final report- athirah

Industrial Internship Industrial Project Report Nurul Athirah Wahid Ali (13340) October 2012 – April 2013

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EXECUTIVE SUMMARY

One of the main objectives of Universiti Teknologi PETRONAS is to produce

well-rounded graduates. To be a well-rounded graduate, one must be able to relate

theoretical knowledge they gain from lecturers with practical knowledge. This is done

by undergoing practical work in terms of industrial internship prior to their graduation.

This Industrial Internship program carries 14 credit hours and last for 28 weeks since

the attachment period started from October 2012 and lasted until April 2013.

During this internship period, I was assigned under the Engineering Department

of Dyna Segmen, under direct supervisory of Dyna Segmen’s Director, En. Faiz Hussin

Bin Hussin and Iskandar Bin Dzulkarnain as UTP Supervisor. Being assigned to the

Engineering Department, during this internship period, I was able to learn and have

exposure with the engineering aspect itself. Even though I am a Petroleum Engineering

student, but being assigned to Mechanical field and having the golden chances to work

in plants, it opened my eyes, in more than the ways that a student can possibly imagine

getting during the industrial internship period.

The purpose of the final report is to record all relevant activities that contribute

towards developing students’ cognitive and practical skills. This report is divided into

five main sections. Starting with a brief description about the host company Dyna

Segmen Sdn. Bhd., followed by objectives of the internship as well as the scope of work

or projects assigned. The second section tells about the main activities carried out beside

the real project involvement. The third section will explain on the Industrial Internship

Project. Discussion on the valuable lessons and experience gained throughout the

Industrial Internship at Dyna Segmen wil be discussed in section 4 followed by

problems and challenges experienced throughout the 28 weeks internship period.

Finally in section 5, conclusions for the whole 28 weeks of Industrial Internship

Program are made to wrap up this very beneficial experience.


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ACKNOWLEDGEMENTS

I would like to thank, first and foremost, my parents for their unwavering

support, wherever ‘my road’ has taken me. They allowed me great freedom to become

the person I am today and I am grateful for that.

I am deeply indebted and thankful to my Supervisor, Mr Faiz Hussin bin Hussin

who took confidence in me and gave this wonderful opportunity of working with Dyna

family. I have no words to express my gratitude for his intellectual guidance without

which things could have been rather difficult for me. I am also very much thankful to

Mr Nasrul and Mr Adib who irrespective of the situation always helped and supported

me.

I would also like to thank my colleagues who made this 7 months of internship

at Dyna Segmen, while challenging, some of the most fun I have ever had. I will forever

be grateful for the friendships made throughout my time here. It was an honor and

pleasure to work with the staff of Dyna Segmen: Jihan, Fuad, Dqeen, Alya, Gray, Azfar,

Jannah, Hazlinda, Amir and Dila, my fellow intern mates: Ezzuni, Safwan, Sundara,

Ashraf, Mahes, Rahj, Aishah and Irsyad as well as the Senior Interns: Indra, Haziem,

Raju, Chong, Shafiq, Aaron and Siva.

Finally, special thanks to my UTP Supervisor, Mr Iskandar Dzulkarnain for his

guidance and support throughout this industrial internship period.


