iv

4.2.1 Troubleshooting Activities

4.3 Calculation

29
37

vi

vii

viii

ix

CHAPTER 1: ABSTRACT AND INTRODUCTION

ABSTRACT
The project present by this report entitle Instrument Air Compressor
Downtime Issue: Troubleshoot and Rectify the Root Cause of the Failure (High
Air End) at Onshore Gas Terminal (OGT) PETRONAS Carigali Sdn. Bhd. There are
three permanent Instrument Air Compressor that available in OGT that support and
supply instrument air to all required equipment for the whole OGTs plant. Two of the
instrument air compressor are the new equipment and act as the main air supplier while
the other one as the backup with lower capacity. Starting from February 2015, one of
the main air supply for OGT which are K5410B failed to run. The problem getting
worse when the one instrument air compressor that act as backup cannot supply
sufficient air for the whole plant. This is because a lot of equipment added to improve
the performance of the plant. Instrument Air System is one of the most important
system in the plant. Instrument air compressor, dryer, switching mechanism and heater
are the equipment that control the air system of the plant. Air system also describe as
the heart of the plant. Instrument air compressor, dryers, timers, switching
mechanisms, and heaters require periodic maintenance to perform properly. Each
maintenance department should treat this equipment as the heart of the plant because
without it all other systems will soon be experiencing difficulties (Varma, December
1990). This is because the failure of instrument air compressor will cause the whole
plant undergoes emergency shutdown (ESD). When ESD occurs, all the plant process
will automatic stop and cause lost profit in term of productions. One hour of ESD in
OGT will cause approximately RM 1,052926.25. Thus, the instrument air compressor
need to be in online and good condition or else the nightmare of lost profit will happen.

1.1 OBJECTIVES
The objectives of this project can be divided into 4 main objectives which are:
I.

To study about instrument air compressor

Learn about the instrument air compressor including the function of the
instrument air compressor and each part and how does it work starting from
the air intake until discharge into the plant

II.

To find the root cause of the instrument air compressor failure due to high
air end temperature issue
Run troubleshooting to find the main cause of the instrument air compressor in
OGT failure. This project focus on the current failure due to high air
temperature

III.

To propose the solution based on the outcomes and the root cause of the
failure
Find the solution based on the data and finding result after troubleshooting
procedures. The solution can be consider as the Cost Saving Initiative for the
PCSB.

IV.

To suggest any recommendation and precaution that need to be consider

based on the failure
To share the idea for the recommendation and precaution for OGT staffs
especially for the maintenance teams in order to reduce the instrument air
compressor downtime

1.2 SCOPE OF STUDY

This project is a project that involve troubleshooting and rectifying one of the
equipment which is instrument air compressor. This project involves few scopes of
studies in engineering theory especially in mechanical engineering, electrical
engineering, and chemical engineering fields. It also involving the maintenance skills
and knowledge by maintenance engineers and also technicians. The study is focusing
on each part of the instrument air compressor that might be lead to the answer of why
the instrument air compressor failed to operate as what it supposed to.
Instrument air compressor manual supplied by Ingersoll Rand is need to be
understand and refer before conducting this project. This is because the subject or the
equipment that will be used are manufactured by Ingersoll Rand Company, which are
one of the big instrument air compressor supplier all the world.
Due to the main objective of this project is about to tackle the high temperature
issue, this study will focus more on the cooling system of the instrument air
compressor itself. The temperature of the flow of the lubricant oil and the compressed
air will be recorded and will be presented in form of table and graph which can be refer
at the result and appendix. The temperature will be recorded at certain duration and
period in order to know the pattern and how thus the cooling system in the instrument
air compressor works. The reading of the temperature will be taken by using
temperature gun. The average of the reading will be calculate to improve the accuracy
of the data taken.

1.3 PROBLEM STATEMENT

The operation in oil and gas industry are mostly control by using valves. Valves
can be classified by using the type and the function of the valve itself. In OGT, most
of the important valve that used to control the operation are control by using instrument
air. Not only valves, some of the pump also used instrument air to operate. Based on
the data calculation, the estimated air consumption that required in OGT are 3406.00
SCFM or 885.563 /. Due to high amount of air consumption for the plant,
instrument air compressor need to continuously supply enough air to prevent the plant
shutdown because of valve failed to operate. The continuous operation of the
instrument air compressor can reduce the instrument air compressor lifetime. The
study about instrument air compressor are needed in order to know how the instrument
air compressor that used in OGT in order to maximize the performance and also the
reliability of the equipment itself.
Instrument air compressor that available in OGT failed to operate for several
times. The failure mostly because of the high temperature issues. The reason of the
high temperature is most probably due to high demand of air supply for the equipment
in OGT which cause the compressor need to work at its 100% load. It also caused by
the environment or the other related equipment problem that might lead to the failure
of the instrument air compressor to perform at its best. The several study require to
investigate the root main cause of this failure. By eliminate the root cause, the
instrument air compressor can be used with the maximum efficiency and indirectly
reduces the money spend for the repair and rewinding cost.
With the current economy status and the oil price of the world that decreasing
pattern for this last 12 months, all companies or industries that run the oil and gas
business faced some lost intern of profits gained. Repairing and rewinding the
equipment require a lot of money. The cost is not only for the buying new parts, but
the service fees and also transport fees need to be calculate to. If the troubleshoot and
rectifying process can be done by the host company itself, it can be save a large amount
of money. This also can be considered as the cost saving initiative that not only give
the benefits for the company in term of money, but also can be the advantages for the
staff especially for the engineers, technicians and also the trainees that are involved to
gain some experience and knowledge about instrument air compressor.
4

The result or outcomes based on the troubleshooting process are needed in

order to come out with the best solution. The relevant suggestion or precaution also to
make sure the same problem is not happening again. But if the same problem
happening again, it would be easier for the person in charge to do the rectification. The
suggestion need to be compile into a file as a reference since the troubleshooting
procedure that supply by the manufacture company might not enough.

1.4 THE RELEVANCY OF THE PROJECT

PETRONAS Carigali Sdn. Bhd. or known as PCSB can be divided into three
sections which are Peninsular Malaysia Operation (PMO), Sarawak Operation (SKO)
and Sabah Operation (SBO). PCSB main business is exploring and searching for oil
and gas which can be categorized as the upstream business. PCSB are responsible in
handling the business starting from the offshore platform until the onshore terminal.
Focusing on PCSB-PMO, there are four onshore terminal that located in Kerteh,
Terengganu. The terminal are Onshore Gas Terminal (OGT), Terengganu Crude Oil
Terminal (TCOT), Onshore Slug Catcher (OSC) and a new terminal that will start
operating in September 2016, Terengganu Gas Terminal (TGAST).
The author are given an opportunity to have industrial exposure in one of the
PCSB-PMO terminal which are OGT. OGT is a center of the gas production between
offshore platform and the downstream which is Gas Processing Plant (GPP). The
relevancy of this project can be evaluate based in the amount of cost saving in
troubleshooting the instrument air compressor and also the performance of gas
production due to the efficiency of the instrument air compressor in OGT.
Align with the Mechanical Engineering background, the author already
exposed to the study of the compressor during his study in Universiti Teknologi
PETRONAS (UTP) through thermodynamics engineering course. This project also
can be related with the one of the Major in Mechanical Engineering which are Plant
and Facilities which involve in reliability and maintenance which are under
troubleshooting plant equipment. The author fined this project really helpful in order
to understand more on rotating equipment which not only give benefits during
internship period, but also during final year study.

