Pgb Internship 2012

7/30/2019 Pgb Internship 2012

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Industrial training report

1. Executive summaryThis 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. AcknowledgementFirst 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 14September 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. Contents1. Executive summary 1

2. Acknowledgement 2

4. Introduction 4

5. Process 9

6. Projects and activities

6.1 The safety valve project 11

6.2 Activities involved

6.2.1 Unit 4k and 8k running maintenance 23

6.2.2 Jom Sembang program 24

6.2.3 Site visit for new lube sampling point 25

6.2.4 Site visit schedule waste 28

6.2.5 Site visit to PETRONAS CUF Gebeng to collect

Demineralized water 30

7. Problem encountered and ways overcoming it 31

8. Lesson learned 32

9. Suggestion 32

10. Conclusion 33

11. Reference 33

12. List of Appendices 33


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4. Introduction

Figure 1 Petroliam Nasional Berhad

Figure 2 PETRONAS Gas Berhad (PGB) logo

PETRONAS

PETRONAS GasBerhad

Plant OperationDivision

TransmissionOperation Division

Facilities

Metering

Pipeline Compressor

Technical Maintenance

Centralised UtilitiyFacilities

Technical andFacilities

DevelopmentDivision

RegasificationTerminal Division

PETRONASCarigali

PETRONASDagangan


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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 Task

Plant Operations Division (POD) 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.

Transmission Operation Division (TOD) 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.

Centralised Utility Facilities (CUF) 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.

Technical and Facilities Development Division

(TFDD)

TFDD is the engineering and project management

arm of PETRONAS Gas Berhad. Having in place asolid 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.


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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 ofMalaysias 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.

Figure 3 KTNCS top view

Station A

Station B


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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 Station B

Unit 1,2,3 4,5

Capacity (mmscfd) 700 500

Conversion ratio 1:1.35 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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Figure 4 KTNCS organization chart

Ismail b. Othman

Kuantan Regional Operation

Mohd Faiz b.Mohd Mustafa

Executive CompressorOperation

Fazley Zulfikar b.Ismai

Technician (MT - OperationCompression)

Matsaliniah b.Yusof

Technician (MT - OperationCompression

Mohammad Faris

b. M ZayadiTechnician (MT - OperationCompression

Mat Ghani b.Mohd Salleh

Technician (MT - Process)

Mohammad Faizalb. M. Noor


Mohd Hashim b.

EmbongTechnician (MT - Process)

Norli b. Yajid


Ahmad TawfikFathir b.

MuhammadTechnician (MT - Process)

Khairul Anuar b.

MamatTechnician (MT - Process)

Ahmad Naim Abd.Rahman

Executive CompressorMaintenance

Azmi b. Mamat

Technician (MT- Electrical)

Azizul b. Hosma

Technician (MT- Electrical

Mohd Fauzi b.Mamat

Technician (MT - Mechanical)

Tahir b. Shariff

Technician (MT - Mechanical

Zamri b. Embong

Technician (MT - Mechanical

Azanmudin b.Deraman

Technician ( MT - MechanicalCompression)

Nik Mohd Fauzib. Sapian

Technician ( MT - MechanicalCompression

Ariffin b. Sulaiman

Supervisor Administrator

MohammadHusni

Muhammad SaniExecutive Compressor

Maintenance Mechanical


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5. ProcessKuantan 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, n-

heptane 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 0.004049 0.008720

CO2 0.040647 0.022521

Methane 0.910743 0.869046

Propane 0.028511 0.069902

i-Butane 0.009277 0.020331

n-Butane 0.002939 0.003100

i-Pentane 0.000880 0.001450

n-Pentane 0.000440 0.000730

n-Hexane 0.000420 0.000320

n-Heptane 0.000190 0.000060

Water 0.000316 0.000000

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

Moles of methane

flow into the

systemMoles of methane

flow out of the

systemRate 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:

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

Moles of methane

flow into the system

Moles of methane

flow out of the

system

=


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6. Project and activities6.1The safety valve studya) Introduction

The project was handed out by supervisor, Mr. Ahmad Naim, on 28 July 2012. Scope ofthe project includes:

i. Gathers required data regarding PSV and PRV at KTNCSii. 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, pilot-

operated 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 PSVtype.

