STUDENT INDUSTRIAL TRAINING REPORT

_______________________
VERIFICATION STATEMENT
_____________________________________________________________________

This is to verify that this report is written by Ahmad Firdaus bin Ahmad Zubir (13601)
and all information regarding this company and activities related are NOT confidential.

(Supervisors signature)

NAME M SALLEH AMRI BIN ZAHID

DESIGNATION MAITENANCE EXECUTIVE

HOST COMPANY PETRONAS CARIGALI SDN. BHD., PMO

DATE 26 JULY 2013

i
STUDENT INDUSTRIAL TRAINING REPORT

ACKNOWLEDGEMENT

Bless to Allah The Most Merciful for helping and guide me in completing the Report of
Student Industrial Training. I have been attached to Department of Reliability and
Maintenance (PRM), PETRONAS Carigali Sdn. Bhd. (PMO) for a total duration of 28
weeks (currently 10 weeks) where I have been placed at Terengganu Crude Oil Terminal
(TCOT). Firstly, I would like to express my greatest gratitude to Mr. Azlan bin Khalil,
the Terminal Superintendent of TCOT for giving me the opportunity to have Industrial
Training at TCOT and ensuring that my training here will be beneficial. I would like
also to thank my supervisor, Haji M Salleh Amri bin Zahid, maintenance engineer for
TCOT for his willingness to accept me as his understudy and teach me the real situation
of worker life. His support and concern are very valuable for me to nurture the quality.
Also, special appreciation to my Universiti Teknologi PETRONAS lecturer, Dr. Khaled
as my university supervisor. The time he spends during his visit to TCOT will be much
appreciated.

ii
STUDENT INDUSTRIAL TRAINING REPORT

TABLE OF CONTENTS

VERIFICATION STATEMENT. I

ACKNOWLEDGEMENT .. II

TABLE OF CONTENTS. III

LIST OF FIGURES. IV

LIST OF TABLE. V

STUDENT INDUSTRIAL TRAINING REPORT:

CHAPTER 1: INTRODUCTION 1

CHAPTER 2: GENERAL OVERVIEW OF THE COMPANY. 4

CHAPTER 3: WORK CULTURE... 14

CHAPTER 4: WORKS EXPERIENCE.. 22

CHAPTER 5: DISCUSSION ON SUSTAINABILITY. 28

CHAPTER 6: CONCLUSION & RECOMMENDATIONS.. 31

REFERENCES..... 33

APPENDICES... 34

iii
STUDENT INDUSTRIAL TRAINING REPORT

LIST OF FIGURES

Figure 1: PETRONAS logo

Figure 2: PETRONAS Carigali Sdn. Bhd. logo

Figure 3: Kompleks Operasi PETRONAS (KOP)

Figure 4: Divisions of Department in PMO

Figure 5: Terengganu Crude Oil Terminal (TCOT)

Figure 6: Peninsular Malaysia Upstream Crude Network

Figure 7: TCOT Overview

Figure 8: PRM Workflow Chart

Figure 9: ZeTo Rules

Figure 10: Maintenance issue in TCOT

Figure 11: Sources of P1 Action Items

Figure 12: Metal and Plastic Drums

Figure 13: Jumbo Bad and Wooden Pallet

iv
STUDENT INDUSTRIAL TRAINING REPORT

LIST OF TABLES

Table 1: Types of schedule waste

v
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 1: INTRODUCTION

Student Industrial Training Program pragmatic experience of work training which is

relevant to professional growth before the graduation of student. In Universiti Teknologi
PETRONAS (UTP), one of the crucial requirements for the Bachelor of Engineering is
the industrial training itself. Students from the engineering department should complete
a total of twenty eight weeks of industrial training before pursuing for their final year
studies.

Upon completion of third year studies, students must be in industrial training in a

company for the whole 28 weeks. The training concludes all kinds of engineering
application s related to the field of studies. Besides, it also works as preparation for the
students to face real life working upon graduation. This kind of exposure is important as
the students will get prepared to face challenges after transition of study life later on.
Students shall be exposed to real life engineering life such as the process flow,
laboratory, designation as well as safety ethical work.

1
STUDENT INDUSTRIAL TRAINING REPORT

1.1 Objectives of Student Industrial Training

1.1.1 To expose students to work culture and industrial practices

- Undergoing the Industrial Training Program will expose the student with the
real working environment and understand the roles and responsibilities of
workers especially in oil and gas industry. Students shall exposed to working
environment that requires good time management skill, punctuality, safety
working condition and good working attire and behavioural which will cover
the whole 8 months of the Industrial Training.

1.1.2 To study the integration of theoretical knowledge to its application in

industry

- These industrial training act as a platform for students to utilize and

implement the knowledge gained at the campus with related skills in a real
working environment.

1.1.3 To provide opportunity to students to work with industrial practitioners

- During this internship program, the student have an opportunity to develop

the safety practice and precaution by attending the safety training, safety talk
and practicing Personal Protective Equipment when performing job at plant.

