PLO 3, JALAN PEKELILING, 81700 PASIR GUDANG JOHOR DARUL TAKZIM
NAJAH SYAHIRAH BINTI MANSOR MB11140 FACULTY OF MECHANICAL ENGINEERING UNIVERSITI MALAYSIA PAHANG
05 AUGUST 2013 17 JANUARY 2014
ii
SUPERVISORS DECLARATION We hereby declare that we have checked this report and in our opinion this report is satisfactory in term of scope and quality for the award of the degree of Diploma of Mechanical Engineering.
Signature: Name of Supervisor: MOHD HAFIZ BIN YAHYA Position: TECHNICAL EXECUTIVE Date: 30 th DECEMBER 2013
iii
AUTHORS DECLARATION I hereby declare that all information written in this report is true. This report has also been certified by my supervisor. All information written in this report is based on knowledge and work experience that is shared by my supervisor.
Signature: Name: NAJAH SYAHIRAH BINTI MANSOR ID Number: MB 11140 Date: 30 th DECEMBER 2013
iv
DEDICATION
Special dedication of the grateful feeling to my
Supervisors: Mr. Mohd Noh B. Kasmurid Mr. Mohd Hafiz B. Yahya Mechanical Discipline Personnel in FPSO Cendor Project FPSO Cendor Family Members Turcomp Members
Beloved parent: Mr. Mansor Bin Ibrahim Mrs Zailan Binti Hashim
Siblings: Najah Adibah, Najah Aisyah Sophia, Azizah Thuraiya, Muhammad Harith
And all that involved
For their love, support and best wishes
v
ACKNOWLEDGEMENTS Grateful to Allah for all blessings he bestowed in completing this report. I would like to return my gratitude and courtesy to all personnel who involve in this Industrial Training and Industrial Training Report and especially to those who assisted and encourage me in completing this whole industrial training. Firstly special thanks to my supervisors Mr. Mohd Noh B. Kasmurid and Mr. Hafiz B. Yahya for the whole guidance for 6 months during my undergoing in this industrial training. Thanks also to Mr. Devendran, Mr. Edwin, Mr. Naqiuddin, Mr. Nazri, Mr. Mahat, Mr. Arbain, Mr. Azlan, Mr. Fadzil and Mr. Hardee from Mechanical Discipline for guiding and helping me throughout the learning process session during the industrial training and also thanks to Turcomps personnel for their assistance while using the tools and equipment on board. I also would like to show my appreciation to Malaysia Marine Heavy Engineering Sdn. Bhd (MMHE) for giving me an opportunity to undergo industrial training here. Thanks also for the useful information and technique skill that taught to me. Not forget to my family and to all peers who should be recognized for their support during the industrial training period. All the comment, suggestion and tips were useful to complete this industrial training and industrial training report and to ensure this training run smoothly.
vi
ABSTRACT The objective of industrial training is to experience and understand real life situations in industrial organizations and their related environments and accelerating the learning process of how students knowledge could be used in a realistic way. Besides, it provides the exposure to practice and apply the acquired knowledge hand-on in the working environment. Moreover, students can gain hands-on experience that is related to the students majoring so that the student can relate to and widen the skills that have been learnt while being in university. Furthermore, students implement what they have learned and learn more throughout this training. Besides, students can also gain experience to select the optimal solution in handling a situation. During industrial training, students can learn the accepted safety practices in the industry. Students can also develop a sense of responsibility towards society. In addition, industrial training is to provide opportunities for students to be offered jobs in the organizations in which they undergo their industrial training.