CHAPTER 2: BACKGROUND AND LITERATURE REVIEW

2.1 BACKGROUND OF THE PROJECT
The project was conducted in PCSB Onshore Gas Terminal (PCSB-OGT).
OGT are capable to conduct approximately 1/3 of the gas produce in peninsular
Malaysia. OGT receive the gas and liquid from two offshore platform which are
Sotong Collector Platform that connected to Joint Delivery System (JDS) in OGT.
Another platform which are connected to OGT Resak Delivery System (RDS) is Resak
Platform.
JDS are commissioning in June 1984 which is the first or the older delivery
system for OGT. The raw product that receive from Sotong Collector Platform are
transfer using 30 inch pipeline under the sea for 156 km long. JDS are design with the
capability of handling about 500 mmscfd or 14000 kbd of gas. The current production
rates are approximately 430 mmscfd which are about 86% of the design. RDS is a new
delivery system in OGT which are commissioning in 2000. Same with JDS, the raw
product are transfer along 28 inch pipeline across the sea with 135 km long. Even
though the size of the pipe used are smaller than JDS, the raw product transfer are
about 15.5% more than JDS.

Figure 2.1.1: Peninsular Malaysia Gas Production Network

The main operation of OGT are to separate the raw product into gas,
condensate and water. The gas and condensate will be export to the downstream which
are Gas Processing Plant (GPP). The water that coming from offshore also will be
treated in OGT before it release to the sea. In OGT, the separation process are
undergoes naturally by using the gravity and the density of the product. The separation
process are same between JDS and RDS. The main separation are occurs in Finger
Slug Catcher (FSC) which are almost all of the gas and liquid are separated. The gas
separator will directly move to the Gas Separator to separate the dry gas and the wet
gas before it will transfer to gas metering to be export to GPP. The liquid that separated
by the FSC will go to condensate separator to differentiate between condensate and
the water. Condensate will be pump by Condensate Transfer Pump (CTP) to the
condensate metering while the water will be send to Industrial Effluent Treatment
System (IETS) for the treatment.
The overall process in OGT are using the differential pressure of the plant. The
average operating pressure in OGT during normal operation are 72 Barg. The only
pump that use in the main operation is Condensate Transfer Pump (CTP). This is due
to the higher density of the condensate that require higher pressure than the plant
pressure. CTP also used to create the differential pressure between the landing pressure
(pressure that coming from offshore) with the discharge pressure (pressure to GPP).
The differential pressure is important in order to maintain the flow of the gas and
pressure. The other method to create differential pressure is to burn some gas to the
flare. All the gas and condensate flow and the process are control by using the valves.
There are thousand valves that used in OGT. The valves are divided based on
its function and types. There are 43 Shut Down Valves (SDV), 118 Motor Operated
Valves (MOV), 11 Blow Down Valves (BDV) and many other valves that use in OGT.
Most of the important valves are control or operate by using instrument air. The valves
will control the operation process by controlling the flow whether to give the flow or
stop it. This operation are conduct by using ball type of valve which are used for SDV
and also MOV. The valves also control the flow by limiting the opening of the valve
to reduce or increase the flow rate. In order to make sure the plant process are in
control, plant air system need to be monitor for all time.

2.2 LITERATURE REVIEW

Air system is one of the most important and critical power resources in most
of the modern plant. According to Scot Foss, R. (1999), if the pressure of the air system
drop beyond the acceptable limit, it will interrupt the production process. This is
because of the air system are used in the range of seven to forty percent of the total
electric usage in the plants. Air system can be divided into two types. The type of the
air systems are instrument air system and the other one is service system. This types
of the air system are classified based on the air produces or use and also the purposed
of the air.
Instrument air is a compressed air produces by instrument air compressor. The
air from the surrounding are compressed by the compressor into the certain pressure.
Instrument air are mostly used to operate almost all the instrument equipment. For
example, the equipment that require instrument air to be operate in OGT are the control
valves including pressure control valve (PCV), Level Control Valve (LCV), Flow
Control Valve (PCV) and etc.. 1% of the element inside the environmental air is a
water in form of liquid or moisture (Scot Foss, 1999).

Composition Of Atmospheric Gas

Oxygen, 20%
Inert Gases
(Mainly Argon),
0.97%
Carbon Dioxide
and Other Gases,
0.03%
Water Vapor, 1%

Nitrogen, 78%

Figure 2.2.1: Percentages of the Composition in the Atmospheric Air

The moisture in the air is very harmful to the most of the equipment especially
for the equipment that made from the steel. This is because of the water or moisture is
one of the element that can cause corrosion. The corrosion can caused the lifespan of
the equipment reduces. The corrosion from the inner part of the equipment also can be
classified as the critical hazard. This is due to unable to detect the corrosion at the early
stage. Therefore, in order to reduce the moisture in the compressed air, the air will be
transfer to the dryer to filter the moisture before used to the desire equipment.
Services air also is the product produces by the compressed air of the
instrument air compressor. The different between the service air and the instrument air
compressor is the service air is used without need to remove the moisture. Normally,
the service air are used to run pump diaphragm pump. Diaphragm pump are used to
transfer the slugged that treated in IETS into the slugged thickener. Basically service
air is the air that compressed and store into the receiver tank before enter the dryer.
Service air are less used compared to the instrument air. The number of the equipment
that require service are is in small amount of number and it only used only when it
required to be run.

Filters
Filter is one of the important equipment in the compressed air system. Filter
normally located before air dryer. In OGT, the filter are located before and after the
dryer. The main purpose of the filter is to remove the dirty particles that are in the
compressed air. The air that enter the compressor not only have the moisture, but also
have some dirty particles that can cause problem to the equipment such as blockage
and damage the equipment.
There are two types of filter that can use in order to remove this particles. One
of the filter is a surface filter which are uses a screen or sieve to trap and catch the
particles. As the number of particles trapped increase, the air flow will be restricted
due to the plugged at the holes. This also cause the pressure drop. Another filter is
known as In-Depth filters. This kind of filter contain a bed of randomly positioned
fibers. The bed is used to catch the particles. In-depth filter can maximizing the dirt
holding capacity with the 90% of void space.