1.1.4 To introduce students to potential employers

- Besides, the industrial Internship program provide opportunity to the students

to work with industrial practitioners and give the overview how to mix and
mingle around with the staffs and technicians to gain knowledge and
experiences and to work together with them. This industrial training enables
the students to communicate with various people at different levels, from the
common level to the higher level employment.

2
STUDENT INDUSTRIAL TRAINING REPORT

1.1.5 To motivate students to their right working attitudes and professionalism

to increase their employability potential.

- During this internship program, students will have an opportunity to develop

the safety practice and precaution by attending the safety training, safety talk
and practicing Personal Protective Equipment when performing job at plant.

3
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 2: GENERAL OVERVIEW OF THE COMPANY

2.1 PETRONAS

Figure 1: PETRONAS Logo

PETRONAS, Petroliam Nasional Bhd, is Malaysias national petroleum corporation

established on 17 August 1974. Wholly-owned by the Government, the corporation is
vested with the entire oil and gas resources in Malaysia and is entrusted with the
responsibility of developing and adding value to these resources.

In the wake of the major oil crisis in early 70s, the Malaysia government
established PETRONAS to manage the countrys oil resources in September 1974. Its
origins were modest with only a small office in Kuala Lumpur and handful of
employees. 37 years down the road, PETRONAS is a consistent listing in fortune 500,
one of the most profitable oil companies in the world with international operation in
more than 30 countries around the globe.

Since its incorporation PETRONAS has grown to be an integrated international

oil and gas company with business interests in more 30 countries. As at the end of
March 2005, the PETRONAS Group comprised 101 wholly-owned subsidiaries, 19
parties owned outfits and 57 associated companies.

4
STUDENT INDUSTRIAL TRAINING REPORT

PETRONAS objective is to contribute to the well-being of the people and the

nation. The group is engaged in a wide spectrum of petroleum activities, including
upstream exploration and production of oil and gas to downstream oil refining,
marketing and distribution of petroleum products; trading; gas processing and
liquefaction; gas transmission pipeline network operations; marketing of liquefied
natural gas; petrochemical manufacturing and marketing; shipping; automotive
engineering; and property investment.

2.1.1 Exploration & Production Business

As custodian of Malaysias oil and gas resources, PETRONAS is entrusted with

the responsibility to develop and add value to the nations hydrocarbon resources. In the
early years, PETRONAS focused its efforts on managing the production sharing
contractors who were exploring Malaysian acreages, but PETRONAS soon saw the need
to take on a bigger and more proactive role in augmenting the nations oil and gas
reserves. PETRONAS has also reintensified efforts to strengthen Malaysias upstream
industry through the enhancement of fiscal terms and the introduction of new petroleum
solutions, leveraging on the Governments new tax incentives.

Through its Exploration & Production (E&P) subsidiary, PETRONAS Carigali

Sdn Bhd (PETRONAS Carigali), PETRONAS has developed capability as a hands-on
operator with a track record of successful oil and gas developments. PETRONAS
Carigali works alongside a number of petroleum multinational corporations through
Production Sharing Contracts (PSCs) to explore, develop and produce oil and gas in
Malaysia. Abroad, PETRONAS continues to strengthen its position by securing new
acreages while undertaking various development projects. The Petroleum Management
Unit of PETRONAS acts as resource owner and manager of Malaysias domestic oil and
gas assets. It manages the optimal exploitation of hydrocarbon resources and enhances
the prospectivity of domestic acreages to attract investment and protect the national
interest. PETRONAS has explored some of the world's most challenging terrains and
temperatures to secure new reserves. Additionally, we conduct deepwater exploration,
entering also into highly complex HPHT reservoirs and wells with high CO2 content to

5
STUDENT INDUSTRIAL TRAINING REPORT

enhance our yields. Today, PETRONAS are amongst the world's first in maximising
recovery of discovered fields with Enhanced Oil Recovery (EOR) efforts.

PETRONAS continues to harness and develop new technologies to maximise

opportunities and further strengthen its capabilities as part of its ongoing efforts to
become a leading global E&P player.

2.2 PETRONAS CARIGALI SDN. BHD. (PCSB)

Figure 2: PETRONAS Carigali Sdn. Bhd. Logo

On May 11, 1978, PETRONAS Carigali Sdn. Bhd. (PCSB), a wholly owned subsidiary
of PETRONAS was born as its exploration and production arm. PCSBs domestic
operations are divided into three regions Peninsular Malaysia Operations (PMO),
Sarawak Operations (SKO), and Sabah Operations (SBO). Effective April 1, 2002, these
regional operations were put under PCSBs Division called Domestic and South East
Asia Division (DOMSEA).

PMO started its operation in April 1984 (the first production division in PCSB)
with the commencement of gas production from the Duyong field. Its main office is
located at PETRONAS Office Complex in Kerteh about 110 km south of Kuala
Terengganu.