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 (remotelyconnected 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.

ii. When vessel pressure is below pilot control set pressure, the relief seat ofthe 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.

iii. When the vessel pressure reaches set pressure, the pilot control relief seatopens instantaneously with the closing of lower seat. The pilot control


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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.

iv. When vessel pressure reaches re-seat pressure (typically 95% of the setpressure), 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.

Figure 5 Main valve close

Figure 6 Main valve open

dome

Main valve

Piston

Pilot

Pilot discharge

Relief seat


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b) FindingsStudies 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&IDsare 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

Figure 8 Main valve piston lift

Fi ure 7 Downward Force on Main Valve Piston


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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

No

Tag

no. Equipment

Serial

no.

Manufactur

er Model Inlet Outlet Type

Orifice

(in)

Set Pressure

(KPAG)

Relieve

temperature

(C) Drawing no.

1

PSV

1011

FILTER SEP.

V1010

VA

004779

2 CROSBY 2H3-JOS-45-A

2'' X 600 #

ANSI RF

3" X 150 #

ANSI RF

CONVENTI

ONAL 0.785 7585 64.3

CM202-020-D-

0006 (1)

2

PSV

1021

FILTER SEP.

V1020

VA

004779

2 CROSBY 2H3-JOS-45-A

2'' X 600 #

ANSI RF

3" X 150 #

ANSI RF

CONVENTI

ONAL 0.785 7585 64.3

CM202-020-D-

0006 (2)

3

PSV

1031

FILTER SEP.

V1031

98/3870

6 ANDERSON

D050HS120AK

S1100

2'' X 600 #

ANSI RF

3" X 150 #

ANSI RF

CONVENTI

ONAL 0.785 7585 64.3 2223-110-001

4

PSV

1051

FUEL GAS

FILTER

VA

004703

1 CROSBY ID2-JOS-45-A

1" X 600 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.11 7585 64.3

CM202-020-D-

0013 (1)

5

PSV

1061

FUEL GAS

FILTER

VA

004702


1" X 600 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.11 7585 64.3

CM202-020-D-

0013 (1)

6

PSV

1081 AIR RECEIVER

VA

004702

6 CROSBY 3L4-JOS-15-A

3" X 150 #

ANSI RF

4" X 150 #

ANSI RF

CONVENTI

ONAL 2.853 1380 85.7

CM202-020-D-

0015 (1)

7

PSV

1019

POWR GAS

DEHYDRATOR

VA

004702


1" X 150 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.11 7585 64.3

CM202-020-D-

0019

8

PSV

1013 FUEL GAS SKID

VA

004703

1 CROSBY

11/2 G 2 1/2-

JOS-35-A

11/2" X 150 #

ANSI RF

21/2" X 150 #

ANSI RF

CONVENTI

ONAL 0.503 3272 35

CM202-020-D-

0013 (2)

9

PSV

FUEL GAS SKID

VA

CROSBY

11/2 G 2 1/2- 11/2" X 150 # 21/2" X 150 # CONVENTI

0.503 3272 35

CM202-020-D-


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1014 004703

1

JOS-35-A ANSI RF ANSI RF ONAL 0013 (2)

10

PSV

1015 FUEL GAS SKID

VA

004703

1 CROSBY

11/2 G 2 1/2-

JOS-35-A

11/2" X 150 #

ANSI RF

21/2" X 150 #

ANSI RF

CONVENTI

ONAL 0.503 3272 35

CM202-020-D-

0013 (2)

