Sunday, September 28, 2014

Latihan Industri - Pintu Segala Kemungkinan

Teks : Amir Azli bin Mohd Al-Kharid

Sebahagian dari perjalanan seorang pelajar tertiary untuk melengkapkan kitaran pelajaran mereka ialah melalui fasa latihan industri atau juga dikenali praktikal. Dalam fasa ini, pelajar akan dihantar ke syarikat-syarikat tertentu untuk mendapat pengalaman sebenar dunia pekerjaan. Dalam entry saya sebelum ini mengenai Road to Oil and Gas (baca di sini), latihan industri merupakan salah satu cara yang paling efektif untuk menembusi dunia Oil and Gas sekiranya dijalani dengan betul dan efektif.

Untuk entry kali ini, saya ingin berkongsi pengalaman dua orang pelajar yang telah menjalani latihan industri di syarikat berkaitan Oil and Gas. Seorang pelajar di tempatkan di Jabatan QA/QC manakala pelajar kedua di Jabatan Kejuruteraan Perpaipan.

Semoga pengalaman dua orang pelajar ini dapat memberi gambaran awal kepada mereka yang masih kabur tentang perjalanan latihan industri. Teks dihasilkan oleh mereka sendiri dalam Bahasa Inggeris, pembaca yang ada masalah mungkin boleh dapatkan bantuan dari google translate.

1. Practicalog - Fatin Nabilahuda

Monday, 23 June 2014
Welcome to the world of work! Today is my first day of industrial training at Malaysia Marine Heavy Engineering (MMHE). I feel so excited as I am accepted to enter this industrial company. Today, I have session with Learning and Development, Human Resources Department at Training Centre, MMHE West. They gave me coverall, safety shoes and safety helmet so that I can wear them when I go to the site. Simple briefing about the company background and its business was given at the morning including video on all projects that were carried out in this yard. As stated in internship acceptance letter, I will be attached to QA/QC Department at MMHE East under Offshore Business Unit (OBU).

Tuesday, 24 June 2014

Today is my first day to meet my industrial supervisor as well as entering QA/QC Department. Heavy rain in the early morning does not break my spirit to start my industrial training. I was introduced to my industrial supervisor, En. Mansor bin Ahmat (QA/QC Manager).

En. Mansor bin Ahmat (QA/QC Manager)

Next, Kak Mursyidah (QA Engineer) introduced me to the other QA/QC staff. I’m felt quite shy to know them because this is my first time I feel the working atmosphere in the office. I was given a training schedule by her so that I can follow all the discipline in this department within the period of 10 weeks.

Week 1 (25, 26, 27 June 2014)

I need to be familiarized with the contract documents for project namely SK316. The client for this project is PETRONAS Carigali Sdn. Bhd. and the contractor is TMJV (Technip-MMHE Joint Venture). SK316 Gas Development Project is including Wellhead Platform (WHP), Central Processing Platform (CPP) with Living Quarters and a bridge linked Drilling Platform.

In this department, there are 5 main discipline namely Quality Assurance (QA), Quality Control (QC), Welding, Non-Destructive Testing (NDT) and Source Inspection (SI) for me to follow.

Week 2 (30 June, 1,2,3,4 July 2014)
In this week, I need to learn about QC and NDT. In QC, there are several sub-disciplines involve such as structural, piping, mechanical, electrical & instrumentation, blasting & painting, and lastly dimensional control. And for NDT, the testing will be covering ultrasonic testing (UT), radiography testing (RT), magnetic particles inspection (MPI) and dye penetrant inspection (DPI). To become more familiar with this discipline, I need to read all the procedure involved. Read, read and read. In case I can't understand, do some research in Mr. Google. Still not understand, then ask the engineers!

Steel Temperature Gauge

For this week also, I need to learn about Blasting and Painting. I need to read Blasting and Painting Procedure.The procedure stressing appropriate protection work including safety signboard shall be provided to protect other areas of the work, such as ambient air, water or marine and soil, other personnel or contamination caused by the blast cleaning and coating operations. 

I also attended theory class with blasting and painting engineer and given the opportunity to identify and see the equipment used in blasting and painting.

Dry Film Thickness (DFT) Gauge
Sample of equipment used in blasting and painting : 
  • Dry film thickness and dial temperature gauge used to measuring paint thickness
  • Steel temperature gauge used to measuring surface temperature of the steel beam.

Week 3 (7,8,9,10,11 July 2014)

Because of QC discipline have wide aspect to be covered, I'm still here. SK316 project just getting started, so I have an opportunity to observe the earlier construction stage of the megastructure - construction of the topside and also the jacket. Thanks to structural inspector for allowing me to follow him go to the site. I feel so excited! Besides went to the site, I need to understand several structural drawing including the location of welding joint and the type of connection detail. 
First impression when I saw that drawing, oh what is this. How can I understand this drawing. Im so dizzy. With the help of the engineers and inspectors, finally I can understand the drawing a bit. They explain to me about the dimension and the type of beam involve. They also outline the size and types of materials to be used, as well as the general requirement for connections. This drawing also important because they are also become part of the contract documents which guide the contractors in detailing, fabricating, and installing parts of the structure.