6
STUDENT INDUSTRIAL TRAINING REPORT

Figure 3: Kompleks Operasi Petronas (KOP)

PMO is supported by Kemaman Supply Base (KSB) in terms of warehousing and

logistics activities, Kerteh Helibase for helicopter services and Onshore Gas Terminal
(OGT) at Paka for gas receiving facilities.

The first step taken by PMO in developing the first gas field at Duyong has in fact
sparked and fuel led the growth of the petrochemical industry throughout Peninsular
Malaysia. After Duyongs success, PMO marked another milestone with its first oil
production from Dulang field in 1991. Now, PMO is operating 17 producing fields, 36
platforms, 2 FPSOs, 2 FSOs, 1 Crude Oil Terminal, 2 Onshore Gas Terminal (OSC and
OGT), and 1 supply base (KSB). The Duyong facilities will also become the receiving
gas hub for the first delivery of Indonesian gas from the West Natuna Field beginning
from 8th August 2002.

2.2.1 Peninsular Reliability and Maintenance (PRM)

Peninsular Reliability and Maintenance (PRM) is one of the departments in PMO is

headed by En Mohamad Bin Hassan. There are seven (7) discipline sections namely;
Maintenance Planning and Control (PRM 1), Reliability Management (PRM 2),
Rotating Machinery (PRM 3), Mechanical Static (PRM 4), Electrical (PRM 5),

7
STUDENT INDUSTRIAL TRAINING REPORT

Instrument and Control (PRM 6) and Measurement Assurance (PRM 7). Besides that,
there are six field maintenance clusters under PRM, which are FMM S (Angsi), FMM L
(Dulang/Sepat), FMM D (Duyong/Resak/Tangga Barat), FMM F (Masa/PNL/Abu),
FMM T (Terminal TCOT/OSC/OGT) and FMM P (Tiong/Kepong/Bekok/Tinggi/Pulai).

Figure 4: Divisions of Department in PMO

8
STUDENT INDUSTRIAL TRAINING REPORT

2.2.2 TERENGGANU CRUDE OIL TERMINAL (TCOT)

Figure 5: Terengganu Crude Oil Terminal (TCOT)

TCOT is commissioned in 1983 where it is operated by ExxonMobil for PETRONAS.

TCOT plays important role in oil and gas industries and act as the receiving point for all
the crude from the offshore platforms in Peninsular Malaysia. The terminal is located in
the PETRONAS Petroleum Industrial Complex (PPIC) with immediate neighbours such
as the Onshore Gas Terminal (OGT), GPP and Petronas Penapisan (Terengganu) Sdn.
Bhd. (PPTSB).

The pipelines from the offshore platforms are centred at Tapis Pump before transferred
to TCOT. At TCOT, the crude oil received is stabilized, dehydrated, stored and exported
to customer. TCOT have the complete facilities to handle the crude oil in Peninsular
effectively including two identical trains with total design throughput of 380 KBD.
There is also facility to separate water and light hydrocarbon gas once receives from the
crude prior to export.

9
STUDENT INDUSTRIAL TRAINING REPORT

Figure 6 Peninsular Malaysia Upstream Crude Network

The figure above illustrates the crude flow from Peninsular Malaysia upstream crude
production platforms that is collected in TCOT for processing. The crude receives from
offshore via piping header passing through emergency shutdown valve before entering
the stabilization train. The stabilization system consists of two trains namely train A and
train B completed with crude heating and separation facilities. Each train can handle
between 64.2 SKBD to 192.5 SKBD.

10
STUDENT INDUSTRIAL TRAINING REPORT

Figure 7 TCOT Overview

The processed oil is stored in floating roofs tanks that have the capacity of storing
500,000 barrels of oil. There are 5 tanks in total to handle the crude before exporting
namely T 441,T 442,T 443,T 444 and T 446. The storage period is only temporary as the
crude is then export via custody metering system to two offshore Single Point Mooring
(SPM) and PETRONAS Penapisan Terengganu Sdn. Bhd. (PPTSB). Besides the crude
oil, the stabilization gas from the separation processed is used to fuel fired heaters, or
exported as sales gas via Vapor Recovery Compression (VRC).Before discharging
produced water to sea. It is treated in skimmer pit for further recovery of HC. TCOT is
equipped with complete safety facilities as it is engaging with the highly flammable
crude and gas.

11
STUDENT INDUSTRIAL TRAINING REPORT

2.2.3 Peninsular Reliability & Maintenance Terminal (PRM-T)

The author is attached at TCOT under the Peninsular Reliability & Maintenance
Terminal department in the field maintenance section. This department mostly related in
all maintenance and operations of all terminals which are TCOT, OGT and Onshore
Slug Catcher (OSC).