vii
ABSTRAK Objektif latihan industri adalah untuk mengalami dan memahami situasi sebenar kehidupan dalam organisasi industri dan persekitaran yang berkaitan dengan mereka dan mempercepatkan proses pembelajaran bagaimana pengetahuan pelajar boleh digunakan dengan cara yang realistik. Selain itu, latihan industri memberi pendedahan untuk mengamalkan dan menggunakan pengetahuan yang diperoleh secara praktikal dalam persekitaran kerja. Selain itu, pelajar boleh mendapat pengalaman yang berkaitan dengan pelajar-pelajar jurusan supaya pelajar boleh dikaitkan dengan dan meluaskan kemahiran yang telah dipelajari ketika berada di universiti. Tambahan pula , pelajar dapat melaksanakan apa yang mereka telah belajar dan mengetahui lebih lanjut sepanjang latihan ini. Selain itu, pelajar juga boleh mendapat pengalaman untuk memilih penyelesaian yang optimum dalam menangani sesuatu keadaan. Semasa latihan industri, pelajar boleh mempelajari amalan keselamatan yang diterima dalam industri. Pelajar juga boleh menerapkan rasa tanggungjawab terhadap masyarakat. Di samping itu, latihan industri adalah untuk memberi peluang kepada pelajar untuk ditawarkan pekerjaan dalam organisasi di mana mereka menjalani latihan industri.
viii
TABLE OF CONTENTS
TOPIC PAGE SUPERVISORS DECLARATION ii AUTHORS DECLARATION iii DEDICATION iv ACKNOWLEDGEMENTS v ABSTRACT vi ABSTRAK vii TABLE OF CONTENTS viii-x LIST OF FIGURE xi-xiii LIST OF TABLE xiv LIST OF ABBREVIATIONS xv CHAPTER 1 COMPANY PROFILE 1.1 Company Profile 1-2 1.2 Training Schedule 2 1.3 Company Background 3-4 1.3.1 Company vision 5 1.3.2 Company mission 5 1.4 Company Organization Structure 6
ix
CHAPTER 2 COMPANY ACTIVITY 2.1 Design and Construction Process 7-9 2.2 Fabrication Process 9-10 2.2.1 Normal Casting Fabrication Process 11-17 2.3 Testing and Commissioning (T&C) 18-19
CHAPTER 3 TASK OF JOB TRAINING 3.1 Shaft Alignment 20-21 3.1.1 Causes of Machine Breakdown 22 3.1.2 The Symptoms of Misalignment 22 3.1.3 The Benefits of Shaft Alignment 23 3.1.4 Preparation Checklist 23-24 3.1.5 Alignment Procedure 24-26 3.1.6 Alignment Process on Hot Oil Drain Pump 26-28 3.1.7 Some Equipment or Systems That Requires An Alignment Process 29-31 3.2 Monorail Load Test 32 3.2.1 Safety 32 3.2.2 Test Equipment 32 3.2.3 Pre-Commissioning Work (Mechanical) 33 3.2.4 Commissioning Work Procedure 33-34 3.2.5 Some Module That Requires Monorail Load Test 35-37 3.3 Fresh Water Cooling System 38-39 3.3.1 Safety 39-40 x
3.3.2 Special Tools and Test Equipment 41-43 3.3.3 Pre-Commissioning Work (Mechanical) 43-44 3.3.4 Commissioning Work Procedure 44 3.3.5 Commissioning Test Records 45-47 3.4 Sewage Treatment Plant (Black and Grey Water) 48-49 3.4.1 Safety 49 3.4.2 Special Tools and Test Equipment 49-52 3.4.3 Pre - Commissioning Work (Mechanical) 53 3.4.4 Commissioning Work 54-55 3.5 Bunkering 56-57 3.5.1 Safety 57-58 3.5.2 Test Equipment 58 3.5.3 Bunkering Activities (Mechanical) 59 3.5.4 Pre- Start-up Activities 59-61 3.5.5 Start-Up Activities 61 3.5.6 Completion of Bunkering 61-64
CHAPTER 4 CONCLUSION 4.1 Conclusion 65-66 4.2 Recommendation for Future Work 66-67