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TABLE OF CONTENTS

Executive Summary 2

Acknowledgement 3

Table of Contents 4

List of Figures 6

List of Tables 7

1.0 Introduction

1.1 Host Company Overview 8

1.2 Objective of Student Industrial Internship Program 13

1.3 Scope of Work 14

2.0 Industrial Internship Main Activities

2.1 Tender Process 15

2.2 Blasting and Painting Project at PETRONAS Gas Berhad, Serdang

Metering Station 18

2.3 Crude Sludge Profiling Project at PPMSB Crude Oil Tank T-7101 22

2.4 Training Activities

2.4.1 NIOSH OGSP Certification 22

2.4.2 BOSET 23

3.0 Industrial Internship Project Report

3.1 Abstract 24

3.2 Introduction

3.2.1 Project Background 25

3.2.2 Problem Statement 26

3.2.3 Objectives and Scope of Study 27

3.2.4 Relevancy of the Project 27

3.3 Literature Review 28

3.4 Methodology

3.4.1 Equipments Used 29


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3.4.2 Measuring Method 30

3.4.3 Data Post Processing 32

3.4.4 Data Presentation 32

3.4.5 Project Team 33

3.4.6 Gantt Chart and Key Milestone 34

3.5 Result and Discussion 35

3.6 Conclusion and Recommendations

3.6.1 Conclusion 44

3.6.2 Recommendations 45

4.0 Safety Training and Value of Practical Experience

4.1 Lesson Learned and Experience gained 46

4.2 Leadership, team work and individual activities 47

4.3 Business values, ethics and management skills 48

4.4 Problems or challenges faced and solutions to overcome 49

5.0 Conclusion 50

6.0 References 51

7.0 Appendices 52


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LIST OF FIGURES

Figure 1: Dyna Segmen Organization Chart 11

Figure 2: Consurv Technic Organization Chart 12

Figure 3: Tender Process Flow 16

Figure 4: Blistering and corrosion of pipeline 19

Figure 5: Blistering and corrosion of pipeline 19

Figure 6: Corrosion pitting on pipeline 20

Figure 7: Corrosion pitting on pipeline 20

Figure 8: Almost all insulation has been removed 20

Figure 9: After blasting work completed 20

Figure 10: First coat is being applied 21

Figure 11: Final coat is being applied 21

Figure 12: Insulation is being installed 21

Figure 13: Insulation completed 21

Figure 14: Location of Crude Oil Tank T-7101 in PPMSB 26

Figure 15: VDM 250.2 29

Figure 16: Roof Tank Survey 31

Figure 17: Reading is being logged 32

Figure 18: Tank roof arrangement 36

Figure 19: 2D image of sludge distribution 38


Figure 21: Sludge distribution along the horizontal dashed line 39


Figure 23: Sludge Distribution along the vertical dashed line 40

Figure 24: 3D image of sludge distribution ` 41


Figure 26: 3D image of sludge distribution with 5X vertical scale 43


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LIST OF TABLES

Table 1: Project Schedule 19

Table 2: Ex status and Specifications of Equipments 30

Table 3: Project Team 33

Table 4: Key Milestones of Crude Sludge Profiling Project for Tank T-7101 34

Table 5: Gantt chart of Crude Sludge Profiling Project for Tank T-7101 34

Table 6: Tank information 35

Table 7: Crude Oil Parameters 35

Table 8: Key to Figure 16 36

Table 9: Surveyed roof leg positions 37

Table 10: Key to Figure 19-23 38




Table 14: Sludge Volume 44


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1.0 INTRODUCTION

This section describes the host Company, the work done by the Company and the

purpose as well as the scope of the industrial internship. The company consists of Dyna

Segmen Sdn. Bhd. and Consurv Technic Sdn. Bhd.

1.1 HOST COMPANY OVERVIEW

Dyna Segmen Sdn. Bhd.

Dyna Segmen Sdn Bhd is an engineering company, providing services and equipment to

the Oil & Gas industry. The company also serves civil, power and water industries. Over

the years, Dyna Segmen has grown to become an established contractor having served

Oil Majors like PETRONAS, ExxonMobil and Shell.

Dyna Segmen Sdn Bhd was incorporated in 2004 by a group of senior managers turned

entrepreneurs. Their employment with Oil Majors such as PETRONAS, ExxonMobil

and Shell, along with time in working with global engineering companies like

HoneyWell and Bumi Armada, combine to accumulate more than 100 years of

experience in the Oil & Gas industry. In 2004, Dyna Segmen teamed up with a public

listed company to incorporate Ingress Fabricators Sdn Bhd, an engineering company

involved in offshore structural fabrication and plant maintenance.

During this period, Dyna Segmen also divested its interest in Marine Integrated

Maintenance, a company involved in marine structural protection. In 2007, the Board of

Directors of Dyna Segmen decided to steer the company from predominantly an

investment holding company to become an engineering services and supply company on

its own.


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Dyna value businesses with ever-growing list of clients, and are committed towards

building long-term relationships. Dyna is a young company, but Dynamic. It is an

exciting stage of the company, with exponential growth over the past few years.

Dyna Segmen also divested its interest in Marine Integrated Maintenance, a company

involved in marine structural protection. In 2007, the Board of Directors of Dyna

Segmen decided to steer the company from predominantly an investment holding

company to become an engineering services and supply company on its own.

Besides that, in the year of 2011, Dyna Segmen managed to acquire a contract that

enables the company to operate and manage the maintenance of MOPU Rubicone, an

extension of the Bekok-C platform located at offshore of Kerteh, Terengganu. MOPU

Rubicone is a distinctive Mobile Offshore Production Unit that mimics the whole

operation of the Bekok-C after it came to a mothballed situation due to the tragedy on

the 14th of December 2010. This was a big step for Dyna Segmen as it drives the entire

company and its staffs to an exponential growth concurrent with the company’s vision

and mission.

Businesses that Dyna Segmen is involved in are:

Online Pipe Repair : Dyna Segmen is a local distributor for Diamondwrap. The

DiamondWrap® system includes a bidirectional weave of carbon fiber and a

100% solids epoxy, forming a composite system that is stronger than steel. The

structural system forms a pipe around a pipe, and each successive wrap increases

the pressure rating. Its bidirectional weave allows for strength in both the hoop

and axial directions experiencing little or no creep properties over time, ensuring

that there is no reduction in strength. Because of its low profile, DiamondWrap®

can be installed on tees, elbows, straight runs of pipe, confined spaces and

irregular surfaces that require structural reinforcement or leak containment. The

adhesive properties of the epoxy allow it to be applied to most substrates.


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Valve actuators: Dyna Segmen is the exclusive Malaysian distributor for

SCHISCHECK explosion-proof actuators. Schicheck, based in Germany, is the

biggest manufacturer of electrical actuators in the world. In a world where

industrial processes have become increasingly complex, robust and reliable

actuator solutions are needed and that is what Schischeck together with Dyna

Segmen supplies.

Coatings - Dyna Segmen is in the blasting and painting business. The company

specializes in Polyurea coating, which is fast becoming the coating of choice

replacing epoxy based products, FBE and Tri-lam systems. Polyurea is far

superior in terms of physical properties and cures much faster than other

coatings. Dyna Segmen is also the exclusive distributor for Polyvers Coating

Systems International, a leading manufacturer of Polyurea coatings.

Maintenance - The team at Dyna Segmen has vast experience in Oil & Gas

facility operations and maintenance. Over the years, the people here have had the

opportunity to work and manage offshore platforms, topsides fabrication, rigs,

FPSOs, offshore supply vessels, petrochemical plants, refineries and depots.