PRM-T is responsible in facilitating and coordinating the implementation of planned

and unplanned activities for maintenance of the terminal. Besides that, the main role of
PRM-T is to maintain, control and monitor production facilities in all terminals by
implementing maintenance strategy for all major equipments in order to maximize
production plant uptime.

Figure 8 PRM Workflow Chart

12
STUDENT INDUSTRIAL TRAINING REPORT

PRM-T department has been given the responsibility by PCSB to supervise and review
terminals project plans and designs to ensure effective implementation of new projects
and lesson learnt are incorporated and life-cycle cost are considered to ensure smooth
execution of project as per specifications and according to the related law and
regulations.

Other than that, PRM-T department is responsible in performing timely inspections and
certifications of all relevant equipments and facilities exist in the terminals to ensure all
the regulatory requirements are met.

Besides that, health and safety in workplace always be the priority in all work activities.
Therefore PRM-T has the role of demonstrating and promoting the best HSE practices
via supporting the HSE Management System through its policy, strategies and action
plan.

Listed below is the general work processes under PRM department:

Strategy & Planning

Reliability, Integrity and Maintenance Integration and Execution
Project Integrator
Equipment & System Maintenance Execution (for all disciplines)
Integrated Planning & Scheduling
Asset Management
Asset Reliability & Maintenance
Turnaround Management
PMMS
Performance Management
Cost Management
Contract & Material Management
Discipline Work pack
Bad Actor Management & Resolution

13
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 3: WORK CULTURE

3.1 Occupational Health and Safety

Several regulations, statements, policies, guidelines, trainings and procedure have been
implemented and made compulsory for the staff to obey in order to increase their
awareness on the importance of HSE in their working etiquette.

3.1.1 Safety Regulations

3.1.1.1 PETRONAS Carigali Health, Safety and Environment Policy

To comply with the legal requirements of HSE as well as the implementation of the HSE
Risk Management program, a policy is created. It also measures on how crucial it is to
have a safe working environment provided having an adequate workforce. PMO HSE
Recommended Action Items (HSERAI) and Unsafe Act, Unsafe Condition (UAUC)
Reporting are managed by a web-based HSE System named HSE Online. However, this
website is highly confidential for any public view outside PETRONAS.

3.1.1.2 Drug and Alcohol Policy

PETRONAS Carigali Sdn. Bhd. (PCSB) recognizes that any drug and alcohol abuse will
affect the employees work performance and can be a major threat to the companys
operations which abuses PETRONAS Code of Conduct and Discipline. Employees who
are found to abuse the policy shall be subjected to disciplinary action.

3.1.1.3 Stop Work Policy

It is a policy whereby all employees, including contractor staff, shall stop work when
there is an imminent and real threat which can physically endanger them and others or
cause any adverse impact to the environment. This policy has the full support of
management. When there is doubt on whether work should continue, employees

14
STUDENT INDUSTRIAL TRAINING REPORT

including contractor staff, should promptly notify their immediate supervisor for
assessment of the hazardous condition.

3.1.1.4 Zero Tolerance (ZeTo Rules)

ZeTo Rules involves any work that has potential to cause any risk on the employees,
which can be expressed briefly in ten (10) elements:

Figure 9 ZeTo Rules

15
STUDENT INDUSTRIAL TRAINING REPORT

3.1.2 Training provided

3.1.2.1 Safety Briefing for onshore terminal

Basic briefing for any personnel who which to enter the terminal ( eg: TCOT, OSC and
OGT) for the first time. Includes video on safety briefing as well as quiz right after that.
Basically this briefing is conducted by the Safety and Health Officer. In order to pass the
quiz, one must obtain less than five(5) mistakes. Failure to do so will require he or she to
retake the quiz as well as the briefing on another time slot.

3.1.2.2 BOSET for offshore platform

Before going to offshore platform for the first time, one must attend BOSET as the
required basic training. He should pass the Medical Examination before joining BOSET.
The three days of training combined safety courses and assessment inclusive of Safety
and Survival (SAS), Basic Fire Fighting and Helicopter Underwater Escape Training
(HUET). This training is important for the staff to know things to do when dealing any
situation which are related to the safety in the platform.

3.1.3 Company SOP

There are many standard operating procedure (SOP) that need to be followed in order to
perform any task in correct way. In TCOT, several SOP which are relevant to PRM-T
department.

3.1.3.1 Health, Safety & Environment Management System (HSEMS):

HSEMS is a part of the overall management system and share the same degree of
importance with financial management, quality management, operations management,
human resource management, and business planning systems in an organization.
HSEMS is made up of nine (9) elements.

Leadership & Commitment

Policy & Strategic Objectives
Organization, Resources, Competency & Documentation
Suppliers & Contractors HSE Management

16
STUDENT INDUSTRIAL TRAINING REPORT

Hazards & Effects Management

Planning & Procedures
Implementation & Monitoring
HSE Assurance
Management Review

By achieving the entire element, HSEMS can clearly define the responsibility and
accountability of an individual towards HSE regardless of the level of leadership. It also
serves as a clarifier to HSE requirements. This system also been made to alert the
stakeholders about the nature of PCSB business and how safe it is being managed to
provide a sense of security to all.