Table 2.1: Difference between Surface and Depth Filtration

Surface Filtration

Size of the particles is bigger

Depth Filtration

than the mean pore size of the

medium

Smaller size of the particles that

can retained

Less mechanical strength of the

High mechanical strength of the

filter medium

filter medium (can use stainless

High capacity

steel to increase the mechanical

The size of the particles that will

strength)

Low capacity

The size of the particles that will

retained less predictable

Cheaper equipment (Not require

ancillary equipment)

retained are more predictable

Expensive equipment (require

ancillary equipment)

The dirty particles or contaminant that in the compressed air are not only
coming from the dust coming with the atmospheric air, but also from the lubricant oil
during compression process. The oil carryover will causes the damage to the final
product of the compressed air, but it also can become health hazard if untreated or
disposed improperly. Kwok, T. W. (2009) has mention that a typical reciprocating
compressor will have approximately 45 mg/ m3. While the typical contact cooled
rotary compressor will have about 3 mg/m3 of the coolant carry-over.
Focus on the project site, coalescing air filter are used in OGT. This filter
currently supplied by one of the big company that doing air compressor business which
is Ingersoll Rand. Pre-filter that are located before the dryer is a coalescing filter type.
Coalescing filter can remove the contaminants such as aerosols of water and oil. This
filter removes this unwanted particles by causing it to unite or coalesce into droplets.
10

The combined droplet will gain it mass will accumulate at the bottom of the filter
cartridge due to gravity. The type of filter that used in OGT are capable to remove
effectively and efficiently about 0.5 mg/m3 to 0.01 mg/m3 of oil mist. In the common
practice of oil and gas industry, coalescing filter is applied before any dryer which the
contaminant especially from the oil will damage the drying medium.

Figure 2.2.2: Coalescing Filter used in OGT

After the compressed air enter the pre-filter which are the coalescing filter, the
air will go through another filter which call after filter. After filter is an air pre-filter
type which used to trap dust and unwanted particles. HE 350 manufactured by
Ingersoll Rand that used in OGT are capable to remove dirt particles effectively and
efficiently from 5 down to 0.01 microns.

Air Dryer
After the compressed air filtered by the coalescing filter to remove the aerosol
and mist and also the pre-filter to remove dust, the compressed air will enter into the
air dryer. This is because the coalescing filter cannot remove water vapor from the air.
The one that used in OGT is desiccant air dryers. The basic operating principle of the
desiccant dryer is by using adsorption concept.

11

The adsorption occurs inside the dryer when the water vapor molecules are
captured on the surface of porous desiccant. As adsorption concept are applied, the
drying process are completely reversible and repeatable by purging the air. The reverse
process is called regeneration in the common term. In OGT, there are two dryer system
which are D5430A and D5430B. One of the dryer will be on service and the other one
will be as backup. Each of the dryer have two drying vessel. In normal operation, one
vessel will be on service and the other one will undergoes regeneration. The vessel on
service will adsorb the moisture on the air while the regeneration will desorb the
moisture from the desiccant. The vessel will switch their function from service to
regent approximately around 5 minutes. This system are control by the junction box

On Service

Regeneration

Regeneration

On Service

located at the middle of both vessel which will control the anti-surge valve.

Figure 2.2.3: The Flow of the air in the dryer vessel during on service and
regeneration

Based on the Figure 2.1.4, basically the process of the regeneration and drying
services are control by the anti-surge valve (ASV) which are for this case ASV5430A,
B, C and D. The valve ASV5430A and B are used to control the flow of the compressed
air to the dryer vessel while ASV5430 C and D are used to control the flow to the
atmosphere.

12

As other equipment, dryer also have its own maintenance schedule. The dryer
that used in OGT contain desiccant to trap the moisture in the compressed air.
Desiccant is an activated alumina need to change every 3 years. The desiccant also
need to be replace if the dew point cannot be achieve. Dew point can be describe as
the temperature at which air is saturated with water vapor or gaseous state of water
(Marc. L, 2014 http://www.livescience.com/43269-what-is-dew-point.html). If the
dew point of the compressed air cannot be achieved, the water vapor will not
undergoes condensation and remain in the air and go to the equipment
The Flow of the Air System
In general, the flow of the air system for the industrial plant are almost the
same. The process flow of the instrument air compressor starting from the air intake
into the instrument air compressor. The air will be compressed and then cooled inside
the instrument air compressor. The compressed air will be store into the air receiver
tank. For OGT, the technical ID for receiver tank is V4820. From the V4820, the
compressed air will be divided into two which are a line to V5410 which is the vessel
for service air and the other one will go to the dryer.
The dry compressed air or known as the instrument air will store into V4890.
The instrument air compressor will load the compressed air until both of the vessel
that contain services air and instrument air reach the certain pressure.

Figure 2.2.4: The Typical Plant Air System

13

Instrument Air Compressor

Instrument air compressor is an air compressor that supply compressed air
which will go through air dryer before it supply into the equipment. Lee (2015) has
mentioned that an instrument air compressor are used to controls the use of air
operating valves especially in pneumatic instruments. Air compressor is an equipment
that used to supply instrument air can be in various types and sizes and the common
used are the rotary screw type and the other one is reciprocating piston type. The types
of the air compressor are determine by the mechanism of the compressor to compress
air.
The rotary screw type air compressor is a heavy duty compressor which is able
to function or run 24 hours a day continuously without overheating (A&W Compressor
& Mechanical Service, Inc., n.d.). Most of the industries used this kind of air
compressor due to the capability to be utilized for jobs that required 20-30 horsepower
or more. The rotary screw type air compressor works by interlocking two screws to
compress air. Even though the cost of the rotary screw types is a little bit higher, but
the efficiency and the capability of this type of air compressor to handle the plant is
balance with the initial cost and maintenance. Rotary screw compressor normally will
come in single or two stages. The single stage is a bit costly due to the motor run
constantly with the steady output air. The energy efficiency which are the two stages
will cause the difficulties in maintaining the output air as the cost to the energy
efficiency.

Figure 2.2.5: The Compression Process in the Screw Type Air Compressor

14

Another types of the air compressor that commonly used is reciprocating

compressor. According to A&W Compressor & Mechanical Service, Inc. (2015),
reciprocating compressor is an old technology over hundred s of years which used
powerful pistons to compress air. This kind of compressor is very efficient and cost
effectiveness in a smaller application which are about 30 horsepower or less. The
advantages of the reciprocating compressor is it can produces steady air output. This
compressor can be maintenance-free for quite a long time, but once it break the repair
cost will be higher compared to other compressor. The other disadvantages of
reciprocating air compressor is the noise pollution. The sound created by the
compressor is louder than the sound produce by screw type air compressor.

Figure 2.2.6: The Working Principle of Reciprocating Type of Air Compressor

15

Mechanism of the Screw Type Air Compressor

Compressed Air
Air Filter

Radiator
Separator
Tank

Coolant Filter
Thermostatic
Valve

Figure 2.2.7: the Process Flow of the Air Compressor

Inlet Air Filter
The air compression process in the instrument air compressor is beginning
from the air filter. The atmospheric air will be entering the air inlet and going through
the air filter. The main purpose of the air filter is to trap the unnecessary particles that
in the atmospheric air before it enter the air compressor. The air filter that used in
K5410B need to be replace after 2000 to 4000 hours of used. It also depending on the
environment.
The air intake are control by the plunger. The plunger will open the air inlet to
allow the air to come in. The air will be entering the air compressor during the pressure
in the plant are dropping. The supplying the air into the plant system is called loading
process. During the loading process, the air will enter from the inlet and compressed
before it supply into the plant. The plunger will closed the air intact process called
unload. During unload process, the motor of the compressor still running but the inlet
and the discharge of the air compressor will be closed.