Dyna Segmen offers maintenance services, including but not limited to the

following:

o Valve servicing

o Marine Generator and Engine overhauls

o Underwater and Diving services

o Mechanical and structural repairs


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Figure 4: Dyna Segmen Organization Chart Consurv Technic (M) Sdn. Bhd.

Consurv Technic (M) Sdn. Bhd. was incorporated in 2003 as a consulting company. Its

founders, Faiz H. Hussin and Ali Izhar Ahmad were established in the Oil & Gas

industry as oil traders and surveyors providing support services to the multi-million

dollar oil trading world. Consurv become a consultant to companies engaged in trading

and provided key advisory services to ensure trades were executed profitably.


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Over the years, Consurv has grown to be an established company, providing services

and supplies to a multitude of industries with special focus in Oil & Gas. Consurv

specializes in Radio Frequency iDentification (RFiD) solutions, providing clients with

state of the art technology in meeting their needs in asset and people tracking. Consurv

is a Systems Integrator (SI), providing the required platform for a diverse set of systems

to integrate and perform optimally. The company is also an approved distributor for a

range of IT products, both in hardware and software.

Figure 5: Consurv Technic Organization Chart

In 2007, Consurv took a major leap into new technologies, venturing into state-of-the art

Radio Frequency Identification (RFiD) solutions. The company remains committed to

serving the Oil & Gas industry and is set to grow to greater heights. Consurv Technic

businesses are:


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Oil Trading Consultancy - Consurv helps companies get off the ground. Oil

trading and its associated business spin-offs are rapidly growing given the boom

in oil demand and appetite from Asian countries. More and more companies are

venturing into the industry and Consurv provides invaluable advice and

consultancy to ensure its clients are well prepared to meet challenges.

Radio Frequency Identification - RFiD is one of the newest and fastest growing

technologies in the world. Consurv Technic is doing an outstanding job in

applying this new technology in real time applications and charting new paths

into providing O&G customers. Consurv, with the support of its technology

partner ActiveWave Inc. is moving to become a global leader in RFiD solutions

for the O&G industry

General Trading - Apart from the two core businesses of the company, Consurv

is also active in general trading, providing office equipment and general supplies

mainly to clients in the O&G industry

1.2 OBJECTIVE OF STUDENT INDUSTRIAL INTERNSHIP PROGRAM

To gain experiences and self improvements for preparing myself towards the real

working environment.

Attaining both a challenging and dynamic industrial training in the best company

that seeks quality and excellence in its operation.

Helps student to acquire and enhance the soft skills such as ethics,

communication, leadership, interpersonal, management etc, which are of great

importance in the working life.

Good exposure to decide which career best fits, and being close to many

companies widens our networking.


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1.3 SCOPE OF WORK

For a period of 28 weeks working with Dyna Segmen, I was involved in various

activities divided as follows:

1. Tender Process

2. Stackers Blasting & Painting Project at Tg Bin Power Plant

3. Blasting & Painting Project at PETRONAS Gas Berhad, Serdang

4. Crude Sludge Profiling Project at PPMSB Crude Oil Tank T-7101

5. Training Activities

Each one of the above mentioned activities will be elaborated in the next section.


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2.0 INDUSTRIAL INTERNSHIP MAIN ACTIVITIES

2.1 TENDER PROCESS

As a trading company, Dyna Segmen as well as Consurv Technic do tender for Oil and

Gas companies.

Dyna Segmen has a Petronas license on Instrumentation/Control Engineering &

Maintenance on Actuators, Control Valves, Temperature Instruments, Corrosion

Protection, Pipe Fittings, Coating Services, PipeWrapping, Fire & Gas Detection &

Alarm System, also in Civil,Structural & Building Maintenance Serivices on General

Structural/Building Pinting, Water Proofing, Concrete Repairs, Locksmith Services, and

under Valves Repair & Maintenance on Mechanical Valve, Relief Valve, Governor

Valve. It gives Dyna the right to bid, supply and deliver abovementioned items

requested by Petronas and other Oil and Gas companies.

While Consurv Technic has acquired license from Petronas for Safety and Protection

System on Personnel Protection Equipment (PPE), Consultancy Services on

Computerized Inspection & Maintenance Consultancy Services and Business & ICT

Consultancy, also in ICT Services on Storage and Retrieval of Backup Media, Software

Development & Programming Services, Software License Leasing, Software Support

Services, on Office/Residential/Operational Equipment and Supplies on Computer

Hardware that includes Data Storage, Accessories, Mainframe, Mini/Micro, Personal,

Directional Drilling Engineering & Training Software, Uniform & Accessories,

Corporate T-Shirt, the other category is Safety & Protection System that includes Eye

Wash Station & Shower, AO Windows, Self Contained Breathing Aparatus,

Resuscitator, First-Aid Kit, Helicopter Crash Box, Stretchers, Module Cladding

Firewalls & Decking. It gives Consurv the right to bid, supply and deliver

abovementioned items requested by Petronas and other Oil and Gas companies.


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Commissioning tender involve a few process which the company’s trainees are heavily

involved in. Most of the times, trainees are the one in-charge of the tender itself. Below

are the steps involved in the process:

Figure 6: Tender Process Flow

Screening: This is the process when clients like Petronas, Exxonmobil,

Talisman etc. send out screening letter. Screening purpose is to know whether

vendors like Dyna Segmen are interested in taking the tender.