With Inspectors at Fabrication Workshop

Week 4 (14,15,16,17,18 July 2014)

Welding! This week I was scheduled to follow welding engineer and learn more about welding section. In the beginning of the week, I have an opportunity to follow welding technician conducting Welding Qualification Test (WQT). Example of WQT activity before we start the test are checking welder ID, preparing the work area (set up the equipment), identify the type of welding used (SMAW / FCAW) and recognize the position of welding (3G / 4G). This test conducted for the whole day. 
Welder will do the test in the morning and then the result of test piece will be inspected by visual inspection by the welding inspector and also the client in the evening. Only one of the welder pass the test as his welding produce the good result with no defects.

Besides that, I was so happy when welding engineer invited me to join him to Professional Testing Services Sdn. Bhd at Gelang Patah to observed the mechanical testing on the test piece from WQT. Example of test conducted are bending test, tensile test and charpy-impact test. The results of these test will be attached to Procedure Qualification Record (PQR).

Welder Qualification Test (WQT)
Test Piece
Mechanical Test

Week 5 ( 21,22,23,24,25 July 2014)

Already a month passed for my industrial training. This week, I still covering welding section. If last week I have followed WQT and mechanical testing, this week I need to cover on how to manage the PQR documents. The welding engineer gave me the PQR template so that I just need to fill in all the information and detail of test conducted for last week. The information including type of base metal and welding material, electrical and technique used during WQT, the joint detail, the mechanical and non destructive result which are needed to be recorded in PQR documents.

Week 6 (28,29,30,31 July, 1 August 2014)

One week holidays for Hari Raya Aidilfitri! Raya mode turn on!

Week 7 (4,5,6,7,8 August 2014)

Still in holiday mood! But need to strengthen our mind as this is our responsibility during the industrial training. There are a lot of things that I need to learn. Done with welding section, this week we proceed with piping section because this section just started in this project. My first task is to read procedure on piping and to understand the drawing for the pipe support, especially the type of beam used and its dimension because there is special dimension for beam that attach to the existing structure. For the next day, I followed the piping inspector to workshop. I observed the construction of the pipe support which help me to understand more about what I have read and indentified the different design of pipe support. The design is different depending on the type of pipe that they want to support. Large pipe size need more complex structure conmpared to normal pipe support. 

Sample of Pipe Support

Week 8 (11,12,13,14,15 August 2014)

This week, I followed NDT coordinator to learn more about Non-Destructive Testing. First thing that I did was to read all the procedure for UT, RT, MPI and DPI.
First testing that I learnt was UT. UT use sound wave to detect the weldment discontinuities. This testing use high frequency sound to penetrate the materials. I also followed the UT inspector to observe how they conduct the testing on the weldment. I also have an opportunity to conduct the testing myself which I need to set-up the analog pulse-echo ultrasonic instrument, apply the couplant to the test material, used suitable probe and then move the probe to the inspectian area on test material as well as observed the cathode ray tube screen of the ultrasonic instrument if there is signal due to discontinuities. Such a good experience!

UT Instrument
UT Inspector In Action!

The next day, I learnt about RT. For this testing, the radiation source is gamma radiography which  Iradium-192 is used as the isotope. This isotope has 73.83 days half life and will emits beta (β) and gamma (γ) radiation as it decays. Besides that, NDT coordinator took me to dark room to observe the sample of RT film after radiography testing conducted. Dark room is a place for processing the films after radiography testing.

RT Film for Butt Weld

RT Film for Pipe

Week 9 (18,19,20,21,22 August 2014)

There a lot of thing that I need to learn for NDT. This week, I followed NDT inspector to conduct MPI. For MPI, we used yoke as the inspection device. It will used magnetic flow or current flow to produce magnetic field on the object. The pattern of field distribution provides indication of the existence of weldment discontinuities. I also observed how the inspector conduct the MPI as well as have a chance to conduct the testing. The yoke used just too heavy! MPI can detect all surface and near surface crack type defects which is corresponding to their position and size, proportionally influence the magnetic field.

Application of white contrast paint by MPI inspector (Left), 
Handling the yoke by MPI inspector (Right)

For DPI, although the method is an easy NDT procedure to perform, it can lead to simple mistake. I just read the procedure for DPI and do some researh about how they conduct this testing as I do not have opportunity to observe this testing. The material that we wish to inspect by using this method must non-magnetic material. The flaws that we wish to detect must be open to the inspected part’s surface.
My last day for this week, I need to do slide presentation to my industrial supervisor and other engineers about what I has learned during my industrial training. I am so nervous!