3.1.3.2 Permit to Work

PTW is a written document authorizing a person to carry out work related, stating them
of the possible hazard and way forward to overcome it. This is important to ensure that
the job done safely without causing any accident. It is needed to be applied for all
activities which may harmfully affect the personnel, environment, asset, and reputation
carried out on PETRONAS Carigali facilities. All PCSB staff working at plant/platform
are compulsory to attend three days of PTW Training which enables them issue PTW
upon working there. There are two types of PTW documents, Cold Work Permit (A4
green colour document) and Hot Work Permit (A3 document). Permit applicant should
be responsible to his work stated in his PTW and make sure to enclosed together
document of Job Hazard Analysis (JHA) for future review. Before doing the job, permit
applicant should open the PTW. Upon finishing the work, he should close the PTW
as an indicator of stop work and need verification from authority in plant. This shows
that the job is completed without confronting any accident related to hazard mentioned
in PTW. The permit that has been issued can only be valid for a maximum period of one
shift, approximately about 8-12 hours.

17
STUDENT INDUSTRIAL TRAINING REPORT

3.1.3.3 Job Hazard Analysis (JHA)

JHA is a process of determining the hazards associated with a job so that control
measures may be taken to safeguard the safety of the personnel, facilities and also the
environment. The personnel have many imminent hazards that may affect him or her in
different working environment. JHA is a tool that contributes to the environment of
standard operating procedures for specific jobs and it is applicable on ultimately every
job that have been performed. As to perform a JHA, the person needs to consider the job
steps, identify the existing or potential hazards that may happen and determine the
control measures of the system. Safer working conditions will be achieved once JHA is
implemented successfully.

Figure 10: Sample of Job Hazard Analysis

18
STUDENT INDUSTRIAL TRAINING REPORT

3.2 Work Environment

3.2.1 Team Work

Since the author has been attached to Terengganu Crude Oil Terminal (TCOT) for about
eleven weeks, the value of team work between employees and also contractors is totally
crucial in doing any work. As for PETRONAS Carigali employees, in TCOT there are
three different departments which are Production Planning Department (PPD-T),
Reliability and Maintenance Department (PRM-T) as well as Health, Safety and
Environment Department (PSE). All of these departments must work together as one
team to ensure the production at TCOT goes as well as planned. As for example, the
production team job is to ensure all the operation process goes well. However to achieve
the objective they need the support from people in maintenance and reliability
department to ensure all equipment in the plant are working in a good condition. Apart
from that, authority from safety department must ensure that all of the activities that are
done in TCOT are been carried in safe manner. One of the examples is that the Safety
and Health Officer and his team always do a permit to work (PTW) audit to all
contractors. This is to ensure that the PTW of certain works is been fill correctly and
also their Job Hazard Analysis (JHA) is filled with correct hazards that involve in their
work.

3.2.2 Work Ethics

3.2.1 Morning Meeting with Contractors

Each morning a meeting will be held between PETRONAS staffs and contractors who
are assigned to do works inside the plant site (TCOT, OSC, OGT). Contractors will
present their scheduled work prior to the Permit to Work (PTW) they have filled before
starting their task.

3.2.2 Weekly Maintenance Meeting

A weekly meeting basically held by the staffs who are assigned to the plant site (TCOT,
OSC and OGT). Includes any maintenance issue arise prior to the daily operation of the

19
STUDENT INDUSTRIAL TRAINING REPORT

plant. Any maintenance required regarding any part of the site will be noted down and
suggested solution will be heard.

3.2.3 Flexi-Hours System

A system that allows the staffs to choose their own working hours that suit to the their
schedule. The flexibility between timeframe 7.00am until 9.00am to enter the office and
must complete nine (9) hours before completing their working hours (inclusive one hour
of lunch). During the interval time, all staffs need to be remained in working hours to
perform their working tasks.

3.2.4 PETRONAS Dress Code

Every employee needs to be in correct and neat dress code prior to the place of working.
Upon working in the office, one should wear standard and professional working attire.
Coverall with suitable personal protective equipment (PPE) must be worn at plant site
(TCOT, OSC and OGT)

3.2.5 Safety Talk

During any event or morning meeting, there will be scheduled safety talk given on topics
of Health, Safety and the Environment (HSE) by officers in that department. This act as
reminder for the employees of PETRONAS as well as the contractors on how important
issues regarding safety during working it is.

3.2.6 TCOT Fire Drill

TCOT fire drill acts as safety awareness among the workers in the site on how important
it is for authorities to act correctly when there is fire happened in plant. Correct
procedures on evacuate site should be followed to avoid any risk if actual fire incident
happened.