16

Figure 2.2.8: The Air Filter of the Air Compressor

Separator Tank
Separator tank is a tank that used to separate the lubricant oil or coolant with
the compressed air. The separator tank or also known as coolant separator have two
stages of the separation which are the first stage is mechanical separation of coolant
from the compressed air. The second stages are by using separator element that used
to filter the excessive oil from the air that cannot be removed by mechanical separation.
The separator element require maintenance activities which are need to be replace after
4000 hours or 80 kPa at full load.
Coolant separator also function as the coolant reservoir or storage. The capacity
of the tank is up to 34.2 liters of the coolant. On top of the tank has minimum pressure
check valve. The main purpose of this valve is to control the air to exit from the
separator tank after reach certain pressure. It also used as the check valve that prevent
the discharge air from flowing back into the separator tank.

17

Coolant + Compressed Air

(Discharge)

Separator
Element

1st Stage of Separation

(Mechanical Separation)

2nd Stage of Separation

Coolant + Compressed Air

(Inlet)

Coolant
Collector

Figure 2.2.9: The Separation Process inside the Coolant Separator

Figure 2.2.10: The Separator tank of K5410B in OGT

18

Thermostatic Control Valve

Thermostatic control valve is a valve that controlling the flow of the coolant
based on the temperature. The thermostatic valve will allow the hot coolant to enter
the radiator for cooling purpose before it enter back into the air end. The thermostatic
valve will open the flow to the radiator at 70 C to 75 C. If the temperature of the
coolant is below than 70 C, the thermostatic valve will closed the flow into the radiator
and the coolant will flow into bypass path. The main reason of the bypass line is to
prevent the coolant from overcooled which will affect the viscosity of the coolant.
The coolant of the air compressor is used to absorb heat from the compressor.
It also used in the oil supply type compressor to increase the compression ratio of the
air. The compression of the coolant with the air caused the temperature of the coolant
increased. The total heat absorb by the coolant are from the compression of the coolant
itself and also from the heat of the body of the compressor.

Figure 2.2.11: Thermostatic Control Valve in K5410B

19

Coolant Filter
Coolant filter also one of the important part of the air compressor which are
used to remove the dirt particles from the coolant system. The dirt particles need to be
removes to avoid the pipe clog. The coolant filter that used in OGT need to be change
after 150 hours from the installation day and then every 2000 hours.

Figure 2.2.12: The Author Studying about the Coolant Filter

Cooling System of the Air Compressor

K5410B is an air cooled type of air compressor. This is because the compressed
air and the coolant of the air compressor is cooled by using cooling fan. The
compressed air increase in temperature after the compression process as stated in the
ideal gas law formula.

20

Ideal Gas Formula:

=
Where: P

= Pressure

= Volume of the Gas

= Number of Moles of the Gas

= Ideal Gas Law Constant (a proportionality constant)

= Temperature

Based on the ideal gas law formula, the temperature of the gas are proportional
with the pressure. So when the pressure is increase, the temperature also will become
higher. The compressed air and the coolant will enter the radiator to be cooled by the
air flow by the cooling fan.

21

CHAPTER3: METHODOLOGY
3.1 STUDY METHODOLOGY
In order to complete this project, several steps or methods are used to gather the
information and data that relevant. The steps or method used can be simplified as
below:

Problem Identification

Scope of Study

Objectives

Data Gathering

Data Analysing

Results and Findings

Solutions and Recomendations

Conclusion

Final Report
Figure 3.1.1: Methodology of the Project
22

3.1.1 Problem Identification

The author is assign under Peninsular Reliability and Maintenance (PRM)
supervise under Senior Maintenance Engineer was monitoring the frequent
maintenance activities of all equipment in OGT. Based on the analysis, one of the
critical equipment that frequently failed to operate in instrument air compressor. After
a few discussion with the engineers and technician regarding the instrument air
compressor, most of the instrument air compressor failed were due to high temperature
issue. Since the instrument air compressor is a critical equipment in OGT plant, the
failure of the instrument air compressor can be consider as the high priority issue and
need to be tackle as soon as possible.
3.1.2 Scope of Study
This project are involving a few scopes of studies especially in mechanical
engineering, chemical engineering and electrical engineering fields. The scope of
study are narrow down to the troubleshooting which focusing to the cooling system of
the equipment which high possibility the cause of the high temperature issues. The
data or the details of each part of the equipment also need to be study in order to
complete this project
3.1.3 Objectives
The author has determine the objectives of this project based on the problem
statement. The objectives are use as the guideline for the whole project to make sure
the project can achieve the target within the limited time.
The objective of this project are:

To study about instrument air compressor

To find the root cause of the instrument air compressor failure due to high air
end temperature issue

To propose the solution based on the outcomes and the root cause of the failure

To suggest any recommendation and precaution that need to be consider based

in the failure

23

3.1.4 Data Gathering

A few method or resources that taken by the author in order to collect all the
data that require in order to do this project. The data or the information for the
instrument air compressor are gather by do the research on the internet, journals,
articles and the books. The information also collected based on the knowledge sharing
from the technician especially from the mechanical maintenance team and the
engineers. The author also joining the troubleshooting activities with the maintenance
team to get the data such as temperature reading. All the data are compile and used as
the reference in order to find the best solution.
3.1.5 Data Analyzing
All the data that has been collected from the authors self-research,
troubleshooting activity and the sharing knowledge are analyzed and do the further
study in order to solve the issues. The information regarding the instrument air
compressor part are used to identify which equipment that need to be focus. This is
important due to the time constraint. The temperature that recorded during
troubleshooting activities are transform into the graph in order to see the pattern of the
temperature rise for the internal part of the instrument air compressor.
3.1.6 Result and Findings
The findings are made after completed the data analyzing. Every findings that
were found has been tried to find the best solution for the problem. The brainstorming
between the engineers and the contractor based on the finding and the result to get the
solution.
3.1.7 Solutions and Recommendations
Based on the result and the findings, the solution was obtained. The solution
will be consider as success after the rectifying process completed and the instrument
air compressor are back online. Based on the troubleshooting activities, several
recommendations are proposed in order to make sure the problem will not happening
again.

24

3.1.8 Conclusion
The author will conclude the project can be consider as success or fail based
on the solution. The project will be consider as success if the instrument air compressor
can operating as normal condition and pass the endurance test for 72 hours.
3.1.9 Final Report
All the data collected starting from the beginning of the project will be compile
as a report. The report will be used as the reference for the person in charge if the
problem is happening again in OGT. The report also will be submit to UTP supervisor
to be review and evaluate.

