)

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Figure 18 Line tracing

Figure 19 Existing sampling point

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6.2.4

Site visit schedule waste

Selection for contractor for schedule waste management is subject to open bidding. The contractors that present for the site visit were from Hiap Huat Chemicals and Kualiti Alam. The intent for the site visit is to clarify scope of work for the contractor. One of the key points of the 14 pages document is the safety rule set by PGB. They must submit a proposal that includes nine basic points: a) b) c) d) e) f) Company policy on safety Detail method statement and other standard documentation Certificate of competency List of manpower with their I/C and contact no. Schedule of work Job Safety Analysis (JSA), where highlight of potential hazard and its preventive method g) List of vehicle to be used inclusive of copy drivers license and Puspakom Inspection Certification h) Copy of Worker Protection Scheme (SOCSO) for all workers involved i) PETRONAS-NIOSH Safety Passport (NPSP) for all workers After the meeting, technician, Mr Fazley led the contractors to visit schedule waste site. The present schedule waste includes: a) Spent filter/contaminated rag (SW410) 2000 b) Oil residue from oil and grease interceptor (SW 312) 48000kg All the schedule waste should be disposed by Kualiti Alam or recycle by authorized company. By interviewing the contractors, it is found that Hiap Huat Chemicals intended to recycle the oil residue to second grade oil. The second grade oil can be used as combustion fuel or basic component in paint. Kualiti Alam in the other hand focuses on dispose the chemical.

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Figure 20 Schedule waste shed

Figure 21 Spent filter flammable label

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Figure 22 mixture of oil residue and water sample

6.2.5

Site visit to PETRONAS CUF Gebeng to collect demineralized water

Collecting demineralized water (demin water) at PETRONAS Centralized Utilities Facilities (CUF) in Gebeng have given me the chance to see others PETRONAS plant. demin water is exclusively used for turbine engine cleanup procedure. Also known as deionized water, it is a water type that has its mineral ions removed, such as cations from sodium, calcium, iron, copper and anions such as chloride and bromide. With four others, we travelled by pickup truck to Gebeng. The PETRONAS CUF provided PETRONAS and others plants utilities for everyday operation. Examples of utilities are electricity, steam, nitrogen, oxygen, dematerialized water, cooling water, boiler feed water and raw water. Although it is not quite what engineers are expected to do, but travelling with work colleague is essential experience and it open chances to get to know them better. CUF plants at Kerteh and Gebeng have successfully commenced operations and the supplying of utilities to the intergrated Petrochemical Complexes (IPCs) in stages since November 1999. The plants first came on-operation with the first delivery of electricity on 19 November 1999 for Gebeng and 27 January 2000 for Kertih. The Heat Recovery Steam Generator system was brought online in Ketih in June 2000 and Gebeng in August 2000. This was followed by the Air Separation Unit (ASU 1) plant which produces gases low pressure nitrogen and oxygen to the IPC customers. The dematerialized Water and Waste Water Treatment plants were commissioned in July 2000 and August 2000 respectively.

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4 main units to produce respective utilities includes, Co generation unit (steam, electricity), Air Separation Unit (oxygen, nitrogen, argon), Waste Treatment Unit (Demineralized, cooling, potable and boiler feed water) and Waste Water Treatment Unit (treatment of waste water).