Bidding: After screening, clients came out with a Request for Quotation (RFQ).

Vendors have to bid with a Quotation for the prices of equipments/materials

stated in the RFQ. Usually, vendor that came out with best Quotation will win

the tender. Upon winning the tender, vendor received Purchase Order (PO) from

their client.


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Execution: Execution is the process where vendor that won the tender obtain

the equipments from their suppliers, and deliver them to their clients. Items are

delivered to client together with Delivery Order (DO) and Invoice from the

vendor.

Payment: Payments are made once clients have received the equipments and

make sure they are in good conditions and match the criteria given in RFQ.

Tenders are completed once payments are made.

Trainees at Dyna Segmen are involved in most of the process. It was a great experience

and lots of benefits are obtained, mostly in developing soft skills since a lot of

interactions are made with both clients and suppliers.

Below are some of the tenders that I was involved directly:

EPOMS: Supply of PPE

NEWFIELD: Supply of Schischek Actuators

EMEPMI: Supply of Cameron Actuators

SARAWAK SHELL: Supply of Schischek Actuators

PCSB: Supply of CEAG Pipe Clamp

CARIMIN: Supply of Rosemount Temperature Transmitters

PETROFAC: Supply of Portable Eye Wash Bottle

PCSB: Supply of Schischek Actuators

SARAWAK SHELL: Supply of Butt Weld Reducing Pipe Tees

PCSB: Supply of Seal Ring

PPMSB: Crude Sludge Profiling Project for Crude Oil Tank T-7101

CARIMIN: Supply of Electrical and Instrumentation

CARIMIN: Supply of Name Plates

PCSB: Supply of Norgren Air Filter


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2.2 Blasting and Painting Project at PETRONAS Gas Berhad, Serdang Metering

Station

Serdang Metering Station insulation repair was awarded on 11th November 2012. The

project was executed from 26th November 2012 until 29 December 2012. The project

was divided into three phases which are:

1. Insulation removal & inspection

2. Blasting & painting

3. New insulation installation

Insulation removal was done in two days where old insulation was removed by cutting it

from below section using appropriate cutting tools. The old insulation was suspected to

be lead base and was planned to be replaced with new insulation. After completion of

insulation removal, inspection by PGB personal was done together with Dyna Segmen

Sdn Bhd personnel. Findings were recorded and submitted to PGB for review.

Method used for surface preparation was wet blasting to remove the risk of explosion

occurring because of presence of combustible gas at all time. The wet blasting used

garnet mesh 40/60 to get an anchor profile of at least 75 microns. Equipment used was

the usual blasting equipments with an additional of water pump to inject water at the end

of the blasting nozzle to produce wet blasting.

Painting specification was agreed for wet surface application as the regulator runs

surfaces were wet intermittently. Paint used is Sureseal 1208 UWE by PLC. The

recommended coating thickness is 300 microns with 2 layers of coatings. The

recommended new insulation is Rockwool 125kg/m with 50 mm thick and covered with

0.5 mm thick aluminium sheet. The installation was done in 8 days and was inspected

before job completion.


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The project schedule is as follows:

Date Descriptions

26 Nov – 27 Nov 2012 Insulation removal

28 Nov – 30 Nov 2012 Equipment mobilization and blasting preparations

1 Dec – 11 Dec 2012 Blasting & Painting works

12 Dec – 13 Dec 2012 Housekeeping & insulation installation preparations

19 Dec – 29 Dec 2012 Insulation installation

2 Jan 2013 Trash & old insulation removal from site

Table 1: Project `Schedule

Some of the defects on the pipeline due to corrosion are shown below:

Figure 4&5: Blistering and corrosion of pipeline


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Figure 6&7: Corrosion pitting on pipeline

Figure 8: Figure 9:

Almost all insulation has been removed After blasting work completed


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Figure 10: Figure 11:

First coat is being applied Final coat is being applied

Figure 12: Figure 13:

Insulation is being installed Insulation completed


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The job was completed in 33 days which is actually slightly delayed from the original

schedule. There were many factors that caused the delayed schedule. Main factor is that

the location of SARO is very far from the Serdang MS which bought us plenty of time

to get the PTW approved before our job can be started every morning. Weather

condition also played a part in affecting our schedule. But overall the job had been

safely carried out without any incidents that could affect both sides. Both sides play

their own role in completing the job successfully.

2.3 Crude Sludge Profiling Project at PPMSB Crude Oil Tank T-7101

This project will be further elaborated in Section 3.0 as I have chosen this project as my

Industrial Internship Project.

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2.4 Training Activities

During 32 weeks of internship in Dyna, interns were given chances to do NIOSH and

BOSET certification. These training will benefit both the company and the interns.

2.4.1 NIOSH OGSP Certification

The one day training are compact with lessons on oil and gas industry safety,

occupational hazard, and health issues from top to bottom. This is the summarized

training activities during the one day training at NIOSH Headquarters Bangi, Selangor:

1. Legal Requirement on OSH

2. Causation and Prevention of Incidents

3. Common Hazards in The Oil and Gas Industry and The Control Measure

4. Common Safety Violation in The Plant and Lesson Learnt

At the end of the course, there was a test to certify that we fully understand all the

material lectured in class and as a pre-requisite before we can get our NIOSH card.


