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INDUSTRIAL TRAINING REPORT

MALAYSIA MARINE HEAVY ENGINEERING SDN. BHD


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