3.2 KEY MILESTONE

WEEK
1

WEEK
2-3

WEEK
4-11

WEEK
12-13

WEEK
14

Confirm and finalize the Student Industrial Project (SIP) title

Planning and organizing the project

Working on the project

Join troubleshooting activities

Compile all the data in form of final report

Submit the final report to HC and UTP supervisor

Evaluation by HC and UTP Supervisor (Presentation)

Figure 3.2.1: The Milestone of the Project

25

3.3 GANTT CHART

Table 3.3.1: Gantt Chart of the Project

Project Planning

Week
1

10

11

12

13

14

Project Title Proposal

Project Title Confirmation
Identifying Problem
Information Gathering/ Collection
Drafting the Project Report
Troubleshooting Activities
Analyzing collected data
Result and Finding
Rectifying Process
Monitoring the Result
Completing Final Report
Submission and Evaluation for the Project
Report

26

CHAPTER 4: RESULT AND DISCUSSION

4.1 Findings
Instrument air compressor K5410 A and B is a new air compressor that install
in OGT. It used to be the main supply for compressed air into the OGT air system. The
new compressor K5410 will take over the main function of the old compressor
(K5400). K5410 will be operated by lead and lag concept which are one of the
compressor will on service to supply compressed air (lead), and the other one (lag)
will be used as stand by in case of the lead air compressor failed. This lead and lag
operation will be switch about 2 weeks.
K5410 is a rotary screw type compressor model SSR-100 HP manufactured by
Ingersoll Rand. It is a heavy duty air compressor with the power of 100 HP and can
operate 24 hours without any overheating issue.
In February 2015, one of the air compressor in OGT which is K5410B was
reported tripped. The tripped of the compressor was reported due to the high
temperature reading at air end part of the compressor. By referring on the manual
operation book supplied by the manufacturer, the high air temp issue will cause the
compressor trip when the temperature reach 110 C or equivalent to 230 F. Before the
compressor trips, the alarm will be trigger at 106 C. This temperature are read by the
temperature sensor located at the air end part of the air compressor.

History of High Air Temperature Issue in OGT

The high air temperature issue is not the first time occurs for the compressor in
OGT. The same problem occurs at the K5410A on June 2011 which are cause by the
sensor and electronic card faulty. The temperature read by the sensor was 110 C while
the current is about only 82 C which are 34.15% of the percentages error. The
percentages error can be calculate by using the formula below.
=

100

The issue has been tackle by replace the new sensor and the electronic card of
the K5410A.
27

4.2 Data Gathering and Analysis

As this project is a troubleshooting project, the main objectives is to find the
root cause of the specific problem. For this project, the issue is the high temperature at
the Air End part that cause the instrument air compressor to trip. In order to find the
root cause of this issue, the author has taken several procedure in order to find and at
the same time to carry out with the solutions.
Fault Tree Analysis
One of the method that use by the author to identify the root cause of the issue
is by using Fault Tree Analysis (FTA) method. FTA is a method that used to think
through all the possible causes of the problem all loss and find the most probable
sequence of the events that leading to the main problem.

Clog in the radiator

Thermostatic Valve
Failure
Flow of the coolant
Insufficient Volume
of coolant
Cooling System
Failure

Clog at the Coolant

Filter
Motor Shorted
Cooling Fan Motor
Not Functioning

High Air Temperature

Error Temperature
Reading
Sensor Failure

Obstacle Prevent Fan

to Rotate
Sensor are Out of
Claribation
Sensor Faulty

No Temperature
Reading

Broken/
Disconnected Cable

Figure 4.2.1: Fault Tree Analysis for High Air Temperature Issue

28

4.2.1 Troubleshooting Activities

Replacing the Temperature Sensor
The faulty tree analysis is used as the troubleshooting guideline which means
the troubleshooting are focusing more on the listed probability of the failure. The
troubleshooting activities are started based on the troubleshooting method that supply
by the manufactured company specific for the high air temperature issue. The first
activity are focusing on the temperature sensor that attached to the air end part of the
air compressor. This is due the previous problem that happened to the K5410A that
caused by the failure of the temperature sensor. The troubleshoot activity is including
replacing the temperature sensor for the K5410B itself. But the changing of the
temperature sensor still did not solve the high air temperature issue. In other word, the
old sensor is in good condition and not the cause of this issue.

Check the Cooling Fan Motor

The other potential cause that possible contribute to the high temperature at air
end is the cooling system of the air compressor. The cooling fan is one of the important
part in cooling system. Main function of the cooling fan is to cool the coolant or
lubricant oil that absorb the heat from the air end part. During the troubleshooting
process, the fan were confirmed in good condition and functioning. The fan blade also
rotating with the normal speed during test run. The bearing of the motor of the cooling
fan also inspected and it still in the good condition.

Radiator Cleaning
In normal condition, the coolant will be flow into the radiator to be cooled.
The air will be blow to the radiator and the convection of heat transfer occur between
the coolant and the air blown by the cooling fan. There are several pipe that have fin
inside the radiator which are used to flow the coolant and the compressed air. In order
to make sure the coolant to be cooled, the coolant need to be always flowing through
the pipe inside the radiator.

29

As the high temperature at the air end is caused by the high temperature of the
coolant, the maintenance team and also the author suspecting that there are clog inside
the radiator that cause the inefficiency of the cooling process. The radiator has been
sent to the outside vendor for the cleaning the pipe inside the radiator.
After the radiator has been receive from the vendor and had been cleaned, the
radiator was installed and the compressor was ready to test run. As the result, the
instrument air compressor was tripped again with the same error code. Even though
the cleaning of the radiator is not the cause of the problem, at least we eliminate one
of the possible cause of the problem that are based on the fault tree analysis.

Check the Flow of the Coolant (Change the Filter and Other Normal
Maintenance Operation)
After several troubleshooting measure has been done, the maintenance team
tried to come out with the simple maintenance activities as what has been told by
Confucious, Life is simple, but we insist on making it complicated. The several
activities that has been done is changing the air filter and the coolant filter. The main
reason of changing the filter is to make sure there is no clog inside the filter that will
give impact to the coolant flow. The other maintenance activity is change the coolant
in case of the old coolant is already out of the specification.

Figure 4.2.2: Troubleshooting Activity at K5410B

30

The temperature of the pipe in the cooling system has been monitor. The
activity was conducted to check the flow of the coolant and the same time, it used to
identify the location that has the highest temperature that has high possibility to be the
cause of the high temperature of the coolant. The temperature reading of the K5410B
that faced high temperature problem was compared with the K5410A that is running
in normal condition. The temperature was taken by using temperature gun at the
marked point. The point selected are focusing more on the air end part and the inlet
and discharges from the thermostatic valve. The average temperature of each point is
calculate and transfer in the form of graph to make it easier for to be analyze.