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2.4.2 BOSIET

Three days training was conducted in SEQU Offshore Safety Sdn Bhd. The training

consists of Re-breather, Helicopter Underwater Escape Training, Offshore Safety

Induction, Sea Survival, Basic Fire Fighting, First Aid and Boat Transfer & Swing

Rope.

Beside theoretical lesson inside the classroom, practical lesson were also conducted,

they are:

1. Helicopter Underwater Escape Training

Five different scenarios were executed. Two times escape training without re-

breather. We had to escape from vertically sinking helicopter fuselage. Also

from rolled over helicopter body, both without re-breather. Windows and escape

doors were left open for these scenarios.

In the next three escape trainings, re-breather was used. The two scenarios were

the same as previous two trainings. While the last one, we had to escape from

helicopter fuselage that was rolled over upside down with windows and escape

doors fully closed. In this scenario we had to break those windows and escape

doors before we can escape from the helicopter body.

2. Sea Survival

Some basics in sea survival technique were studied in the swimming pool. How

to use life jacket, how to swim with one, and how to swim together in a group

were among the items practiced.

Life raft usage and the basic survival on the life raft were favorites among the

students. This practical lesson closed with jumping practice from 3 feet platform.

3. Basic Fire Fighting

A few methods to fight fire were practiced, they are: Fire Blanket, 3 types of fire

extinguisher, and also find a way out of a dark room, simulated as a burned

offshore compartment.


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3.0 INDUSTRIAL INTERNSHIP PROJECT REPORT

MAINTENANCE PROJECT: MEASUREMENT OF SLUDGE VOLUME AND

SLUDGE DISTRIBUTION IN CRUDE OIL STORAGE TANK

3.1 ABSTRACT

Dyna Segmen Sdn Bhd was awarded with Crude Sludge Profiling Project at Crude Oil

Tank T-7101 by PETRONAS Penapisan Melaka Sdn Bhd (PPMSB) on the 11th

December 2012. Dyna Segmen together with its Inspection Specialists in International

Tank Services worked on this project to provide PPMSB with volume and distribution

of sludge in the tank. PPMSB has been facing a lot of sludge problems in their huge

tanks and we were the second contractor that is called to help quantify the sludge

volume after their first contractor failed them. Equipment used is the Viscosity Density

Meter (VDM 250.2) that records viscosity, density and temperature of the crude in the

tank at different intervals. The data is processed to calculate the sludge volume and

generate 3D views of the sludge distribution. This information can be used in the future

for planning prior to the sludge processing and to verify the sludge volume after

processing. The project was executed on the 25th January until 27th January with a team

of 7 members lead by me. Final report on the sludge quantification showed that 3.7% of

the crude volume in the tank is filled with sludge.


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3.2 INTRODUCTION

3.2.1 Project Background

Dyna Segmen Sdn Bhd (DSSB) with its sub-contractor, International Tank Services

(ITS) worked on this Crude Sludge Profiling Project at PPMSB Crude Oil Tank T-7101

and all the relevant works associated with the project referred. International Tank

Services have now developed a method of accurately measuring these tank sludge

deposits and can offer a range of services from ad hoc surveys to complete sludge

management solutions. International Tehnical Specials Ltd is a wholly own subsidiary

of International Tank Services (Asia Pacific) Pte Ltd which is a leading service provider

to the petrochemical industry.

After the project was awarded to Dyna Segmen, a few meetings were conducted with

PPMSB to clarify further on the methodology, safety issues and date of execution. A

window of 16th January 2013 to 31st January was given by our client, PPMSB to get the

project done. This window is given in conjunction with their plant turnaround where a

lot of maintenance work is carried out as well. Once all paperwork and documentation

required by PPMSB are ready, our team of 7 members went down to PPMSB to attend

In-House Trainings before we are able to execute our job. The job only took 2 days to

complete with 31 points taken.

Tank T7101 is a crude oil storage tank with an external floating roof. The tank is located

in the Melaka Refinery Complex as shown in Figure 13.


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Figure 14: Location of Crude Oil Tank T-7101 in PPMSB

3.2.2 Problem Statement

Crude oil in large above ground storage tanks has a propensity to separate and deposit

heavy end hydrocarbons on the tank floor. These accumulations referred to as “sludge”

or “tank bottoms” can create several problems for storage tank operators.

Reduction in storage capacity

Accelerated bottom plate corrosion

Disruption to maintenance operations


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3.2.3 Objectives and Scope of Study

The objective of this Crude Sludge Profiling Project is to quantify the volume and

distribution of sludge in the tank. The ITS Intelligent Viscosity Density Meter is based

on a resonant method (vibrating element) of measurement that records density, viscosity

and temperature of medium in the tank The data is processed to calculate the sludge

volume and generate 3D views of the sludge distribution. This information is used for

planning prior to the sludge processing and to verify the sludge volume after processing.

3.2.4 Relevancy of the Project

Crude Sludge Profiling is important in order for us to plan ahead prior to sludge

management (cleaning). The amount of sludge quantified from Crude Sludge Profiling

is used as a reference to know the amount of chemical additives needed or the amount of

pumps and filters needed for Sludge Management Project which liquidize the sludge

back to crude.