Week 10 (25,26,27,28,29 August 2014)

My last week for internship?? How fast time passes! Although this is my last week, it will not prevent me to keep learning. Mechanical section just started. Same like piping, I need to understanding the drawing to get overview about the type of support used and its dimension. I also went to the workshop to observed the working activity. Firstly, they need to prepare the work area and make sure that area are safe for working. All the safety instruction and the procedure need to be displayed at mechanical board area to fulfill the requirement as well as to remind the workers about the safety matter. Fortunately, I am glad because have chance to attend the First Cut Event which the cutter to cut the first beam as a symbol the starting of work in the field of mechanical.

First Cut Steel Event
Briefing Before Activity Start
Electrical and instrumentation section also just started about two months. I read the Instrumentation and Electrical Installation Procedure as the first step to understand more about the scope of work. These procedures are standard of practice set as a guideline for the fabrication of support and installation of electrical and instrumentation equipments including fire and gas and also telecom systems. I also have opportunity go to the workshop to see the construction of instrument and electrical cable ladder support.

Next, for dimensional control section, I just read the Leveling and Dimensional Control Procedure as this procedure will provide project specific guidelines to ensure proper control of the dimensional. 
I also have chance to identify the equipment used for the dimensional inspection such as theodolite and went to the site (upper deck section A) to observed how they conduct the inspection.

Dimensional Inspection In Progress
Lastly, I need to cover source inspection discipline. Source inspection is a quality inspection in which buyer require the quality check and compliance verification to client's requirements before the material received at yard. The quality inspection need to be performed at vendor’s location. I have class session with QA Engineer about source inspection. She explain to me about the source inspection flow chart starting from purchasing the order and contract agreement until submission of final report to the client and final compilation.

There are a lot of new things that I able to learn during my industrial training which focusing on quality management in oil and gas field. Thanks so much to my industrial supervisor, engineer, coordinator, inspector, technician as well as department staff for guiding me during my attachment in QA/QC department.

2. Three Months Training Experience - Nur Ain

I am a third year degree student who is currently taking a course in Bachelor of Chemical Engineering at Universiti Teknologi Malaysia. During my industrial training, I was placed in an Engineering Department in the SK316 project at Malaysia Marine and Heavy Engineering Sdn. Bhd. I am glad to say that I have had a very supportive mentor named as Muhammad Syafiq bin Jamil who works as a Piping Engineer. Apart from studying about oil and gas at my faculty, I have productively gained other experience in the fabrication engineering of the platform. Afterward I will combine both knowledge and use it in the future as an engineer in oil and gas sector. 

Pipeline Facility
 For the first week of training, I was told by my mentor to have a full understanding of the Piping Handbook which consist all the procedures needed, meaning for all the terms involved, responsibilities for the engineer and so on. In order to understand the content of the piping handbook, my mentor gave full guidance and clear explanation on a certain complicated topics. 
ASME B31.3

Next, I studied the code and standard of ASME B31.3 which refers to the piping process. In the slide of ASME B31.3, guidelines are given on how to choose the materials, the procedures involved and etc. Then my first task was to manually perform material take off from the piping and instrumentation drawing which is used for purchasing process. From this MTO we can identify the quantity of the material needed to be purchased along with their standard and material grade. Material take off was one the most important procedure that must to be done by the piping engineer before proceeding with the material purchasing. 

Sample of ISO Drawing
Sample of Process and Instrument Diagram (P&ID)

Other than that, I had done the mark-up process for the isometric drawing. The designer engineer at this department taught me on how to check the drawing detail and mark-up the drawing. In order to check the drawing, I have to refer to the line list, P&ID, piping material class specification (PMS) and etc. 

Besides that, my mentor told me to perform the vendor data review (VDR) drawing on the double block and bleed valve (DBB) and compare with specifications and dimensions. Based on the checking, there were a lot of missing data such as the design temperature, pressure test, painting and coating data and wrong material that were used for some parts of the valve. Hence the drawing was not approved, needs to be corrected and resubmit for approval.

During the practical training, I have significantly expanded my knowledge. I went to the workshop and warehouse at west yard and observed various piping components such as valves, gaskets, flanges, and fittings such as elbow. Although I was really hoping to experience being on the platform, regrettably I was unable to go the site and experience standing on the platform. It was because the platform was still in the early progress.

Sample of Flanges
Pipe Fittings Diagram

Sample of Pipe Fittings

Throughout the practical period, I had fallen in love with the environment in the department. From my observation, all of the workers have a great team spirit and work well together in completing their task. The working environment is very comfortable and hassle free, to my liking. 
Moreover, I am feeling thankful because despite of my position as a mere trainee, all of the staffs have treated me well. The relationship between employer and employee are also great.