31

Table 4.2.1: Temperature Reading for K5410A and K5410B during Loading and Unloading Condition
K5410B

K5410A

Condition

Unload

Load

Reading

Air End

172.8

173.5

3
4
5
6
7
8
9
10

174.0
175.4
177.2
181.9
181.8
189.6
190.2
191.4

Temperature (F)
Inlet Thermostatic
Discharge
Air End
Valve
Thermostatic Valve
144.2
162.9
168.4
144.9
166.8
179.7
171.0
171.6
174.0
177.2
188.4
184.0
186.0
187.3

143.8
146.0
147.4
145.8
152.2
152.2
149.4
150.2

169.6
169.2
171.4
196.3
198.5
203.0
230.1
231.8

Inlet Thermostatic
Valve

Discharge
Thermostatic Valve
156.3
155.2
161.5
159.8
163.1
165.0
168.3
185.8
187.5
178.2
192.5
195.3

165.3
167.4
169.2
189.5
191.7
198.2
221.3
223.1

32

Temperature (F) against Time (min)

178
176

174
172
170
168
166
164
162
0

0.5

1.5

2
K5410A

2.5

3.5

4.5

K5410B

Figure 4.2.3: Graph of the Temperature against Time at Air End Part during Unloading

Temperature (F) againts Time (min)

240
220
200
180
160
140
120
100
0

0.5

1.5

2
K5410A

2.5

3.5

4.5

K5410B

Figure 4.2.4: Graph of the Temperature against Time for Air End Part during Loading

33

Based on the graph plotted for the unloading time, K5410A is refer as the normal
condition of the air compressor while K5410B is the air compressor that are undergoes
troubleshooting activity. During the unloading time, the K5410B is shown the lower
temperature compare to normal condition. This is due to the temperature was taken
during the starting of the test run activity. The temperature of the coolant was
increasing dramatically from 162.9 F to 169.6 F between the first until the third
minutes. The loading time shows the temperature of K5410B is higher than K5410A.

Temperature (F) against Time (min)

250

240
230
220
210
200
190

180
170
160
150
0

2
K5410A (Unload)

K5410B (Unload)

8
K5410A (Load)

10

12

K5410B (Load)

Figure 4.2.5: Graph of Temperature against Time at Air End Part for Loading and
Unloading time

34

By referring to the Figure 4.2.5, the coolant in K5410B shows the increasing
in term of the temperature rapidly from the starting time for the test run until the
loading before it start to tripped. While the K5410A that can be refer as the normal
condition of the air compressor is increasing from unload to load time steadily and did
not reach the temperature limit. The highest temperature recorded for the K5410A is
only 191.4 F compared to 231.8 F for K5410B. The cooling system of K5410B seems
not functioning by referring to the huge different of the temperature between both air
compressors. The maintenance team start to focus more on the temperature reading at
the cooling system and specific to the thermostatic valve which are used to control the
flow of the coolant to the cooling system.

Based on the analyzing, the coolant of K5410B seems not cooled by the
radiator. This is based on the observation from the temperature of the coolant at the
inlet and the discharge of the thermostatic valve. The temperature of the coolant
discharge from the thermostatic valve supposed to be cooler than the inlet. This is due
to the coolant has been flow to the radiator to be cooled before in entering back to the
air end part. After some investigation and discussion, the thermostatic valve was
suspected to have problem which are the thermostatic valve kit that unable to control
the flow the coolant into the radiator.

From the data, the thermostatic valve kit supposed to be open the flow of the
coolant into the radiator. The thermostatic valve are set by the manufacturer to be open
to allow the coolant to enter the radiator at 70-75 C (158-167 F). By referring to the
data at K5410B, the temperature are at 185.8 F for the inlet of the thermostatic valve
which is higher than opening temperature. But the temperature at of the coolant at the
discharge keep on increasing. This phenomenon shows that the coolant are directly
flow to the discharge of the thermostatic valve without go thru the radiator.

35

To
Compressor

RADIATOR

Thermostatic
Valve Kit
(Closed)

Notes:
Cold Coolant

From
Separator Tank

Figure 4.2.6: The flow of Coolant in Thermostatic Valve (Cold)

To
Compressor

RADIATOR

Thermostatic
Valve Kit
(Open)

Notes:
From
Separator Tank

Hot Coolant
(T >= 70 C)

Cold Coolant

Figure 4.2.7: The flow of Coolant in Thermostatic Valve (Hot)

36

4.3 Calculation
Cost Saving
This project was conducted by the OGT Maintenance Team itself to supporting
the idea and initiative from the higher management to do the First Line Maintenance
(FLM). FLM is one of the program that use as the cost saving program in PETRONAS
Carigali Sdn. Bhd. in order to minimize the manpower cost due to maintenance
activities. The troubleshooting and rectifying activities that need to be done in the plant
will be handle by the PETRONAS staff at the first, and only call for support from the
other vendors if needed.
Rectifying K5410B is one of the good example of the successful FLM program
which save approximately about RM 33500 without any incident happen. The cost are
calculated by based on the manpower cost, avoid Emergency Shut Down for the plant,
and etc. The calculation is shown as below:

i.

Troubleshooting and Rectifying Activities:

Table 4.3.1: Estimated Cost for Troubleshoot and Rectify Activity by Vendors
No

Fee (s)

Cost (MYR)

Manpower per day X 10 Days (troubleshoot + rectify)

3000 X 10 = 30 000

Installation Fees

Spare Parts and Tools

Thermostatic Valve

Ultra Coolant (20 L)

Air Filter

Coolant Filter

Other Tools

3500.00

3695.50

TOTAL

37195.50

37

Based on the estimated total cost for the troubleshooting and rectifying activity,
the grand total is about RM 37195.50. Since this program is conducted or done by the
OGT team itself, the cost of the manpower and installation fees can be deduct. So the
total cost that need to rectify K5410 reduced to RM 3695.50 only for the purchased of
the spare parts. The amount of cost save from the troubleshooting activity is about
RM 33500.

( 10 )

Figure 4.3.1: Formula to Calculate the Total Cost Saving

ii.

Avoiding Emergency Shut Down (ESD)

As per discuss from the beginning of this project, the author decided to conduct

this project is due to the important and critical function of Instrument Air Compressor
in the plant that might lead to ESD due to the its failure. In OGT, the gas and
condensate are exported to Gas Processing Plant (GPP) every day without stop. The
only reason the exporting process will be stop is because of the planned plant shut
down or ESD.
The ESD will caused the OGT product cannot be export. This will cause the
lost in term of profit to OGT itself. The lost are calculated by refereeing the total hour
of the operation stop, and the amount of the product that failed to export.

38

Nominal Gas Exported per day

= 536 mmscf/d
Average Condensate Exported per day (August-October 2015)
= 3931 bbl/d
Approximate Gas Price (OGT)
= RM 14 000 per mmscf
Approximate Condensate Price (10% less than Crude Oil Price)
= 90% X RM 209.24 (Current Oil Price- 16th Sept 2015) = RM 188.31 per bbl

Estimated Loss of Profit due to ESD for one hour:

Gas

: 536

14000 24

= RM 312 666.67

Condensate : 3931 188.31 24

= RM 740259.58
TOTAL Loss = RM 312 666.67 + RM 740259.58
= RM 1 052 926.25

39

CHAPTER 5: CONCLUSION AND RECOMMENDATION

5.1 Conclusion for the Project
As conclusion, the project can be considered as a successful project seems the
objectives are achieved. The instrument air compressor K5410B which are the subject
of the project to rectify is running in normal condition after the project is done. The
main solution for the problem is by replacing the thermostatic valve that was suspected
the cause of the issue after the analyzing of the data and information.
In this project also the author successfully give some contribution to the OGT
itself from the amount of the cost that had been save throughout this project. The total
cost saving is about RM 33500. The large amount of the saving can be used to other
maintenance activity or any other project for the improving the efficiency and the
reliability all equipment in OGT.
For the future benefits, this project also will be keep by the author, UTP and also
for the OGT itself. It will help the maintenance team as the maintenance record
activities and as the reference of the issue of the high temperature issue at the air end
part happen again. It also can be used as the learning sources for the new staffs or
trainees to learn more details about the instrument air compressor.