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3.3 LITERATURE REVIEW

New technology and new method, for the crude oil tanks, tankers and waste pits (pools)

sludge emptying and cleaning operation, this operation advanced with a complete

recovery for the crude oil that exists in the sludge content, and with minimum reducing

for the materials to be disposing and wasting, and with the minimum reducing for most

of the environmental hazards, all of this with minimum reducing of the total coasts.

To take an idea about the actual size of the issue, please know that the average crude oil

storage tank capacity is about 50'000 ton, if this tank needs a sludge emptying and

cleaning that means that the sludge content in the tank has reached 40% up to 80% of

the tank capacity.

This means, that we are dealing with a huge amount of a useless, non-disposal and

environmentally danger sludge, this huge amount of sludge is from 20'000 ton up to

40'000 ton of the sludge that content in only ONE average crude oil storage tank

So it was very needed to develop the ordinary methods, or search for a new effective,

economic and environmentally safe new method, for dealing with this huge amount of

useless sludge and without harming the environment or forming and digging for more

pits (Sien Chemicals, 2005).

As sludge accumulates inside your storage tanks, it slowly reduces your profits along

with the usable tank space. Conventional tank-cleaning methods can be just as

detrimental to your business revenue, because they can work against you in three ways.

They take your tanks out of service for prolonged periods, they generate waste and

sludge volumes, and they can require dangerous work practices (Miswaco,2010).


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3.4 METHODOLOGY

3.4.1 Equipments Used

The viscosity/density meter (VDM 250.2) is a precision instrument that is ATEX rated

and designed for density measurements in tanks containing crude and related oil

products.

Figure 15: VDM 250.2


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Inspection Equipment

Item Description Ex status Qty L(cm) W(cm) H(cm) Kg

Inspection System to collect data on tanks and derivatives, inspection equipment consists of:

1 BOX1 1 46 33 15 11

Viscosity density meter VDM 250.2

-Level block with sensor ATEX Category 1

-Controller ATEX Category 2

2 BOX2 1 46 33 15 7

Ruggedised Laptop Not applicable

Table 2: Ex status and Specifications of Equipments

3.4.2 Measuring Method

Data points are collected for position, viscosity, density and temperature. These are then

reconstructed as vertical profiles to determine the sludge interface and generate 2D and

3D maps of the sludge volume in the tank. The instrument can be deployed through any

opening in the roof that is >50mm in diameter.

The roof of the tank is surveyed to measure the position of the legs that will be removed

to allow measurements to be made with the viscosity/density meter. The leg entries are

selected to give a well distributed sample across the floor of the tank. A reference point

is selected and all measurements are made with respect to the centre and the reference

point. See Figure 16.


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Figure 16: Roof Tank Survey

Legs are removed using manpower, 3 personnel per leg. All personnel are trained for

confined space operations and carry personal gas detectors and escape respirator masks.

The viscosity/density meter sensor is lowered into the tank and readings logged

at suitable vertical intervals. See Figure 17. The data is stored for future download to a

PC in a safe area using a wireless Bluetooth connection.


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Figure 17: Reading is being logged

3.4.3 Data Post Processing

The goal of the post processing software is to determine the position of the sludge

interface in the tank and to produce a composite 3D/2D image of the sludge distribution

and a calculation of the sludge volume. The density, viscosity and temperature

measurements from the tank are used to determine the sludge interface height at each

entry. A surface is then reconstructed with these points using the Radial Basis Function

(RBF). The tank geometry including the floor (cone up/down) is known, so the volume

under the surface can be calculated in cubic metres.

3.4.4 Data Presentation

The sludge interface is presented in the report as a two dimensional (2D) and three

dimensional (3D) colour contour height maps overlaid on the tank bottom. The colour

scale range in meters is displayed in the top right corner. Orthogonal section views are

also provided.


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3.4.5 Project Team

No Name IC/Passport No

Position NIOSH No./ Safety Pass No

Expiry date of NIOSH / Safety Pass

1 Robert Alexander Auld 211018269 Supervisor 680723 16/7/2013

2 Nuno Manuel Carvalho De Matos

G820493 Specialist 225985 17/7/2015

3 Nurul Athirah Wahid Ali 910430105420

Project Leader OG012591N 14/11/2015

4 Sundara Pandian A/L Perumal 910123105631 Engineer OG012607N 17/11/2015

5 Amir bin Wahid 870312055457 Engineer OG009112N 9/2/2015

6 Akman Nur bin Abdullah 780506146219

Confined Space Specialist OG001768M 20/9/2015

7 Mohd Sukri bin Mohd Rasul 850320115693

Confined Space Specialist OG016598T 21/4/2014

Table 3: Project Team


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3.4.6 Gantt Chart and Key Milestone

Table 4: Key Milestones of Crude Sludge Profiling Project for Tank T-7101

Table 5: Gantt chart of Crude Sludge Profiling Project for Tank T-7101


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3.5 RESULT AND DISCUSSION

The tank information in Table 6 below was provided by PPMSB:

Table 6: Tank information

The values measured by Dyna Segmen for the crude oil product in the tank are shown in

Table 7 below:

Table 7: Crude Oil Parameters


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The measurements were carried out between 26th and 27th January 2013. Thirty one (31)

roof legs were removed in total. The tank roof arrangement is shown in figure 18 below.

Figure 18: Tank roof arrangement

Table 8: Key to Figure 16


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The surveyed roof leg positions on Tank T-7101 are shown on Table 9 below. A total of

31 entries were used.