11

PSV

1023

UTILITY GAS

SKID

VA

004703

4 CROSBY 1E2-JOS-15-A

1" X 150 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.196 825 46

CM202-020-D-

0014

12

PSV

1024

UTILITY GAS

SKID

VA

004703


1" X 150 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.196 825 46

CM202-020-D-

0014

13

PSV

1025

UTILITY GAS

SKID

VA

004703

6 CROSBY

11/2F2-JOS-

15-A

11/2" X 150 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.307 250 21

CM202-020-D-

0014

14

PSV

1071

ODOURIZER

POT

VA

004703


1" X 150 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL 0.196 690 21

CM202-020-D-

0014

15

PSV

1001

STN DISCH

HEADER

93E

00079 FARRIS

47312-

81010/SI

8" X 600 #

ANSI RF

10" X 150 #

ANSI RF PILOT N/A 7240 50

CM202-020-D-

0006(1)

16

PSV

112-1

PIPELINE

RECEIVER

KA2319

3

FISCHER

(FARRIS)

26 GC 13-140-

A10

11/2" X 600 #

ANSI RF

21/2" X 150 #

ANSI RF

CONVENTI

ONAL N/A 6895 N/A 0516-33-008

17

PSV

112-2

PIPELINE

LAUNCHER

KA2318

4

FISCHER

(FARRIS)

26 FC 13-140-

A-10

11/2" X 600 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL N/A 6895 N/A 0516-33-008

18

PSV

112S

RL

PIPELINE

RECEIVER

328896-

1-A10/R

TELEDYNE

(FARRIS) 26 GC 13-130

1.5" X 600 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL N/A 6895 N/A 0516-33-008

19

PSV

112SIL

PIPELINE

LAUNCHER

328896-

2-A10/R

TELEDYNE

(FARRIS) 26 FC 13-130

1.5" X 600 #

ANSI RF

2" X 150 #

ANSI RF

CONVENTI

ONAL N/A 6895 N/A 0516-33-008


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Table 5 Pressure Safety Valve Station B

No Tag no. Equipment

Serial

no.

Manufactu

rer Model Inlet Outlet Type

Orifice

(in)

Set Pressure

(KPAG)

Relieve

temperature

(C) Drawing no.

1PSV-2010 FILTER SEP V-2010

06-40359 CROSBY

1D2-JOS-E-45-J

1" x

600#

ANSIRF

2" x

150#

ANSI RF

CONVENTIO

NAL0.11

7585 311.36

8022-KN-DR-PR-007(1)

2

PSV-

2016 DISCHARGE SIDE

VALVE

06-

40378 CROSBY

44312T810/

S1

8" X

600#

ANSI

RF

10'' X

150#

ANSI RF

PILOT

26

7240 508022-KN-DR-PR-

007(1)

3

PSV-

2020

FILTER SEP V-2020

06-

40360 CROSBY

1D2-JOS-E-

45-J

1" x

600#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.11

7585 311.368022-KN-DR-PR-

007(2)