3.2.7 Usage of personal protective equipment (PPE) at site

Each one of workers/visitors must wear proper PPE every time when entering the
working area. The basic PPEs are coverall, safety boots, glasses, and helmet. Other PPEs

20
STUDENT INDUSTRIAL TRAINING REPORT

that are needed special attention include earplug, glove, face sheet, apron, respirator and
body harness should be applied according to task given.

21
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 4: WORKS EXPERIENCE

4.1 Skills Gained

Figure 10: Maintenance issue in TCOT

As a trainee of PRM-T department, the author had learned many new things throughout
internship period in PCSB. Unlike daily routine in the university, working in PCSB does
require students to adapt life in corporate working environment. Jobs that have been
assigned must be completed on time schedules. Any spillover will jeopardize the
company to other consequences such as reputation, cost management, etc. Each activity
is unique and totally different compared to campus life in UTP.

The author is assigned to experience working in one of the three PETRONAS onshore
terminals which is the Terengganu Crude Oil Terminal (TCOT). Since the first day of
the training, the author has learned many things mainly on operations in TCOT. Like the
author has mentioned earlier, the job scope of PRM-T basically on the maintenance wise
wholly in TCOT with more advantage on hands-on experience.

On the early week in TCOT, the author experience to learn the operation overview of
TCOT, mainly on process flow of the crude from offshore platform until the export line
(the end flow of TCOT), production quantity per day, separation process in the crude,
storage mechanism of crude oil and many more. Mainly to be involved in the things
related to TCOT, one must have the basic knowledge of physics, chemistry as well as

22
STUDENT INDUSTRIAL TRAINING REPORT

facilities engineering. The principle of maintenance should be mastered as well as it can

help to ease any job related to the field.

With assistance from the authors supervisor and staff in TCOT, the learning process
seems to be a lot easier to be digested. The use of Pipeline and Instrumentation Diagram
(PNID) is one of the important technical skills the author has learned. PNID is a set of
complete diagram which illustrate the piping and equipment flow installed in the
terminal. It plays a major role in maintaining the integrity of the terminal whereby each
location of the items exists in the terminal can be searched and located. Throughout the
PNID, the author is able to differentiate locations in the terminal by the process facilities
equipped in that specific location.

The first task assigned by the authors supervisor is to locate several passing valves
which reported by the inspection team of TCOT. By the definition, passing valves are
valves that leak internally can lead to major losses of valuable product, or unintended
transfer of process constituents, in some cases seriously elevating process risks. A total
number of 34 passing valves reported consist of various sizes that need to be replaced
mainly due to corrosion. The application of PNID initiated as to locate those valves.

After locating the valves, site visit is done to acquire photos and tag number of the
valves as evidence that will be brought up during weekly maintenance meeting. A report
is done for the documentation purposes and as future reference for further action such as
purchasing the new ones. Basically, PRM-T acts upon any inspection done by the
inspection team of TCOT.

Being an engineer requires one not to just mastering only engineering works, but also
administrative ones also. As for example, trainees in TCOT help to prepare
documentation as well as presentation pack prior to work given earlier. In this task,
filing, presentation pack and database are parts of the administrative work done by the
author in assisting the executive in their work.

Being in the PRM-T department section is not an exception to just only stick to the work
related on the department. In TCOT, the author also assists executives from other
department of PRM in TCOT. For example, the job scope of the author includes on the

23
STUDENT INDUSTRIAL TRAINING REPORT

TCOT Major Equipment Status by PRM-3 (rotating machinery). It involves on checking

the status of pumps and compressors equipped in TCOT from different sections of area:

Firewater pump
Stripping/Spiking pump
Sump pump
SU-265
Effluent Water Discharge
PWSU
Flare Knock Out Drum
Hot Oil Drum
Crude Oil Circulation Pump
Condy Transfer Pump
Crude Export Pump
Booster Pump
Air Compressor
Heater
VRC
Condensate Recovery System

The equipment checklist requires the author to get information from TCOT Centralized
Control Room (CCR), whereby crews of operation and production of TCOT works
there. From the assignment, the author gained more knowledge on the operations of the
equipment.

Working directly in terminal has been an advantage for the author to have a better
understanding on the operation in TCOT. Apart from the basic job scope the author has,
he also acts as the guider for people from outside to have visit at the site. As for
example, the author together with a maintenance engineer used to escort a team from
PIE-2 (Engineering) to the various specific locations of pipelines and valves that are
potentially to be replaced due to some reliability issues with the guidance from PNID.

24
STUDENT INDUSTRIAL TRAINING REPORT

The team did manage to locate all the wanted locations and thus ease them for further
job assigned from the department.

During the ten week of industrial training, the author also receives the job of inspecting
and closing PI item in the terminal that has been registered. In order to maintain the
terminal integrity, thorough inspection by the specialist is done for every five years.