Table 9: Surveyed roof leg positions

DC: Distance to Centre

DR: Distance to Reference Point

R, phi: Polar coordinates of leg entry

Offset: Distance between measuring tool datum and product height


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A two-dimensional (2D) image sludge distribution is shown in Figure 19. The sludge

depth scale is shown on the right in meters.

Figure 19: 2D image of sludge distribution

Table 10: Key to Figure 19-23


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2D View with Horizontal Cross Section


depth scale is shown on the right in meters. A section view in Figure 21 shows

distribution along the dashed line.


Figure 21: Sludge distribution along the horizontal dashed line


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2D View with Vertical Cross Section


depth scale is shown on the right in meters. A section view in Figure 23 shows

distribution along the dashed line.


Figure 23: Sludge Distribution along the vertical dashed line


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3D View

A three dimensional (3D) image of sludge distribution is shown in Figure 24. The

vertical heights and horizontal scales are 1:1




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3D View with Tank Shell Mimic


vertical heights and horizontal scales are 1:1




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3D View with 5X Vertical Scale


vertical heights are scaled 5X horizontal scales.

Figure 26: 3D image of sludge distribution with 5X vertical scale



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Sludge Volume

The sludge volume calculated for the distribution in Figure 24 is shown in Table 14.

Table 14: Sludge Volume

The 2D image of the sludge shows a typical distribution for a tank with inlet outlet pipes

in one area and no tank shell mixers installed. The flow of product in and out of the tank

helps to disrupt the settlement of sludge. At the sides of the tank the product flow is not

sufficient to disrupt the settlement and sludge accumulates over time due to gravity.

3.6 CONCLUSION AND RECOMMENDATIONS

3.6.1 Conclusion

The objective of carrying out this project is to quantify the volume and distribution of

sludge in Crude Oil Tank T-7101. This is performed using ITS Intelligent Viscosity

Density Meter (VDM 250.2). The project was executed within 2 days and the report

came out a week later. The report described the distribution of sludge in 2D and 3D

view which is sufficient enough for our client, PPMSB. Also, from the report we know

that the amount of sludge in the tank is 2026 cubic meters which is about 3.7% of the

total volume of crude in the tank. In a nutshell, all of the objectives have been achieved

and parallel with the task planned. This project is expected to give a clearer

understanding on sludge cleaning activities in the tank.


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3.6.2 Recommendations

During our project execution to quantify the volume and distribution of sludge in Tank

T-7101, our team were required to work under the safety policy of a confined space.

However, the tank was at high level in which its floating roof was only at 2 meters

below top and our job does not require any men-entry. Therefore, it is recommended

that PPMSB’s safety policy is reviewed again to address this issue. This is because our

work was totally conducted in open air without any condition of a confined space

involved. This would also expedite the whole process of job execution because it took

us a lot of time in order for us to comply with the confined space requirements.

Besides that, it is also recommended that PPMSB to install mixers in their tanks because

with mixers available in the tanks, they can control and prevent the accumulation of

bottom sludge and water pockets in crude oil storage tanks.


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4.0 SAFETY TRAINING AND VALUE OF THE PRACTICAL

EXPERIENCE

4.1 LESSON LEARNED AND EXPERIENCE GAINED

Technical Experience

During training and activities along my internship placement at Dyna Segmen, a lot of

technical experience has been gained. Some of them are:

Tender Process and Execution

Polyurea Coating

Crude Sludge Profiling

Basic Offshore Safety and Emergency Knowledge

Occupational, Safety, and Health Knowledge for Oil and Gas Industry

Such exposure to technical topics gave me the chance to deploy whatever has been

learned in the university in real situations. Beside this, it showed the difference between

the theory and the practical considerations in the engineering design.

Communication Skills

Communication is primary factor to ensure efficiency of the work done. As a trainee, I

had the opportunity to meet and deal with all kinds of people from different

backgrounds. In my daily working life, I corresponded most frequently with my

managing director, engineers, clients, suppliers, supervisors, technicians, contractors and

other trainees. All these have directly or indirectly polished up my communication skills

as each individual carries different attitude and work habit, thus everyone needs to be

tackled using different techniques. After the internship program, I am more confident

while dealing with people. I learnt how to adapt and handle the individual behavior and

character. To have those ideas expressed without having any parties feel uncomfortable.


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And throughout the training, I also learnt to be bold in voicing my opinions or

uncertainties.

Safety Awareness

Throughout the Industrial Internship, I have been exposed to a lot of safety briefings and

awareness programs mainly by PETRONAS in order to show the significance of the

safety and how the surrounding hazardous cost lives and money. So far I attended safety

briefings conducted by PPMSB and PGB since all the plant’s contractors are required to

attend the safety briefing, that is the first and foremost thing to go through before

entering the plant. The safety briefing mainly covered the safety guidelines and

procedures and how to deal with hazards in case of emergency.

4.2 LEADERSHIP, TEAM WORK AND INDIVIDUAL ACTIVITIES

Leadership

Leadership skills can only be developed through practices. Throughout the internship

period, I have observed how managers lead engineers and contractors from different

backgrounds. I was given the chance to see how the professional managers assign the

work load wisely and professionally under stressful environment. In such kind of

environments, one needs to use time management tools such as tasks prioritization. Such

exposure has contributed to the enhancement of my leadership and management skills. I

was also given the trust by our Director to lead the Crude Sludge Profiling Project at

PPMSB Crude Oil Tank T7101 and from this I have learned how to delegate tasks and

manage my team mates wisely. I have also learned how to lead people with a higher

ranking than myself and at the same time respect them as a person with more experience

and a lot wiser.