REFERENCES 68-69
xi
LIST OF FIGURES
FIGURE NO. TOPIC PAGE Figure 1.1 Signboard MMHE 1 Figure 1.2 Yard MMHE 4 Figure 1.3 Company organization chart 6 Figure 2.1 Integrated Process between design and construction 9 Figure 2.2 Types of precast concrete elements 10 Figure 2.3 Assembly of mould 11 Figure 2.4 Mould cleaning and preparation 12 Figure 2.5 Fixing of rebars or cast in items or prestressing strands 13 Figure 2.6 Final inspections before casting 14 Figure 2.7 Concreting 15 Figure 2.8 Curing 15 Figure 2.9 Demoulding 16 Figure 2.10 Final inspection or Transfer to storage yard 17 Figure 3.1 Misalignment Condition 20 Figure 3.2 Angularity describes the angle between two rotating axes 21 Figure 3.3 Offset describes the distance between rotation axes at a given point 21 Figure 3.4 Misalignment machine breakdown 21 Figure 3.5 Rim and face method 26 Figure 3.6 Hot Oil Drain Pump Skid 26 Figure 3.7 Reading of dial gauge taken at 0 0 ,90 0 , 180 0 and 270 0 27 Figure 3.8 Adjustment of the thickness of shim 27 xii
FIGURE NO. TOPIC PAGE Figure 3.9 Cutting process of the shims 28 Figure 3.10 Central Cooling Sea Water Pump 29 Figure 3.11 Water Injection Pump 29 Figure 3.12 Diesel Oil Purifier Feed Pump 30 Figure 3.13 Ballast Water Pump 30 Figure 3.14 Gas Turbine Compressor 31 Figure 3.15 Produced Water Recycle Pump 31 Figure 3.16 High Valve Store Monorail Hoist 35 Figure 3.17 Hot Work And Welding Workshop Monorail Hoist 35 Figure 3.18 Instrument Store Monorail Hoist 36 Figure 3.19 Mechanical Store Monorail Hoist 36 Figure 3.20 Mechanical and Machine Tool Workshop Monorail Hoist 37 Figure 3.21 No. 1 Electrical Store Monorail Hoist 37 Figure 3.22 Vibration Meter 41 Figure 3.23 Tachometer 42 Figure 3.24 Infrared Thermometer 43 Figure 3.25 Cooling Fresh Water Pump Motor 47 Figure 3.26 Utility Cooler 47 Figure 3.27 Vibration Meter 50 Figure 3.28 Tachometer 51 xiii
FIGURE NO. TOPIC PAGE Figure 3.29 Infrared Thermometer 52 Figure 3.30 Sewage Treatment Plant Tank 54 Figure 3.31 Sewage Treatment Plant Pump Motor and Blower 55 Figure 3.32 Switchboard and Auto Controller 55 Figure 3.33 Transfer diesel fuel from bunker barge to Diesel Oil Storage Tank 62 Figure 3.34 Diesel Fuel insert into pipelines 63 Figure 3.35 Bunker Hose Reel 63 Figure 3.36 Top View of Bunkering 64 Figure 3.37 Signage and Barricade 64
xiv
LIST OF TABLES
TABLE NO. TOPIC PAGE Table 1.1 Table of Gantt Chart 2 Table 3.2 Cooling Freshwater Pump 81-P-6002A/B Running Test Record 45-46 Table 3.3 Pre - Commissioning Mechanical Work 53
xv
LIST OF ABBREVIATIONS
DAC Discipline Acceptance Certificate
ESD Emergency Shutdown FPSO Floating Production Storage and Offloading ICSS Integrated Control and Safety System IPO Initial Public Offering JSA Job Safety Analysis LCP Local Control Panel LOTO Lock Out / Tag Out LUN Livening-Up Notice MCC Motor Control Center MMHE/MH B Malaysia Marine and Heavy Engineering Holdings Berhad (MHB) MSE Malaysia Shipyard and Engineering Sdn Bhd P&ID Piping and Instrumentation Diagram PSD Process Shutdown PTW Permit To Work