5.2 Recommendations
After the project has been completed with the success, some of the
recommendation has been suggested in order to improve the air system in OGT
especially on the instrument air compressor. Besides that, one of the main objectives
of this project is to suggest some recommendation based on the issue. The suggestion
were suggested based on the experience and the problem faced during troubleshooting
and rectifying activities.

40

5.2.1 Reconfirm the Material for Thermostatic Valve Kit

One of the recommendation that suggested based in the problem faced during
rectifying activity is the maintenance team need to make sure the type of the
thermostatic valve used. This is because of after the team suspecting the high
temperature issue is caused by the thermostatic valve that unable to control the flow
of the coolant into the radiator.
One of the suggestion is to replace the thermostatic valve kit only which are the
controller for the coolant flow. But after replacing the thermostatic valve kit, the
problem is still occurs. After have some advices from the manufacturer, the
manufacturer ask to replace the whole set of the thermostatic valve. The manufacturer
inform that the new thermostatic valve part cannot be used with the old thermostatic
valve part.
To avoid the same mistakes from happening again, it actually the responsibility
of the manufacturer to inform the end user regarding any update or modification of the
products. The end user also need to take initiative to ask the manufacturer every
purchased details even though the product is still same product number and type.

5.2.2 Track and Check the Instrument Air Line System in the Plant
The other recommendation that need to be implement in order to improve air
system in OGT is all workers including the PCSB staffs and also contractor need to
check and report if there any leakage on the instrument air system pipeline. This is due
to the instrument air pressure for the whole plant are dropping faster than it should be.
The drop of the instrument air pressure cause the instrument air compressor to keep on
running to load the instrument air. The loading of air for the instrument air compressor
not only will cause the increasing in temperature of that equipment, but it also will
reduce the lifespan of the instrument air compressor itself.
A campaign about finding the leakage in OGT need to be frequently
conducted to make sure the leakage can be detected and repair as soon as possible.
From the campaign itself, it can help the workers to alert with their surrounding and at
the same time can help the OGTs management itself.

41

5.2.3 Upgrade the Air System in OGT

A study regarding the air system in OGT has been conducted in order to
review the amount of the air required for the whole plant. After the calculation has
been done, the total amount of air that required in OGT is about 3406 scfm or
885.563 /. The total air consumption are calculated by adding the continuous air
consumption with the intermittent consumption. The total of both intermittent and the
continuous will be added by 30% of uncertainties that stated on the PTS.
With the current upgrade of OGT facilities which are the new solid-liquid
removal project, it will required an additional amount of air supply to control the valve
and the other equipment. Therefore, the air system in OGT also need to be improved
to avoid the plant shut down due to not enough air consumption.

5.3 Impact
The impact of this project is basically give benefit for the OGT especially in
term of cost saving. As the author has been calculated for this project, the total of cost
has been save throughout this project is about RM 33500 and preventing loss about
RM 1 052 926.25 from the ESD. The amount of money can be used for other activities
of any other project to improve the OGT reliability and efficiency.
The project also give some impact toward the people which are the staffs in OGT
especially for those who are involve in this project. The impact is can be classified by
the experience and knowledge gain regarding the air compressor and its part. As some
people say that experience is the best teacher. The experience in troubleshooting the
air compressor is very valuable. The experience cannot be gain in normal operation
time since the air compressor is a critical equipment that need to be online most of the
time.
Furthermore, this project also give some impact toward the environment. By
referring to the PTS, two instrument air compressor need to be in good condition for
normal operation. One of the instrument air compressor will on service mode and the
other one will used as backup. If the compressor K5410B cannot be rectify soon, OGT
42

need to use the portable air compressor as the backup for K5410A. The portable air
compressor used diesel to operate. The harmful gas released from the exhaust of the
portable air compressor diesel engine. By reducing the down time of the K5410B, the
demanding to the portable air compressor will be decrease. In line with that,
automatically the amount of the harmful gas released from the portable air compressor
can be reduces.

5.4 Relevancy to the Objectives

On the beginning of the project, the authors has been highlighted that this project
is focusing to the four main objectives. The objectives are used in order to achieve the
goals for this project which are troubleshoot and rectify the high temperature issues
for the K5410B. One of the objectives that stated by the author is to study the
instrument air compressor. In the literature review, the author has study and mention
about the instrument air compressor and its parts. The purpose of the study is to
understand the function of each part in instrument air compressor. Based on the
function for each part, the author and the team can identify and classify which part that
need to be focus on and which are most related to the current issue.
The second objectives are to find the root caused for the high air temperature
issue. From the result and discussion, the author has been describe some analysis that
has high possibility to become the factor of the high temperature issue. There are
several method that has been done starting from the temperature sensor until the
cooling system of the air compressor. After gone through the troubleshooting
activities, the third objective of the project which are to proposed the based outcomes
for the current problem are discuss in the discussion to the conclusion part.
The last objectives of this project is to give some suggestions and
recommendation based in the current problem. By referring from the troubleshooting
and rectifying activities, the author and the team list down the problem and challenge
that happen during the project was conducted. The recommendation has been
suggested in the conclusion and recommendation part by the author. This
recommendation are for the benefits and precaution for future staffs and worker as the
reference in case the same problem happening again.
43

5.5 Suggested Future Work for Expansion and Continuation

The facilities in OGT are having improvement from the time to time in order to
improve the efficiency of the operation process. As the author has been suggested in
the recommendation part, the further work that need to be done is to upgrade the air
system in OGT. This is based on the calculation of the air consumption for the whole
plant is can be consider in below normal condition. The Facilities Improvement
Proposal (FIP) has been raised by the maintenance engineer which are also one of the
team member for this project to improve the current air system.
The FIP are focus on the upgrading the air compressor to the higher capacity of
the air compressor. The FIP is still need to be review by the higher management and
will be proceed after get the approval.