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Teamwork

From the given tasks during the internship, I have observed the significance of

teamwork in accomplishing any task such as completing the departmental initiatives.

The Internship has shown me the real meaning of team working. The real spirit of one

team appears when different engineering disciplines interface with each others in order

to work out a solution for complicated problem to deliver a proper outcome before

specific date. The same case was applied when I was handling the Crude Sludge

Profiling Project as I truly believe that it would not be a successful project without the

teamwork shown by my team mates. We supported each other and we strived to give the

best for our project. From these activities I have truly gained valuable lessons in

understanding the importance of teamwork and how to be a good team player.

Individual Activities

Our main job at Dyna Segmen is handling Tender from the start until the end which is

until payment is made. This tendering process is mainly an individual activity since we

have to manage the screening, RFQ, costing, delivery of items and payment by

ourselves with supervision by our Director. From all the tendering process that I have

managed, I learned to be independent mostly in making decisions. I learned how to

make tough decisions and a lot of critical thinking has been applied. The pros and cons

have to be analyzed in detail before any such decision is made.

4.3 BUSINESS VALUES, ETHICS AND MANAGEMENT SKILLS

Throughout my internship period in Dyna Segmen, I was exposed to vast business

values and ethics since I had the chance to attend a lot of meetings with clients and

suppliers to discuss about business deals. I believe that Dyna Segmen has shaped my

management skills during my experience of handling the Crude Sludge Profiling

Project. It was a great challenge to me as a lot of requirements by PETRONAS that I

need to comply in order for us to execute the job and we were given only a short period


49

of time to get things done. Thankfully, my team mates and I managed to handle both the

paper work and technical part well.

4.4 PROBLEMS OR CHALLENGES FACED AND SOLUTIONS TO

OVERCOME THEM

Problems and challenges are part of the daily life of anyone. But their impact depends

on the way a person tackled them either as obstacles or motivation. Some of the

challenges faced during my internship were:

Task Delegation

As a trainee at Dyna Segmen, everyday is filled with tasks and work that have to be

completed. Handling few tasks at a time was not easy. All the task need to be delegated

wisely in order to complete them by the dateline given. Solution that I came out was to

manage time and work wisely. Set priorities to the tasks given and start with the one that

is most important and followed by the next task. This experience will surely benefit me

into handling task later in the real working world.

Project Responsibilities

During the time that I handled the Crude Sludge Profiling Project, there were a lot of

issues and problems faced as there were a lot of requirements by PETRONAS. I would

say that at that point of moment we were working under a lot of pressure to comply with

their needs but thankfully, with our strong team work, we managed to handle them

smoothly. Trainees at Dyna Segmen are very lucky to experience doing serious work but

at the same time, they have to bear the responsibilities. Because of this, each job needs

to be done very carefully and tasks need to be completed perfectly. To experience real

responsibilities as a trainee is great and I personally thank my supervisor for having such

a great trust in me.


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5.0 CONCLUSION

As a conclusion, the 28 weeks attachment with Dyna Segmen has been a very fruitful

experience and vast knowledge was gain from it. The training objective was met

perfectly. Experience at the office and going for site project have been a real exposure to

working environment. Theories learned in class are also matched with the practical done

along the way.

The internship was also a great platform in soft skills development. The experience of

dealing serious business with people was priceless. The communication skills in

handling situations and delivering messages had been sharpened day by day. The

internship has also taught the importance of teamwork. Works are done more efficiently

in groups rather than personal.

Last but not least, the company provides fun working environment. Although there was

pressure, but the staffs are very supportive and able to give helping hands whenever

needed, which makes the office feels like home. All of this has created a great impetus

in the internship learning process of becoming a real future engineer.


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6.0 REFERENCES

1. UTP Industrial Internship Program Guideline

2. www.dyna.com.my (Dyna Segmen Sdn Bhd Official Website)

3. www.consurv.com.my (Consurv Technic Sdn Bhd Official Website)

4. ITS Sludge Measurement VDM 250.2 Job Method Statement

5. ITS Final Report on Sludge Inspection for Tank T-7101

6. www.lemis-process.com (VDM 250 Series)

7. M. Paul, M. Ken, and S. R. Nick, “Measurement of Sludge Volume in Crude Oil

Storage Tanks,” Inspectioneering Journal.,August. 1999.

8. De-sludging Operation (2005). Retrieved March 23,2013, from

http://www.siengroup.com/de-s.html

9. Refinery and Terminal Oil Storage Tank Cleaning and Sludge Management

Services (2010). Retrieved March 23,2013, from

http://www.slb.com/~/media/Files/miswaco/brochures/idrabel_tank_cleaning.pdf

10. Density and Viscosity Meters for Gas and Liquids (2009). Retrieved March 4,

2013, from http://www.viscosity-testing.com/?mid=41&measure=44&pid=24


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7.0 APPENDICES

Appendix A: ATEX Certification for VDM 250.2

Appendix B: Job Safety Analysis for Crude Sludge Profiling Project

Appendix C: Crude Oil Tank T-7101 Drawings


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Appendix A


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Appendix B


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Appendix C


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final report- athirah

Documents