Based on the inspection, there are numbers of equipment that are needed be repaired or
replaced. Classifications of the items are P1, P2 and P3 items respectively. Items that
need immediate action where a period of one year is allocated for solving the issue are
called P1 items, followed by P2, and P3 items. After a certain time limit, status of P2
and P3 items can be converted to P1 items as no action taken to close them. Several
sources of P1 are listed as follows:

Figure 11: Sources of P1 Action Items

The list of P1 items are distributed by authorities from Kompleks Operasi Petronas
(KOP). Inspection is done to confirm the presence of P1 items. Then contractors are

25
STUDENT INDUSTRIAL TRAINING REPORT

hired to settle the issue to certain length of time. Second inspection will be made to
confirm the maintenance done by them. P1 items are considered closed if designated
items are well maintained and photo taking on those items will be done as evidence for
the closure.

To enhance the knowledge to handle the task, the author has been sent to PMO P1
Workshop. Basically it is not just focusing only on issue regarding closing P1 items, but
also tracking any P2 and P3 items that can be neglected or close without any serious
maintenance with the list of items provided by Peninsular Malaysia Operations (PMO).
During the workshop, it is also shown graphical analysis of P1 items that can be closed
by 31 December 2014 and way forward to any issue that delays the objective.

Generally, Reliability and Maintenance (PRM) Department does really play a major role
in maintaining the performance of the terminal as TCOT is the aging facilities that have
been operated for about thirty years. Thus proper time and cost planning is needed to
ensure that the maintenance is done on schedule.

4.2 Communication Skills

Communication skills are needed to be mastered in working life. Without it, or not fully
mastering it, one will have difficulties in his or her pursuit to express the knowledge or
ideas, asking questions and befriend with another person. It is vital because it is
happening on daily occurrences, and majority of the works needs communication
between groups of persons to happen. The author can say that communication skill is
one of the most crucial skill to obtained as regular communication happened not just
between the staffs, but also with the contractors as well as visitors from outside. Besides,
the skill adapted can be seen as golden opportunity to interact and understand more on
jobs people do in the site as lots of valuable information are shared.

4.3 Time management

A proper time management can ensure the productivity of the work of staffs. The author
is instructed to be in the office as early as 8.00am and complete eight hours of working

26
STUDENT INDUSTRIAL TRAINING REPORT

hours every day. Without proper time management, one will face problems to cope with
the demands of the work and private life which may coincide with each other at certain
point. A punch card is made compulsory to all trainees in order to ensure obliged to
eight hours productive working time. When dealing with work demands which have
deadlines, the author will make sure a proper time allocation for each task is done. This
will help the author to cope the work situation without encounter heavy pressure from
work.

4.4 Initiative & Knowledge

Being a trainee requires the author to explore many things in the terminal. Knowing that
not all are fortunate to be involved in terminal operation as trainee, the author tries his
best to gain knowledge related to the facilities. Apart having assistance from the
supervisor, staffs do really give a big contribution for him to understand more on his job.
If there is any lack of information regarding the task he did, the author always have
reference from people in CCR as well as sources from the internet that really give much
contribution to the task completion. Although the authors background is from
Petroleum Engineering Department, opportunity to have industrial training in TCOT
enables him to gain knowledge in mechanical engineering. Instead, the author feels
highly gratitude as he is able to broaden his knowledge not just in his field of study, but
to other field as well.

27
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 5: DISCUSSION ON SUSTAINABILITY

Sustainability is the capacity to endure. In ecology the word describes how biological
systems remain diverse and productive over time. Long-lived and healthy wetlands and
forests are examples of sustainable biological systems. For humans, sustainability is the
potential for long-term maintenance of well being, which has ecological, economic,
political and cultural dimensions.

5.1 Common practice and future recommendations on:

5.1.1 Environmental

Generally TCOT generates about 100 drums of waste every year and this amount varies
to the maintenance activities that happen in TCOT. Apart from that, there are several
types of waste that is classified by the Department of Environment Malaysia that are
situated in TCOT. All of the wastes are stored cautiously in seal containers which are
plastic drum, steel drum or jumbo bag. This container will be placed on a wooden pallet
to make it easier to mobile from one place to another.

Figure 12: Metal and Plastic Drums

28
STUDENT INDUSTRIAL TRAINING REPORT

Figure 13: Jumbo Bag and Wooden Pallet

Some common waste in TCOT:

Type Description
SW201 Asbestos waste in sludges, dust or fibre form.
SW311 Waste of Oil or Oily Sludge.
SW109 Waste containing mercury or its compound.
SW408 Contaminated soil, debris or matter resulting from cleaning up of a spill of
chemical, mineral oil or schedule waste.
SW410 Rags, plastics, papers or filters contaminated with schedule waste.
Table 1: Types of Schedule Waste

In TCOT, Kualiti Alam Sdn Bhd has been given the contract to handle waste
management. This means that Kualiti Alam will come and collect all the waste in TCOT
and manage it afterwards. Safety Officer of the plant is the person who is responsible on
the schedule waste. As for that in TCOT, usually there are about four lorries per week
from Kualiti Alam Sdn Bhd to manage all the schedule waste. All of this completes to

29
STUDENT INDUSTRIAL TRAINING REPORT

the maintenance activities in TCOT. The hypothesis is the more maintenance activities
in TCOT the more schedule waste will produce.