7. Problem encountered and ways overcoming it


There are many problems that we faced in everyday life and whats important is how we tackle it. Settling in as new staff at KTNCS is the first problem that I faced here. Since I didnt know anybody and relatively fresh in the engineering world, I have to prove to everyone and most importantly my supervisor that I really am interested in this field. Overcoming the problem is really are simple, being friendly, show respect and other positive attitudes are the key. First impression is important, and make sure they get the right one. Besides, always volunteer and make ourselves available to work, this attitude helps greatly to promote ourselves and gain experiences. Another problem is the work scope that I should be involved during these 10 weeks internship period. Not having program planned for me is one thing, and the fact that the station concentrate mainly on the mechanical and electrical work is the other. A discussion between me and my supervisor help to encounter this problem. To me, I did not have any problem learning all these mechanical equipment, such as turbine and compressor parts again as I think its going to help me big time in the future. The compressor and turbine are also important equipments in oil and gas industry, and by having knowledge regarding it, Im going to have a big advantage. For my supervisor, he wants me to take this chance to learn as many things as I can here. The internship period is also a problem. 10 weeks is a short period, compared to some universities that sent their student for 8 months, so hard work is needed to make sure that the time is used wisely. All these problem arises before I even started the internship. Overcoming all these, I started joining the activities and gain some experiences. Other problems also arises, such as during mechanical maintenance. Not knowing the parts and even how it operates makes maintenance work confusing and hard to me. To overcome this, I make sure that I asked the technician all the things that I didnt know and make effort to study its manual book. The Solar Turbine, Dresser-Rand Compressor looks complicated at first but studying it, everything became simpler. Besides that, during project progress, some problem also arises. I have no knowledge at all regarding pressure safety valve. The pressure safety valve could be understood easily by using Wikipedia on the internet, but to locate it at the site, I need help from my colleagues. Luckily, they all are very helpful and I managed to finish the project ahead of schedule.

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8. Lessons learned
There are too many lessons that I learned from the first day I reported to duty. From activities that I joined, I was able to gain knowledge of performing engineering tasks. Being able to compliment many of the theories that I learned before, such as valves, piping, and control system was amazingly fun and challenging. The newly acquired knowledge was also a big plus for me as a fresh member in this field. Being actively involved in the activities also helps improve my personal soft skills. Being able to communicate with contractors, colleague and organizing event helps me greatly in planting self belief and interaction skills. Respecting older colleague was also valuable lesson that I learned. Having a positive relationship with them trough this internship period helps me greatly. I made them aware of my hunger for knowledge and theyre more than happy to share theirs. Respecting others opinion is important although sometimes we didnt share the same view on things. Besides that, through the project assigned, I learn to bear responsibility and handle pressure. To make sure that the project finish on time, it is important to make sure that proper planning is made. I needed to make sure that the project is in progress although I wanted to involve in other activity. This is the responsibility that I need to take in order to make the project a success. The project sometimes having its rough patch, easiest example is when sometimes reference is needed and the required data is not there. There are also others, such as the exact location of the valves, where to look for further reference, and whats needed in the data. Thankfully all of these were sorted out by the help of my colleague. Each of my questions is answered easily, thanks to their wide experience at the station. Last but not least, by undergoing internship here, I was treated to a grand introduction of natural gas transmission industry. The flow of PETRONAS gas transmission which is so distant before has become crystal clear to me.

9. Suggestions
Here are some suggestions that can be useful in the future. First and foremost, being friendly, show respect and other positive attitudes are important if you really serious to learn. Always volunteer and make ourselves available to work whenever the opportunities come, dont expect others to ask you. In reality, the only person that can help us is ourselves. Besides that, I think that the student progress during internship is time constrained. The time provided is too short, and not much progress can be made. The student knowledge might be wider, but theres not much activity and task that they can join because of this. I suggest that the internship period for the students in the future should be longer, approximately six to eight months.

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10.Conclusion
This internship period has been a successful and enjoyment journey for me. Many positive points have been taken from my first taste working in this engineering field. Many of these outcomes surely will be useful tools for me to perform the final year project next semester. Although the period is too short, the experience gained is vastly big and invaluable for me. Furthermore these experiences will also act useful guide for me in determining my direction after completing my degree.

11.References
Dresser-Rand Service Manual, Solar Turbines, Inc./Brown&Root Eng. PETRONAS Kuantan Station, Malaysia Operation and Routine Maintenance Course, Mars Gas Turbine Mechanical-Drive Set, Solar Turbines Anonymous, history, Retrieved online from http://www.petronasgas.com/Pages/History.aspx, Jult 17th, 2012

12.List of Appendices Appendix A A.1 A.2 A.3 A.4 A.5 A.6 Relevant Figures KTNCS layout Inner gas seal diagram Piping symbols Letter designations P&ID dry gas seal Dresser-rand 50PDI

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