4

PSV-

2030 FUEL GAS FILTER SEP V-

2030

06-

40361 CROSBY

1D2-JOS-E-

45-J

1" x

600#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.11

7585 313.198022-KN-DR-PR-

011

5

PSV-

2040 FUEL GAS FILTER SEP V-

2040

06-

40362 CROSBY

1D2-JOS-E-

45-J

1" x600#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.11

7585 313.198022-KN-DR-PR-

011

6

PSV-

2061

UTILITY GAS

06-

40363 CROSBY

1D2-JOS-E-

15-J

1" X

150#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.11

825 258022-KN-DR-PR-

012


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7

PSV-

2062

UTILITY GAS

06-

40364 CROSBY

1D2-JOS-E-

15-J

1" X

150#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.11

825 258022-KN-DR-PR-

012

8

PSV-

2070 INST. AIR RECEIVER V-

2070

06-

40365 CROSBY

1E2-JOS-E-

15-J

1" X

150#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.196

1380 441.38022-KN-DR-PR-

013

9

PSV-

2080 BUFFER AIR RECEIVER

V-2080

06-

40366 CROSBY

1E2-JOS-E-

15-J

1" X

150#

ANSI

RF

2" x150#

ANSI RF

CONVENTIO

NAL

0.196

1380 441.38022-KN-DR-PR-

013

10

PSV-

2090 UTILITY AIR RECEIVER

V-2090

06-

40367 CROSBY

1E2-JOS-E-

15-J

1" X

150#

ANSI

RF

2" x

150#

ANSI RF

CONVENTIO

NAL

0.196

1380 441.38022-KN-DR-PR-

013

11

PSV-

2101

FUEL GAS

06-

40368 CROSBY

2H3-JOS-E-

35-J

2" X

300#

ANSI

RF

3.2" X

150#

ANSI RF

CONVENTIO

NAL

0.785

3450 308022-KN-DR-PR-

011

12

PSV-

2201

FUEL GAS

06-

40369 CROSBY

2H3-JOS-E-

35-J

2" X

300#

ANSI

RF

3.2" X

150#

ANSI RF

CONVENTIO

NAL

0.785

3450 308022-KN-DR-PR-

011

13

PSV-

1080

FUEL GAS SEP. V-1080

06-

40370 CROSBY

1D2-JOS-E-

45-J

1" X

600#

ANSI

RF

2" X

150#

ANSI RF

CONVENTIO

NAL

0.11

7585 64.3CM202-020-D-

0013(1)


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Table 6 Pressure Relieve Valve for Fire Water Pump

N

o Tag no. Equipment Serial no. Manufacturer Model Inlet Outlet Type

Orifice

(in)

Set Pressure

(KPAG)

Relieve

temperature

(C) Drawing no.

1

PSV-

2120 DIESEL ENGINE 07-20505

ANDERSON

GREENWOOD CROSBY

324JLT-JOS-EOR-

15-J N/A N/A N/A N/A 1600 N/A

8022-KN-DR-PR-

019

2

PCV-

2120

RECYCLE TO

TANK 705-108-3 SINGER VALVE INC 106-XX-PR N/A N/A N/A N/A 1100 N/A

8022-KN-DR-PR-

019


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c) ConclusionBy 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

6.2Activities involvedThroughout 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 maintenanceAs 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 systemChange 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.

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

TankFin fan (lube oil cooler) Duplex filter Engine beari

Pump:

Backup

Pre/post

Main line


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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 washThe turbine can be regarded as the core element in the gas process

here. The complex structure of the turbine itself requires professionalhandling 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 changeIn 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. Theagenda 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 pointIn 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 andthe 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 addedtapping 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 afterfilter 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 teamto 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 wasteSelection 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) Company policy on safetyb) Detail method statement and other standard documentationc) Certificate of competencyd) List of manpower with their I/C and contact no.e) Schedule of workf) 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 PuspakomInspection Certification

h) Copy of Worker Protection Scheme (SOCSO) for all workers involvedi) 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) 2000b)

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 waterCollecting 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 itThere 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 learnedThere 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 ofthe 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. SuggestionsHere 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.ConclusionThis 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.ReferencesDresser-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 fromhttp://www.petronasgas.com/Pages/History.aspx, Jult 17th

,

2012

12.List of AppendicesAppendix A Relevant Figures

A.1 - KTNCS layout

A.2 - Inner gas seal diagram

A.3 - Piping symbols

A.4 - Letter designations

A.5 - P&ID dry gas seal

A.6 - Dresser-rand 50PDI
http://www.petronasgas.com/Pages/History.aspxhttp://www.petronasgas.com/Pages/History.aspxhttp://www.petronasgas.com/Pages/History.aspxhttp://www.petronasgas.com/Pages/History.aspx

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Pgb Internship 2012