A form called E-Consignment note is required to fill by PETRONAS Carigali as to track

all kinds of movement of produced waste. By doing so the Department of Environment
Malaysia (DOE) will be able to track all the waste that have been produced by all the
factories and plants in Malaysia.

5.1.2 Economical

In TCOT there is a plan in which can help to reduce the cost that is used to put away all
the scheduled waste (hiring Kualiti Alam Sdn. Bhd.) The plan is to treat all the
contaminated gravel which has been contaminated by hydrocardon by using cement
mixture truck. This plan is said to be executed next year (2014) as there are lots of work
to do before commissioning this project to a certain contractor of company.

5.1.3: Political and Cultural Dimensions

Staff conversation, morning meeting, weekly maintenance meeting are some of the
engagement between staffs that have been practiced here in TCOT. All of them acts as
platform to enhance communication between the management team with all level of
working staff. The author can say that it is a practice that needs to be sustained

30
STUDENT INDUSTRIAL TRAINING REPORT

CHAPTER 6: CONCLUSION AND RECOMMENDATIONS

6.1 Recommendation to Centre for Student Internship, Mobility and Adjunct

Lectureship (CSIMAL)

Strengthen the close relationship between UTP and Host Company

Establish the medium for students to give the feedback and recommendation
Provide more opportunity and support in term of cost for any training (BOSET
for example)

6.2 Recommendation to Host Company

Provide structure module for trainee within the internship period

Provide more opportunity for student to attend more related training

The Industrial Internship Program has given much advantages and benefits to
engineering students of Universiti Teknologi PETRONAS. The placement of training in
PCSB PMO has given a chance and wide exposure to students in learning and practising
technical and management skills. The 28 weeks program in this company also prepares a
good platform, as an exposure of the working environments and culture, and also work
challenges. This program had given an opportunity to work with different level of
people; from the bottom workers to the top management side and this help to improve
the communication and social skills. Some of the theories that have been learned in UTP
are applied in performing any task during the internship.

However there are rooms for changes for both Universiti Teknologi PETRONAS and
the Host Company to improve them. The underlying objectives should be achieved
together in parallel with total co-operation between all personnel involved, either from
host-company or UTP. It is suggested that improvement should be done immediately to
remedy all weaknesses and students should be given a chance to learn, adapt and
familiarize themselves with working environment. More exposure and responsibility
should be given to the trainee so that it will be important lesson.

31
STUDENT INDUSTRIAL TRAINING REPORT

As conclusion, the objective of the industrial internship achieved. The internship has
brought the students to clear view of real working environment as it will be important in
future.

32
STUDENT INDUSTRIAL TRAINING REPORT

REFERENCES
1. PETRONAS. (2012). Petronas. Retrieved
from http://www.petronas.com.my/about-us/Pages/default.aspx
2. PETRONAS. (2013) Petroliam Nasional Berhad. Retrieved
from http://en.wikipedia.org/wiki/Petronas
3. PETRONAS. (2012). Safety & health. Retrieved
from http://www.petronas.com.my/sustainability/safety-
health/Pages/default.aspx
4. PETRONAS GHSED. (2011). ZeTo Rules. Retrieved
from pww.ghsed.petronas.com.my
5. PETRONAS. (n.d.). Petronas Leadership Centre. Retrieved
from http://www.petronasleadershipcentre.com.my/learningphilosophy/program
mes.php
6. PETRONAS. (2010-2013). PTS HSE. Retrieved
from http://pww.axis.petronas.com.my/topic/pts/PTSHSE/Forms/AllItems.aspx
7. PETROLIAM NASIONAL BERHAD. (2012). Petronas code of conduct and
business ethics. 33-37. Retrieved fromhttp://www.petronas.com.my/about-
us/governance/Pages/governance/code-of-conduct-business-ethics.aspx
8. PETRONAS GHSED. (2011). ZeTo Rules. Retrieved
from pww.ghsed.petronas.com.my
9. Risk Management and Assessment for Business. (2013). So what is ALARP?
The ALARP principle. Retrieved fromhttp://www.risktec.co.uk/knowledge-
bank/technical-articles/so-what-is-alarp---.aspx

33
STUDENT INDUSTRIAL TRAINING REPORT

APPENDICES
Appendix 1: Permit to Work (PTW)

34
STUDENT INDUSTRIAL TRAINING REPORT

Appendix 2: Drug and Alcohol Policy

35
STUDENT INDUSTRIAL TRAINING REPORT

Appendix 3: Environmental Objective Statement Policy

36
STUDENT INDUSTRIAL TRAINING REPORT

Appendix 4: Stop Work Policy

37