44

CHAPTER 6: SAFETY TRAINING AND VALUE FOR THE

PRACTICAL EXPERIENCE

6.1 Lesson Learnt and Experience Gained

The author was given the opportunity to become an intern in Onshore Gas
Terminal (OGT) under Peninsular Reliability Maintenance Terminal (PRM-T) and
supervise by the Senior Maintenance Engineer. As the author are from the mechanical
engineering background, a lot of knowledge and experience has been share by his
supervisor which also coming from the mechanical engineering field. The knowledge
also shared by the other engineer and staffs in OGT starting from the Terminal
Superintendent of OGT until the assistant technicians.
The basic knowledge that gained by the author related to the working in plant is
about the rules and regulation. In PETRONAS Carigali Sdn. Bhd. (PCSB), one of the
rules that need to be follow of all the time during inside the plant is Zero Tolerance
Rules or called ZeTo Rules. ZeTo Rules are basically the rules that related to the while
working in the processing plant area. The contain of the ZeTo Rules are consist of the
Permit To Work (PTW) system, Personal Protective Equipment (PPE), chemical
handling and etc.
After undergoes about 7 month in OGT, the author also learn a lot of engineering
knowledge that not limited to the mechanical engineering field only. The author also
get the knowledge about the process, electrical system, instrument system and also the
water treatment system. The knowledge are gained from the help of the operation
engineer, technician and also the supervisor.
Another valuable experience gain by the author during internship period in OGT
are experience of two time plant turn around. In 2015, OGT was having two partial
turnaround which were on August 2015 for Joint Delivery System (JDS) and on
October 2015 for Resak Delivery System (RDS). The author was luckily to experience
both turnaround compared with the other intern which only experience one time
turnaround. From the turnaround, the author experience the real situation of the plant
turnaround where the all maintenance activities that cannot conducted during normal
operation was occur. The activities are including the change of larger valves, welding
45

and cutting the pipeline, and other jobs. The author also join operation team from the
isolation process until the plant are back online. The experience gain by the author can
give the view of the real situation in working in oil and gas field.
By completing this project, the author also experience how to work conduct the
troubleshooting activities with the various kind of peoples or levels. The author also
learn more on the plant air system especially the instrument air compressor. This
experience and knowledge might be useful and helpful for the authors during his final
year of study in UTP.

6.2 Leadership, Team Work and Individual Activities

Leadership skills are one of the important criteria in order to work as the PCSB
staffs. It actually not only for PCSB, but also to other company as well. The leadership
only can be gain from the guidance and practices. The author has an opportunity to
develop his leadership skills by becoming the leader for the interns during the Human
Recourses (HR) visit to OGT. The author was given the responsibility to conduct the
plant visit which are require to explain about the process in OGT. In line with this
responsibility, the author at the same time can gained the confident level to talk in front
of the people during the visit.

Figure 6.2.1: The Author Lead the Site Visit with the Visitor

46

Teamwork also one of the skills that needed in engineering field of work. Any
engineering project required more than one engineering skills starting from the
mechanical, electrical, chemical and other engineering field. The author learnt how to
work together as a team with various level of people in OGT. As the author will
become an engineer for the future, that is really important to know how to
communicate with other worker especially with the technician for the plant itself.
During the internship period, the author was actively involved in maintenance
activities and project inside the OGT. The involvement with the engineers and
technician develop the teamwork skill of the author.

Figure 6.2.2: The author with the OGTs Engineer and Technician after Installation
Cross-Bridge at IETS Project

47

6.3 Business Values, Ethics and Management Skills

As the intern in OGT, the author also need to be the good attitude that represent
as the OGTs staffs. The work ethics was evaluated as the value of the employee. The
basic attitude that need to be taken seriously is the punctuality. Punctuality are
covering starting from the coming to work, completing the given task within allocated
time, and many more. In addition, respect is also one of the ethic that needed for
everybody to be as the good employee. Respect is not limited in term of ages, but also
in term of ideas or opinion from the other. The author experience a lot of meeting in
OGT and learn how to be respectful to others ideas and opinion.

6.4 Problem or Challenges Faced and Solutions to Overcome Them

Throughout almost eight months training in OGT, a lot of problems or
challenges that faced by the author especially during conducting this project. But every
challenges need to be faced in order to improve ourselves to be better man.
i.

Difficulties in Communication
Since this project are troubleshooting project, most of the activity was dealing

with the technician. Most of the technicians in OGT are the local people of
Terengganu. As the local people have their own dialect, the communication between
the people from other states is a little bit challenging. In order to avoid miss
communication between the author and the technician, the author take his own
initiative to learn the some dialect of the local people. The author also always
accompanied by the other staffs which can used as the translator for certain word. This
problem only happening at the beginning of the project. After a few weeks of learning
and training the dialect, the author are able to understand and communicate with the
local technician.

48

ii.

Approaching Different Level of People

One of the challenges while conducting the project is managing different level

of people. Some of the people have its own way to approach other people. Some people
can be approach by show same interest about something, sharing story or experience,
work together as a team and other method. While conducting this project, the other
was dealing with the various kind of the people background and age. In order to
approach different background of people, the author tried several method such as be
friendly, show some interest with the topic that shared by the person, politely asking
question and make some joke with the limit. With this method, the author was
successfully get to know and work together with the team without any problem.

iii.

Time Constraint to Completing the Report

The other challenges that faced during conducting the project is to finish the

project report within limited time. As the Student Industrial Project (SIP) was only
given for 10 to 12 weeks to be completed, the author need to balance his time between
the time for the project and the time for other daily works during internship period. By
referring to the Gantt chart, the author was able to manage his time to finish the report
within the time. This is because the Gantt chart is used as the plan for this project for
every weeks. This also explain the important of the Gantt chart in every project.

49

7.0 REFERENCES
A&W Compressor & Mechanical Service, Inc. Rotary screw vs Reciprocating
compressor: Which is the best for your Tennessee operation?. Retrieved December 6,
2015,
from
http://www.awcompressor.com/rotary-screw-vs-reciprocatingcompressor.html

Ingersoll Rand (1999). Instrument Air Compressor Operators/ Instruction Manual

Option Ingersoll Rand.

Kwok, T. K. (2009) Presentation on Compressed Air Basics- An introduction to

compressed air. Collection of Talang Enery Sdn. Bhd, Onshore Gas Terminal.

Lallanilla, M. (2014, February 11). What is dew point?. Retrieved December 6, 2015,
from http://www.livescience.com/43269-what-is-dew-point.html

Lee, E. (2015, December 4). What is an instrument air compressor?. Retrieved July
10,
2015,
from
http://www.ehow.com/facts_5626443_instrument-aircompressor_.html

Scot Foss, R. (1999, February 1). Improving compressed air system efficiency: Part 5.
Retrieved
July
6,
2015,
from
http://hydraulicspneumatics.com/othertechnologies/improving-compressed-air-system-efficiency-part-5

Shodor, & Department of Chemistry, The University of North Carolina at Chapel

Hill.
Simple
statistics.
Retrieved
December
6,
2015,
from
https://www.shodor.org/unchem/math/stats/

50

APPENDICES
Appendix 1: Schematic Drawing of K5410 A/B

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vi

Appendix 2: Pipeline and Instrument Diagram (P&ID) for OGT Air System (1 of 4)

52
vii

Appendix 3: Pipeline and Instrument Diagram (P&ID) for OGT Air System (2 of 4)

53
viii

Appendix 4: Pipeline and Instrument Diagram (P&ID) for OGT Air System (3 of 4)

54
ix

Appendix 5: Pipeline and Instrument Diagram (P&ID) for OGT Air System (4 of 4)

55
x

Appendix 6: The Points of the Temperature Reading was Taken during Troubleshooting Activity

56
xi

57