Final Report - Athirah

Industrial Internship Industrial Project Report
Nurul Athirah Wahid Ali (13340)

October 2012 April 2013

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 Segmens 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.

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.

TABLE OF CONTENTS
Executive Summary
Acknowledgement
Table of Contents
List of Figures
List of Tables
1.0 Introduction
1.1 Host Company Overview
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
4

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

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
39
Figure 21: Sludge distribution along the horizontal dashed line
39
40
Figure 23: Sludge Distribution along the vertical dashed line
40
Figure 24: 3D image of sludge distribution `
41
42
Figure 26: 3D image of sludge distribution with 5X vertical scale
43

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
41
42
43
Table 14: Sludge Volume
44

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.
8

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 companys 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.

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
Marine Generator and Engine overhauls
Underwater and Diving services
Mechanical and structural repairs
10

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.
11

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:
12

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.
13

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.
14

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.
15

Commissioning tender involve a few process which the companys 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.
16

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
17

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.
18

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
19

Figure 6&7: Corrosion pitting on pipeline
Figure 8:
Figure 9:
Almost all insulation has been removed
After blasting work completed
20

Figure 10:
Figure 11:
First coat is being applied
Final coat is being applied
Figure 12:
Figure 13:
Insulation is being installed
Insulation completed
21

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.
.
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.
22

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 rebreather. 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.
23

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.
24

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.
25

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
26

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.
27

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).
28

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
29

Inspection Equipment
Item
Description
Inspection System to collect
data on tanks and derivatives,
inspection equipment consists
of:
BOX1
Viscosity density meter VDM
250.2
-Level block with sensor
-Controller
BOX2
Ruggedised Laptop
Ex status
Qty
L(cm)
W(cm)
H(cm)
Kg
46
33
15
11
46
33
15
ATEX Category 1
ATEX Category 2
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.
30

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.
31

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.
32

3.4.5 Project Team
No
1
Name
IC/Passport
No
Position
211018269
Supervisor
680723
Expiry date
of NIOSH /
Safety Pass
16/7/2013
G820493
Specialist
225985
17/7/2015
910430105420
Project
Leader
OG012591N
14/11/2015
910123105631
Engineer
OG012607N
17/11/2015
Engineer
Confined
Space
Specialist
Confined
Space
Specialist
OG009112N
9/2/2015
OG001768M
20/9/2015
OG016598T
21/4/2014
Robert Alexander Auld

Nuno Manuel Carvalho
De Matos
Nurul Athirah Wahid
Ali
Sundara Pandian A/L
Perumal
Amir bin Wahid
870312055457
Akman Nur bin

Abdullah
780506146219
Mohd Sukri bin Mohd

Rasul
850320115693
2
3
Table 3: Project Team
33
NIOSH No./
Safety Pass No

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
34

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
35

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
36

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
37

A two-dimensional (2D) image sludge distribution is shown in Figure 19. The sludge
depth scale is shown on the right in meters.
Table 10: Key to Figure 19-23

38

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
39

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
40

3D View
A three dimensional (3D) image of sludge distribution is shown in Figure 24. The
vertical heights and horizontal scales are 1:1

41

3D View with Tank Shell Mimic
vertical heights and horizontal scales are 1:1

42

3D View with 5X Vertical Scale
vertical heights are scaled 5X horizontal scales.
Figure 26: 3D image of sludge distribution with 5X vertical scale
43

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.
44

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 PPMSBs 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.
45

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.
46

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 plants 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.
47

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
48

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.
49

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.
50

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
51

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
52

Appendix A
53

54

55

Appendix B
56

57

58

Appendix C
59

60

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Industrial Internship Industrial Project Report

Nurul Athirah Wahid Ali (13340)

Industrial Internship Industrial Project Report

Industrial Internship Industrial Project Report

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

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

Industrial Internship Industrial Project Report

1.2 Objective of Student Industrial Internship Program

1.3 Scope of Work

2.0 Industrial Internship Main Activities

2.2 Blasting and Painting Project at PETRONAS Gas Berhad, Serdang

2.4 Training Activities

3.0 Industrial Internship Project Report

3.2.2 Problem Statement

3.2.3 Objectives and Scope of Study

3.2.4 Relevancy of the Project

3.3 Literature Review

Industrial Internship Industrial Project Report

3.4.2 Measuring Method

3.4.3 Data Post Processing

3.4.4 Data Presentation

3.4.5 Project Team

3.4.6 Gantt Chart and Key Milestone

3.5 Result and Discussion

3.6 Conclusion and Recommendations

4.0 Safety Training and Value of Practical Experience

4.2 Leadership, team work and individual activities

4.3 Business values, ethics and management skills

4.4 Problems or challenges faced and solutions to overcome

Industrial Internship Industrial Project Report

Figure 1: Dyna Segmen Organization Chart

Figure 2: Consurv Technic Organization Chart

Figure 3: Tender Process Flow

Figure 4: Blistering and corrosion of pipeline

Figure 5: Blistering and corrosion of pipeline

Figure 6: Corrosion pitting on pipeline

Figure 7: Corrosion pitting on pipeline

Figure 8: Almost all insulation has been removed

Figure 9: After blasting work completed

Figure 10: First coat is being applied

Figure 11: Final coat is being applied

Figure 12: Insulation is being installed

Figure 13: Insulation completed

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

Figure 15: VDM 250.2

Figure 16: Roof Tank Survey

Figure 17: Reading is being logged

Figure 18: Tank roof arrangement

Figure 19: 2D image of sludge distribution

Figure 20: 2D image of sludge distribution

Figure 21: Sludge distribution along the horizontal dashed line

Figure 22: 2D image of sludge distribution

Figure 23: Sludge Distribution along the vertical dashed line

Figure 24: 3D image of sludge distribution `

Figure 25: 3D image of sludge distribution

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

Industrial Internship Industrial Project Report

Table 1: Project Schedule

Table 2: Ex status and Specifications of Equipments

Table 3: Project Team

Table 6: Tank information

Table 7: Crude Oil Parameters

Table 8: Key to Figure 16